Lean Six Sigma for Quality and Performance Improvement of POH Process of Wagon Wheel CTRB

Abstract

Due to high competition in present world, every end user of a product demand their products to be delivered to them on time with good quality. Hence it is an objective of every industry to satisfy their customer requirements. In the long run, this can be achieved by continuous and constant process improvements. Lean Six Sigma is an overall quality improvement approach combining and capitalizing the strengths of Six Sigma and Lean Management improvement programs. In CTRB periodic overhaul, several process steps and workplaces are required for the job, the movement of inventory between the workplaces can be very time consuming unless it is suitably planned. The major areas that need great attention in this system are WIP (work in process), Takt time and process variability. In this study, focus is on the application of lean tools and techniques with their principles coupled with six sigma DMAIC methodology. The objective of this study is to identify the best possible tools and techniques to tackle premature failure of CTRBs whilst in service due to early presence of defects which are closely associated to the POH process. It also discusses the methodology generally adopted, tools and techniques used and benefits obtained. By mapping current state of the POH process and takt time, future state improvement can be done in order to reduce cycle time using Lean tools such as Poke-Yoke, Jidoka, 5S, SMED