The aim of this thesis is to reduce the cost of poor quality in the chosen production process. Specifically I focused on the winding lines at the production of rotors, which are components of electronic brake systems (EBS) and heating and ventilation systems of cars. The thesis was worked out in accordance with an announced Six Sigma project in the company. I also dealt with the Six Sigma strategy in the theoretical part. The chosen tools are applied afterwards in the practical part, especially in define, measure and analyse phases. The output of this thesis is an analysis of all possible causes of high scrap ratio in the stated production process. I also proposed to adopt measures for cutting the cost of poor quality in the chosen production process.

Lean, Six sigma y TOC son metodologías enfocadas en la mejora continua que han sido aplicadas en diversos sectores y empresas por separado. Sin embargo, hay pocos estudios sobre la importancia y la potencia que podría tener la sinergia de estas tres herramientas en la mejora del rendimiento y productividad en los entornos donde se apliquen. Es por eso que en este artículo se presenta un modelo donde se combinan estas tres metodologías, teniendo como base los 5 pasos de TOC y en cada fase se implementan las herramientas de Lean que ayudan a identificar el flujo de valor y eliminar actividades, tiempos improductivos y desperdicios. También se utilizan herramientas de Six sigma para calcular el CPK, controlar la variabilidad del proceso crítico y definir el nivel sigma del entorno en estudio. Usando el modelo 6TOC se logra reducir los tiempos y costos de producción, lo que permite un incremento del 6% en la productividad y elevar el nivel sigma en 4 de las Pymes que fabrican muebles de madera en el Perú. Con esto, se puede afirmar que 6TOC es una herramienta potente que se adapta el sector de muebles de madera para conseguir una mejora continua. / Lean, Six Sigma and TOC are methodologies that focus on continuous improvement and have been applied in different industries separately. However, there are a few studies that show the great influence of these three tools synergizing to improve performance and productivity in the environments where these are applied. This paper presents an empirical model denominated 6TOCwhere the three methodologies are combined. The model is based on the five steps of TOC using Lean and Six Sigma tools to identify the value flow in the processes, eliminate unprofitable activities and control variability in the critical process. Using these, it is possible to reduce production times and costs, allowing a 6% increase in productivity and raise the sigma level in 4 of the SMEs that produce wooden furniture in Peru. We conclude that 6TOC is a mighty tool adapted to the wooden furniture sector to achieve continuous improvement. / Trabajo de Suficiencia Profesional

Expone la utilización de la metodología de mejora continua Six Sigma para la mejora de procesos en una empresa textil exportadora, la cual se desarrolló en base a la metodología de cinco fases DMAMC (definir, medir, analizar, mejorar y controlar), con el objetivo de reducir la cantidad de tela no conforme y calificada internamente como no exportable, así como mejorar los principales indicadores de gestión de calidad establecidos por la empresa en estudio. / Tesis

El principal problema que enfrenta un fabricante de tableros eléctricos es la alta tasa de demora en entrega de pedidos. El factor predominante que han dado lugar al retraso de la entrega de pedidos es el cuello de botella que se genera en el proceso productivo. Para resolver este problema, se desarrolló una propuesta innovadora utilizando la metodología DMAIC (Definir, Medir, Analizar, Mejorar y Controlar), la cual esta orientada a la mejora de procesos utilizada por Six Sigma [1] [2]. Para respaldar este análisis, se realizará una simulación, buscando una reducción considerable del cuello de botella y, por consecuencia, el aumento de productividad, mejorando el tiempo de entrega de pedidos. Al implementar la metodología DMAIC Six Sigma, se mejorará el tiempo de entrega de pedidos a 96%, mejorando así la calidad del proceso de producción y generando beneficios económicos. / The main problem faced by a manufacturer of electrical panels is the high rate of late delivery of orders. The predominant factor that has led to the delay in order delivery is the bottleneck generated in the production process. To solve this problem, an innovative proposal was developed using the DMAIC (Define, Measure, Analyze, Improve and Control) methodology, which is oriented to the process improvement used by Six Sigma [1] [2]. To support this analysis, a simulation will be carried out, looking for a considerable reduction of the bottleneck and, consequently, the increase of productivity, improving the time of delivery of orders. By implementing the DMAIC Six Sigma methodology, the order delivery time will be improved to 96%, thus improving the quality of the production process and generating economic benefits. / Trabajo de investigación

No description available.

