Design of Industrial System Using Digital Numerical Control
Abstract
Purpose: This paper would be based on applying quality 4.0 technology to mechanical factories. The overall purpose of quality 4.0 technology is to transition production lines from semi-automatic production to automatic production.
Methodology/Approach: The lean six-sigma with five phases of Define Measure Analysis Improve Control (DMAIC) would be used to measure the quality of 4.0 integration. Each phase is composed of statistical tools, hypothesis testing, experimental design, industrial tools, etc. to provide less error for precision in manufacturing control.
Findings: Results shows that scrap products decreased by 59.66% per year, the productivity of the production line assembly increased by 7.8%, and the total lead time decreased by 20 minutes. As well as the required payments and the monthly reduction of value cost of 500 USD for jig improvement, and profit is 678 USD per month and 7,636 USD per year.
Research Limitation/Implication: Gaseous hydrocarbons or organic compounds from n-hexane can be a challenge for sensors utilizing signals for researchers. Also, another issue would be the power supply output to the sensor due to external interference.
Originality/Value of paper: This research focuses on applying the usage of sensors from a semi-automatic machine tool to an automatic machine tool.
References
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Bedi, H.S., Moon, N.J., Bhatia, V., Sidhu, G.K. and Khan, N., 2015. Evaluation of Musculoskeletal Disorders in Dentists and Application of DMAIC Technique to Improve the Ergonomics at Dental Clinics and Meta-Analysis of Literature. J Clin Diagn Res, [e-journal] 9(6), ZC01-3. DOI: 10.7860/JCDR/2015/14041.6126.
Biju, S. and Nair, N.S., 2017. Measuring academic quality: a three-dimensional approach for internal audit using DMAIC. International Journal of Six Sigma and Competitive Advantage, [e-journal] 10(3/4), pp.236-257. DOI: 10.1504/ijssca.2017.086600.
Carnovale, S., Allen, C., Pullman, M. and Wong, D., 2016. Using Continuous Improvement in Online Program Design: DMAIC as a Tool for Assurance of Learning Assessments. Decision Sciences Journal of Innovative Education, [e-journal] 14(2), pp.128-153. DOI: 10.1111/dsji.12094.
Cunha, C. and Dominguez, C., 2015. A DMAIC Project to Improve Warranty Billing’s Operations: A Case Study in a Portuguese Car Dealer. Procedia Computer Science, [e-journal] 64, pp.885-893. DOI: 10.1016/j.procs.2015.08.603.
De Mast, J. and Lokkerbol, J., 2012. An analysis of the Six Sigma DMAIC method from the perspective of problem solving. International Journal of Production Economics, [e-journal] 139(2), pp.604-614. DOI: 10.1016/j.ijpe.2012.05.035.
Gandhi, S.K., Sachdeva, A. and Gupta, A., 2019. Reduction of rejection of cylinder blocks in a casting unit: A six sigma DMAIC perspective. Journal of Project Management, [e-journal] 4(2), pp.81-96. DOI: 10.5267/j.jpm.2019.1.002.
Garg, A., Raina, K. and Sharma, R., 2020. Reducing soldering defects in mobile phone manufacturing company: A DMAIC approach. In: IOP, Conference Series: Materials Science and Engineering, Volume 748, International Conference on Mechanical and Energy Technologies (ICMET 2019). Noida, U.P., India. 7-8 November 2019. Galgotias College of Engineering and Technology. DOI: 10.1088/1757-899x/748/1/012027.
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Jamil, N., Gholami, H., Saman, M.Z.M., Streimikiene, D., Sharif, S. and Zakuan, N., 2020. DMAIC-based approach to sustainable value stream mapping: towards a sustainable manufacturing system. Economic Research-Ekonomska Istraživanja, [e-journal] 33(1), pp.331-360. DOI: 10.1080/1331677x.2020.1715236.
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Karout, R. and Awasthi, A., 2017. Improving software quality using Six Sigma DMAIC-based approach: a case study. Business Process Management Journal, [e-journal] 23(4), pp.842-856. DOI: 10.1108/bpmj-02-2017-0028.
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Kosina, J., 2015. Shainin Methodology: An Alternative or an Effective Complement to Six Sigma?. Quality Innovation Prosperity, [e-journal] 19(2), pp.18-31. DOI: 10.12776/QIP.V19I2.580.
