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Purpose – A structured problem-solving approach based on the Lean approach to analyse weld
defects in Submerged Arc Welding (SAW) and derive appropriate solutions.
Design/methodology/approach –
Weld defects need to be systematically analysed for valve performance enhancement. In this
research study, Lean approach is used to reduce variations and waste by annihilating the root
causes for failures that occur during submerged arc welding (SAW) process.
Define, measure, analyse, improve and control (DMAIC) framework has been developed with
appropriate Lean tools.
DMAIC Analysis
To have the present scenario of product assembly line, the current state map is
constructed so that improvement opportunities can be identified.
Study the whole workflow process of the assembly line and make a schematic
diagram of the material flow through each workstation.
Data Required - cycle time, changeover time, number of workers and total available
time.
Measure Phase
Current-state value stream analysis. VSM is used to optimize the process by eliminating wastes
associated with it.
Time line is used to separate value-added cycle time and non-value-added time. Finally, all cycle
times and inventory times are added up at the end of timeline. Total cycle time is 159 h and total
production LT is 226 h. Following equation is used to calculate LT in between the process:
Conducting self-inspection for machining and marking instead of separate inspection procedure
reduction in cycle time and LT
reduction in number of steps and improved quality performance
Cycle time of the total manufacturing process was reduced to 84 h and LT was reduced to 93.6
h which was earlier 159 h and 226h
Control Phase
Plan for solving the problems was established to sustain the improvements implemented in
the improve phase.
Documentation of improvements-
CONCLUSION
Lean framework has been systematically formulated by configuring appropriate tools into
the DMAIC framework.
The DMAIC phases have been systematically executed to reduce weld defect rate by 42
per cent and cost saving by INR 250,000.
The study provided appropriate problem-solving methodology for analysis of weld
defects.