Improving Paint Quality of

Machines

Black/Green Belt : Hemant

Sponsor: ABC
Master Black Belt: XYZ
Team Members:

 Institute of Quality and Reliability

July 2007 HPU1

 Institute of Quality and Reliability Painting Case study 2

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Slide 1

HPU1 Use this file to create project summary. Copy and paste data, graphs, analysis from
MInitab of SigmaXL of other software. Include interpretation and conclusion of analysis
and action taken/required.
Hemant Urdhwareshe, 11/20/2006
 One Page Executive Summary
• Objective: Customers complained that the machines look “old”.
This was related to low “gloss”. Objective of the project was Improve
average paint gloss from 75 to 85 and improve capability of coating
thickness.
• Short Statement: Reduce defect level from 5% to 0% and also
related rework.
• Leader: Hemant
• Team:
• Benefits:
– Saving of US$ 250000 per year
– Improvement in productivity
– Company reputation
• Results:
– Paint gloss improved significantly and no rework was required at
customers’ premises.

 Institute of Quality and Reliability Painting Case study 3

July 2007

Flow Chart

Assemble Degrease Dry Paint OK? Yes

No

Rework

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 Process Map

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C and E Matrix

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 Box Plots

 Institute of Quality and Reliability Painting Case study 7

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Box Plots

 Institute of Quality and Reliability Painting Case study 8

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 Multi Vari Charts

 Institute of Quality and Reliability Painting Case study 9

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Multi Vari Charts

Gun type 2 and

distance=80 is
better.

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 Multi Vari Charts

Paint Source 1, Gun type 2 and distance=80 is better.

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Final Capability

 Institute of Quality and Reliability Painting Case study 12

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 Improvements

• Gun type 1, distance of 80 and source 1

selected
• Process Capability improved
• Operators were trained for the new
parameters
• Work Instructions revised
• Purchase Order Data changed

 Institute of Quality and Reliability Painting Case study 13

July 2007