Kumar, S., Wolfe, A.D. and Wolfe, K.A., 2008. Using Six Sigma DMAIC to improve credit initiation process in a financial services operation. International Journal of Productivity and Performance Management, [e-journal] 57(8), pp.659-676. DOI: 10.1108/17410400810916071.
Marques, P.A. and Matthé, R., 2017. Six Sigma DMAIC project to improve the performance of an aluminum die casting operation in Portugal. International Journal of Quality & Reliability Management, [e-journal] 34(2), pp.307-330. DOI: 10.1108/ijqrm-05-2015-0086.
Mustaniroh, S.A., Widyanantyas, B.A. and Kamal, M.A., 2021. Quality control analysis for minimize of defect in potato chips production using six sigma DMAIC. IOP Conference Series: Earth and Environmental Science, [e-journal] 733(1), 012053. DOI: 10.1088/1755-1315/733/1/012053.
Nandakumar, N., Saleeshya, P.G. and Harikumar, P., 2020. Bottleneck Identification And Process Improvement By Lean Six Sigma DMAIC Methodology. Materials Today: Proceedings, [e-journal] 24(2), pp.1217-1224. doi:10.1016/j.matpr.2020.04.436.
Padmarajan, N. and Selvaraj, S.K., 2021. Sig sigma implementation (DMAIC) of friction welding of tube to tube plate by external tool optimization. Materials Today: Proceedings, [e-journal] 46(17), pp.7344-7350. DOI: 10.1016/j.matpr.2020.12.1013.
Pech, M. and Vaněček, D., 2018. Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity, [e-journal] 22(2), pp.1-15. DOI: 10.12776/qip.v22i2.1096.
Pereira, A.M., Silva, M.R., Domingues, M.A. and Sá, J.C., 2019. Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study. Quality Innovation Prosperity, [e-journal] 23(3), pp.103-121. DOI: 10.12776/qip.v23i3.1334.
Prabu, K., Makesh, J., Raj, K.N., Devadasan, S.R. and Murugesh, R., 2013. Six Sigma implementation through DMAIC: a case study. International Journal of Process Management and Benchmarking, [e-journal] 3(3), pp.386-400. DOI: 10.1504/IJPMB.2013.058162.
Rehman, S.T., Khan, S.A., Kusi-Sarpong, S. and Hassan, S.M., 2018. Supply chain performance measurement and improvement system. Journal of Modelling in Management, [e-journal] 13(3), pp.522-549. DOI: 10.1108/jm2-02-2018-0012.
Rifqi, H., Zamma, A., Ben Souda, S. and Hansali, M., 2021. Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry. Quality Innovation Prosperity, [e-journal] 25(2), pp.54-77. DOI: 10.12776/QIP.V25I2.1576.
Smętkowska, M. and Mrugalska, B., 2018. Using Six Sigma DMAIC to Improve the Quality of the Production Process: A Case Study. Procedia - Social and Behavioral Sciences, [e-journal] 238, pp.590-596. DOI: 10.1016/j.sbspro.2018.04.039.
Soundararajan K. and Janardhan, R.K, 2019. Cost-reduction and quality improvement using DMAIC in SMEs. International Journal of Productivity and Performance Management, [e-journal] 68(8), pp,1528-1540. DOI: 10.1108/ijppm-10-2018-0360.
Alqahtani, A.Y., 2020. Improvement of Maintenance Orders Lead Time in Public Universities: DMAIC Approach. In: IEEE, 2020 IEEE International Symposium on Systems Engineering (ISSE). Vienna, Austria. 12 October - 12 November 2020. IEEE. DOI: 10.1109/isse49799.2020.9272017.
Barbosa, G.F., de Carvalho, J. and de Souza, C.H.P., 2014. Deployment of a laser projection solution for stripes plotting based on Six Sigma DMAIC methodology applied to aircraft painting shop. Production & Manufacturing Research, [e-journal] 2(1), pp.697-711. DOI: 10.1080/21693277.2014.943432.
