WCSE

Reducing Waste in the Crankshaft Manufacturing Process by Using Seven QC Tools

Abstract— In today's automotive parts manufacturing industry, waste problems in the production process can affect automotive part manufacturers. Moreover, increased production costs hinder the organization's competition with other competitors. This research aims to study and find a method to reduce the amount of waste in crankshaft production processes by applying the seven quality control tools (7 QC tools). Moreover, reduce costs of products to provide customers with the highest satisfaction. From the past 6-month data collection, it was found that the waste in the crankshaft manufacturing process averaged 3500ppm per month, representing the damage and opportunity cost of about 22,095 baht. The result shows that the primary defect type in the production process was dent caused by the jigs that did not press the workpiece tightly. And the problem of the outside diameter is lower than the specified is caused by the holder corroded and collapsing to make the insert is not tight. These problems caused the main reasons; (1) Working methods (2) Worker (3) Machine and equipment. After improvement, it was found that the waste in the crankshaft manufacturing process was reduced. Initially, the dent problem of 148 pieces was reduced to 8 pieces, a reduction of 140 pieces, representing 95%. In addition, the outside diameter problem was lower than the specified, reduced from 117 pieces to 22 pieces, a reduction of 95 pieces, representing 81%. Therefore, it could save the cost of 7,919.76 baht. In total, this production line was able to reduce waste from an average of 3500 ppm/month to only 930ppm/month.

Index Terms— 7 Wastes, 7QC Tools, 5W1H, Crankshaft, Part Per Million (PPM), Tool Change Reference (TCR).

Anchalee Sirisopha
System Engineering Program, Industrial Engineering Program, School of Engineering, Suranaree University of Technology, Nakhon Ratchasima Provice, Thailand
Jongkol Srithorn
System Engineering Program, Industrial Engineering Program, School of Engineering, Suranaree University of Technology, Nakhon Ratchasima Provice, Thailand

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Cite: Anchalee Sirisopha, Jongkol Srithorn, " Reducing Waste in the Crankshaft Manufacturing Process by Using Seven QC Tools, " WCSE 2022 Spring Event: 2022 9th International Conference on Industrial Engineering and Applications, pp. 988-996, Sanya, China, April 15-18, 2022.