DAWOOD UNIVERSITY OF ENGINEERING AND TECHNOLOGY

MINIMIZATION OF REPAIR RATE

AND REWORKING BY USING LEAN
SIX SIGMA (DMAIC)
METHODOLOGY
AT
TOYOTA INDUS
MOTOR COMPANY
 Lean Six Sigma Overview (2 approaches
in one)
Lean primarily focuses on Increasing Outputs, for
example, increasing process Speed while
eliminating unnecessary Inventory and Waste.
Lean Six Sigma
Increased Speed Increased Quality
with No Wasted with lowered
Effort Defects, Variation
and Cost

Six Sigma primarily focuses on Improving Outcomes,

for example, eliminating Defects (DMAIC) and
reducing unwanted Variation.
Problem Statement:
Excessive repair rate and reworking of
defects coming from manufacturing division in
a single vehicle

IMPACTS:

•Lead time gets affected

•Production target gets hit
•Extra man power consumption
•Customer dissatisfaction in case of outflow
 LEAN SIX SIGMA PROJECT CHARTER

PROJECT TITLE MINIMIAZATION OF REPAIR RATE BY USING LEAN SIX SIGMA

USING DMAIC APPROACH (DEFINE, MEASURE, ANALYZE

METHODOLOGY ,IMPROVE , CONTROL )

REPAIRING OF VEHICHLES IS A VERY CRITICAL PROCESS IN

BUSINESS CASE INDUS MOTOR COMPANY. HIGHER REPAIR RATE INCREASE THE
COST AND DECREASE PRODUCTIVITY.BY DECREASING THE
REPAIR RATE OF THE DEFECTS OVERALL PROJECT QUALITY AND
PRODUCTIVITY WOULD BE IMPROVED.

GOAL MINIMIZED THE REPAIR RATE AS MUCH AS POSSIBLE

ASSEMBLY SECTION, WELDING SECTION, AND PAINT SECTION

PROJECT SCOPE DEPARTMENT’S HEAD SHOULD BE INVOLVE DURING DIFFERENT
PHASES OF THE PROJECT.
 POSSIBLE OUTCOMES
 Reduce defects  Decrease repair
rate

 Reduce man  Improve

power productivity
MEASURE & ANALYZE PHASE

AFTER STUDYING THE NATURE OF THE PROBLEM, OUR TEAM NOW STARTED COLLECTING
DATA FROM DIFFERENT ANGLES TO GET MORE DETAILED INFROMATION ABOUT THE
PROCESS. SOME TOOLS OF MEASURE and analyze PHASE ARE LISTED HERE.

 DATA COLLECTION

PARETO CHART

 CAUSE AND EFFECT DIAGRAM

PROCESS FLOW OF IMC
PRESS
SHOP

WELDING
CUSTOMER
SHOP

DEALER Paint shop

ASSEMBLY
LOGISTIC
SHOP

QUALITY
CONTROL
 PAINT SHOP DEFECTS
SEED: Black and dark color paints which contain
finely ground pigments are more likely to be seed.

Paint sagging is defined as downward movement

of the paint film between the time of application and
drying resulting in an uneven coating.

BLISTER This defect occurs because a remainder of

air water or grease between the topcoat and the
previous layers of paint, lifting and swelling the
finish coat, generating the formation of blisters.
 Paint shop defects
Paint Shop Defects
100%
25% 100%

seed
90%
77% 77%
20% 72% 74% 80%
69%
66%
61% 70%
15% 56% 60%
50%
45% 50%
38%
10% 31% 40%
24% 30%
5% 15% 20%
10%
15% 10% 7% 7% 7% 6% 5% 5% 5% 3% 3% 3% 2% 1% 23%
0% 0%
seeds paint defects unfinish SAG WAX sealer dent blister lint IMPERIAL poor crater ]thin OTHERS
damage in primer repair MARK N/G NEED gloss paint

PAINT QTY CUM QTY CUM % %

Seeds 6981 6981 15% 15%
Paint Damage 4459 11440 24% 10%
Defects In Primer 3250 14690 31% 7%
Unfinished Repair 3150 17840 38% 7%
Sag 3125 20965 45% 7%
Wax Mark 2600 23565 50% 6%
Sealer N/G 2563 26128 56% 5%
Dent 2560 28688 61% 5%
Blister 2343 31031 66% 5%
Lint 1256 32287 69% 3%
Imperial Need 1253 33540 72% 3%
Poor Gloss 1235 34775 74% 3%
Crater 1050 35825 77% 2%
Thin Paint 412 36237 77% 1%
Others 10560 46797 100% 23%
 CAUSE AND EFFECT DIAGRAM OF PAINT SHOP

Methods ENVIRONMENT

Painting over THREADS DUST

other
Improper surface contaminants
FLY/ HAIR
preparation
MOSQUITOS

SEEDS
TRAINING

SKILLS
QUALIFICATION

SEED
MEN
 ASSEMBLY SHOP DEFECTS
Assembly Shop Defects
100%
96%
35% 92% 100%
85% 90%
30% 78%
80%
25% 67%
70%
55% 60%
20%
50%
15% 40%
31%
10% 30%
20%
5%
10%
31% 24% 12% 11% 7% 7% 5% 4%
0% 0%
scratch poor fitment abnormal mark dent tightening missing damage wrong part

ASSEMBLY
976
Scratch 976 31% 31%

1746
Poor Fitment 770 55% 24%

2111
Abnormal Mark 365 67% 12%

2456
Dent 345 78% 11%

2690
Tightening 234 85% 7%

2903
Missing 213 92% 7%

3053
Damage 150 96% 5%

3165
Wrong Part 112 100% 4%
CAUSE AND EFFECT DIAGRAM OF ASSEMBLY SHOP

METHODS
METHODS ENVIRONMENT
ENVIRONMENT

SHARP EDGES
SHARP EDGES
EXCESSIVE INTERFERENCE
INTERFERENCE POINTS
POINTS
HANDLING
EXCESSIVEOF
PARTS
DEFECTIVE
INSERTIONS
SCRATCHES
SCRATCHES
MATELLIC GUNS

PARTS
PARTS MOVEMENT
MOVEMENT
TORQUE WRENCH

MACHINES
MACHINES MATERIAL
MATERIAL
GAPS AND LEVEL DEFECTS
 WELD SHOP DEFECTS
Weld Shop Defects
100%
35% 100%

30% Gaps and 90%

level 68%
70%
80%

25% 64% 70%

60%
55% 60%
20% 50%
44% 50%
15% 37%
40%
28%
10% 30%

15% 20%
5%
10%
15% 13% 9% 7% 6% 5% 5% 5% 3% 2% 30%
0% 0%
gap level dent sealer crack damage BUMP burr deformation loose noise others

weld QTY CUM QTY CUM% %

gap 791 791 15% 15%
level 689 1480 28% 13%
dent 465 1945 37% 9%
sealer crack 365 2310 44% 7%
damage 320 2630 50% 6%
BUMP 250 2880 55% 5%
burr 245 3125 60% 5%
deformation 236 3361 64% 5%
loose 180 3541 68% 3%
noise 125 3666 70% 2%
others 1562 5228 100% 30%
 CAUSE AND EFFECT DIAGRAM OF WELD SHOP

MATERIAL METHODS

DEFECTIVE
INSERTION
IMPROPER
vendor problem HANDLING

GAPS AND
LEVEL

WEAR AND TEAR

IN JIGS

MACHINES