Basios, A. and Loucopoulos, P., 2017. Six Sigma DMAIC Enhanced with Capability Modelling. IEEE, 2017 IEEE 19th Conference on Business Informatics (CBI). Thessaloniki, Greece. 24-27 July 2017. IEEE. DOI: 10.1109/cbi.2017.70.
Bedi, H.S., Moon, N.J., Bhatia, V., Sidhu, G.K. and Khan, N., 2015. Evaluation of Musculoskeletal Disorders in Dentists and Application of DMAIC Technique to Improve the Ergonomics at Dental Clinics and Meta-Analysis of Literature. J Clin Diagn Res, [e-journal] 9(6), ZC01-3. DOI: 10.7860/JCDR/2015/14041.6126.
Biju, S. and Nair, N.S., 2017. Measuring academic quality: a three-dimensional approach for internal audit using DMAIC. International Journal of Six Sigma and Competitive Advantage, [e-journal] 10(3/4), pp.236-257. DOI: 10.1504/ijssca.2017.086600.
Carnovale, S., Allen, C., Pullman, M. and Wong, D., 2016. Using Continuous Improvement in Online Program Design: DMAIC as a Tool for Assurance of Learning Assessments. Decision Sciences Journal of Innovative Education, [e-journal] 14(2), pp.128-153. DOI: 10.1111/dsji.12094.
Cunha, C. and Dominguez, C., 2015. A DMAIC Project to Improve Warranty Billing’s Operations: A Case Study in a Portuguese Car Dealer. Procedia Computer Science, [e-journal] 64, pp.885-893. DOI: 10.1016/j.procs.2015.08.603.
De Mast, J. and Lokkerbol, J., 2012. An analysis of the Six Sigma DMAIC method from the perspective of problem solving. International Journal of Production Economics, [e-journal] 139(2), pp.604-614. DOI: 10.1016/j.ijpe.2012.05.035.
Gandhi, S.K., Sachdeva, A. and Gupta, A., 2019. Reduction of rejection of cylinder blocks in a casting unit: A six sigma DMAIC perspective. Journal of Project Management, [e-journal] 4(2), pp.81-96. DOI: 10.5267/j.jpm.2019.1.002.
Garg, A., Raina, K. and Sharma, R., 2020. Reducing soldering defects in mobile phone manufacturing company: A DMAIC approach. In: IOP, Conference Series: Materials Science and Engineering, Volume 748, International Conference on Mechanical and Energy Technologies (ICMET 2019). Noida, U.P., India. 7-8 November 2019. Galgotias College of Engineering and Technology. DOI: 10.1088/1757-899x/748/1/012027.
Gupta, N., Lteif, A., Creo, A., Iqbal, A.M., Pittock, S., Tebben, P.J., Hansen, J., Heyrman, M., Spee, R., Scanlan-Hanson, L. and Kumar, S., 2018. Improved utilization of waist-to-height ratio in cardiometabolic risk counselling in children: Application of DMAIC strategy. Journal of Evaluation in Clinical Practice, [e-journal] Vol. 125(1), pp.300-305. DOI: 10.1111/jep.13055.
Jamil, N., Gholami, H., Saman, M.Z.M., Streimikiene, D., Sharif, S. and Zakuan, N., 2020. DMAIC-based approach to sustainable value stream mapping: towards a sustainable manufacturing system. Economic Research-Ekonomska Istraživanja, [e-journal] 33(1), pp.331-360. DOI: 10.1080/1331677x.2020.1715236.
Kaoudom, N., Yimtrakarn, T. and Choomrit, N., 2019. Using DMAIC Methodology to Reduce Defects in Sport Bar Products. In: IEEE, 2019 IEEE 6th International Conference on Industrial Engineering and Applications (ICIEA). Tokyo, Japan. 12-15 April 2019. IEEE. DOI: 10.1109/iea.2019.8715225.
Karout, R. and Awasthi, A., 2017. Improving software quality using Six Sigma DMAIC-based approach: a case study. Business Process Management Journal, [e-journal] 23(4), pp.842-856. DOI: 10.1108/bpmj-02-2017-0028.
Kaushik, P. and Khanduja, D., 2009. Application of Six Sigma DMAIC methodology in thermal power plants: A case study. Total Quality Management & Business Excellence, [e-journal] 20(2), pp.197-207. DOI: 10.1080/14783360802622995.