The diploma thesis deals with the possibilities of making the process of realization of the multipurpose process more efficient, in the sense of dismantling of defective parts and return of the perfect parts back to the production process in the automo-tive industry. In the theoretical part of the diploma thesis there are laws and norms related to the automotive industry, including the applied methods in this industry with real researches in many companies all over the world. The following section introduces XYZ and its products. Follows the current process of disman-tling defective parts, Paret analysis with the Lean Six Sigma method. On the basis of analyzes and methods for streamlining the training workplace, one of the options for streamlining the process of implementation of the multi-site training at the XYZ training workplace.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / Currently, in open-pit mining operations, the highest cost among all processes is that of transporting trucks, whether in fuel, roads, tires, or spare parts, among other factors. Therefore, this article proposes the use of the Six Sigma methodology of continuous improvement as a quality management tool to reduce the downtime of the truck fleet to obtain better productivity in operations. The results of the investigation in the case study allowed to visualize that with the election of an optimal fleet appropriate for the conditions given in a mining project, the values of productivity and efficiency improve considerably. This is reflected in a better use of the machinery and in the reduction of unproductive times.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / In the mining industry, the mining cycle is a very important part in the operating stage of every mining unit. Through the exploitation method used, the mining cycle provides mineral ore, which subsequently undergoes various metallurgical processes and its commercialization and thereby generates profits to the mining company. Currently, within this cycle, the hauling and transportation stages are those that have a lower efficiency with respect to the drilling and blasting stages. Therefore, the sector is always seeking effective ways to optimize these processes, reduce downtime and increase productivity. Six Sigma is a technique that allows for the continuous process improvement. In this study, the factors that generate inefficiency in the hauling cycle are determined, and alternatives are implemented to solve the main problem and improve the operations cycle.

This report presents an explorative examination of the scientific literature regarding current methods utilized in mixed-model assembly lines and the challenges that are faced. Empirical data from a real mixed-model assembly line was collected and analyzed to explore the application of the identified methods and the problems that are faced in a realistic situation.  The report consists of a theoretic framework on the topics of assembly systems and topics relevant to managing the challenges. In addition a case study is conducted where an assembly system is observed and real production data is collected. Product assembly lines make up one of the final steps in the manufacturing process of a product. By implementing proven methods for process improvements highly effective assembly lines are realized. If an assembly line is experiencing reliability issues the probability of the company’s end-customers being directly affected is considerably increased.  Ensuring reliability in a mixed-model assembly line (MMAL) is an important task with an increasing level of difficulty given the current evolution of advanced technology. The resulting increase in product variety and complexity made possible increases the demands on the entire manufacturing process and the assembly line in particular. Added product variety and complexity poses an increased challenge from an automation perspective as well due to the limitations in flexibility inherited by industrial robots in comparison to a human operator. Many challenges in manufacturing and assembly processes stem from product development, increased variation between product models, and changes in production systems, due to the resulting increase in the complexity of the production processes (ElMaraghy ​​& ElMaraghy, 2016). Historically, a vast number of manufacturing companies have seen significant improvements in their product quality and productivity, leading to improved financial results as well as customer satisfaction by implementing process development methods such as Lean production, Six Sigma, or Lean Six Sigma.  Therefore, the purpose of this report is to explore assembly system reliability and complexity management. The scope of this report is restricted to focus on reliability in assembly systems from a quality perspective. Suggestions for improvements are biased towards Lean Six Sigma methods and complexity management as described in current literature with the consequence of potentially valid methods and solutions being excluded. The theoretical framework of this report is based on selected books and scientific articles on the topics of complexity, assembly systems, process development, and human performance in the context of assembly systems.  The case study project is executed following the DMAIC-process as per the L6S methodology. Lean six sigma methodologies are applied in accordance with the selected literature with the objective of identifying a potential strategy for mitigating the quality deficiencies observed in the company´s assembly processes. The research presented in this report follows the abductive reasoning concept (Säfsten & Gustavsson 2020). Abductive reasoning is initialized by a conclusion, which is followed up by constructing a theory based on literature, and finally analyzing empirical data to validate the constructed theory in the context given by the initial conclusion.  Additionally, a root cause analysis is conducted. The root cause analysis is initiated by constructing an Ishikawa diagram to categorize and identify possible causes of the identified errors. By systematically working through each of the categories the examined problem is look upon from different points of view, making for a comprehensive analysis. In this step the 5-why’s method is utilized to support the deductive reasoning process. The potential root causes are then utilized to construct a list of possible solutions and suggestions for improvement for the examined problem. The improvement suggestions are based on deductive reasoning as well as documented improvements from the literature.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / In the arms industry, quality is essential because its products are used for special purposes. Therefore, in production, the rate of defective products is low. This study proposes a model to reduce the number of defective products based on the combined use of the Six Sigma and work method tools. For the purposes of this study, the production process of the 7.62 mm ammunition was analyzed because it presents several issues that affect product quality. The current methods and procedures of the production process were analyzed to identify the root causes of the problem and to provide a solution. After implementing the model, defective products were reduced from 20% to 13.67%..