Khayrullina, M., Kislitsyna, O. and Chuvaev, A., 2015. Production Systems Continuous Improvement Modelling. Quality Innovation Prosperity, [e-journal] 19(2), pp.73-86. DOI: 510.12776/QIP.V19I2.576.
Kosina, J., 2015. Shainin Methodology: An Alternative or an Effective Complement to Six Sigma?. Quality Innovation Prosperity, [e-journal] 19(2), pp.18-31. DOI: 10.12776/QIP.V19I2.580.
Kumar, S., Wolfe, A.D. and Wolfe, K.A., 2008. Using Six Sigma DMAIC to improve credit initiation process in a financial services operation. International Journal of Productivity and Performance Management, [e-journal] 57(8), pp.659-676. DOI: 10.1108/17410400810916071.
Marques, P.A. and Matthé, R., 2017. Six Sigma DMAIC project to improve the performance of an aluminum die casting operation in Portugal. International Journal of Quality & Reliability Management, [e-journal] 34(2), pp.307-330. DOI: 10.1108/ijqrm-05-2015-0086.
Mustaniroh, S.A., Widyanantyas, B.A. and Kamal, M.A., 2021. Quality control analysis for minimize of defect in potato chips production using six sigma DMAIC. IOP Conference Series: Earth and Environmental Science, [e-journal] 733(1), 012053. DOI: 10.1088/1755-1315/733/1/012053.
Nandakumar, N., Saleeshya, P.G. and Harikumar, P., 2020. Bottleneck Identification And Process Improvement By Lean Six Sigma DMAIC Methodology. Materials Today: Proceedings, [e-journal] 24(2), pp.1217-1224. doi:10.1016/j.matpr.2020.04.436.
Padmarajan, N. and Selvaraj, S.K., 2021. Sig sigma implementation (DMAIC) of friction welding of tube to tube plate by external tool optimization. Materials Today: Proceedings, [e-journal] 46(17), pp.7344-7350. DOI: 10.1016/j.matpr.2020.12.1013.
Pech, M. and Vaněček, D., 2018. Methods of Lean Production to Improve Quality in Manufacturing. Quality Innovation Prosperity, [e-journal] 22(2), pp.1-15. DOI: 10.12776/qip.v22i2.1096.
Pereira, A.M., Silva, M.R., Domingues, M.A. and Sá, J.C., 2019. Lean Six Sigma Approach to Improve the Production Process in the Mould Industry: a Case Study. Quality Innovation Prosperity, [e-journal] 23(3), pp.103-121. DOI: 10.12776/qip.v23i3.1334.
Prabu, K., Makesh, J., Raj, K.N., Devadasan, S.R. and Murugesh, R., 2013. Six Sigma implementation through DMAIC: a case study. International Journal of Process Management and Benchmarking, [e-journal] 3(3), pp.386-400. DOI: 10.1504/IJPMB.2013.058162.
Rehman, S.T., Khan, S.A., Kusi-Sarpong, S. and Hassan, S.M., 2018. Supply chain performance measurement and improvement system. Journal of Modelling in Management, [e-journal] 13(3), pp.522-549. DOI: 10.1108/jm2-02-2018-0012.
Rifqi, H., Zamma, A., Ben Souda, S. and Hansali, M., 2021. Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry. Quality Innovation Prosperity, [e-journal] 25(2), pp.54-77. DOI: 10.12776/QIP.V25I2.1576.
Smętkowska, M. and Mrugalska, B., 2018. Using Six Sigma DMAIC to Improve the Quality of the Production Process: A Case Study. Procedia - Social and Behavioral Sciences, [e-journal] 238, pp.590-596. DOI: 10.1016/j.sbspro.2018.04.039.
Soundararajan K. and Janardhan, R.K, 2019. Cost-reduction and quality improvement using DMAIC in SMEs. International Journal of Productivity and Performance Management, [e-journal] 68(8), pp,1528-1540. DOI: 10.1108/ijppm-10-2018-0360.
Authors
Ly Duc, M., Bilik, P., & Duy Truong, T. . (2022). Design of Industrial System Using Digital Numerical Control. Quality Innovation Prosperity, 26(3), 135–150. https://doi.org/10.12776/qip.v26i3.1747
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