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    Fyp Presentation (Nasr Part)

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    Nasrullah Khan
    This document summarizes a Lean Six Sigma project conducted at Indus Motor Company Ltd to minimize vehicle repair rates. The project team used the DMAIC methodology and defined the problem as excessive repair rates during manufacturing. The project charter outlined the goal to minimize repair rates to improve quality and productivity. In scope were the assembly, welding, and paint sections. Key stakeholders were identified along the production process flow.

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    Fyp Presentation (Nasr Part)

    Uploaded by

    Nasrullah Khan
    113 views13 pages
    This document summarizes a Lean Six Sigma project conducted at Indus Motor Company Ltd to minimize vehicle repair rates. The project team used the DMAIC methodology and defined the problem as excessive repair rates during manufacturing. The project charter outlined the goal to minimize repair rates to improve quality and productivity. In scope were the assembly, welding, and paint sections. Key stakeholders were identified along the production process flow.

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    This document summarizes a Lean Six Sigma project conducted at Indus Motor Company Ltd to minimize vehicle repair rates. The project team used the DMAIC methodology and defined the problem as excessive repair rates during manufacturing. The project charter outlined the goal to minimize repair rates to improve quality and productivity. In scope were the assembly, welding, and paint sections. Key stakeholders were identified along the production process flow.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    113 views13 pages

    Fyp Presentation (Nasr Part)

    Uploaded by

    Nasrullah Khan
    This document summarizes a Lean Six Sigma project conducted at Indus Motor Company Ltd to minimize vehicle repair rates. The project team used the DMAIC methodology and defined the problem as excessive repair rates during manufacturing. The project charter outlined the goal to minimize repair rates to improve quality and productivity. In scope were the assembly, welding, and paint sections. Key stakeholders were identified along the production process flow.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 13

    [MINIMIZATION OF REPAIR RATE

    AND REWORKING BY USING LEAN


    SIX SIGMA (DMAIC)
    METHODOLOGY]

    [TOYOTA INDUS
    MOTORS COMPANY LTD]
    PROJECT TEAM MEMBERS

    • Nasrullah khan (D-15-IN-53)


    • Faizan Shaikh(D-15-IN-22)
    • Ali Riaz (D-15-IN-41)
    • Muhammad Ahsan(D-15-IN-03)

    INTERNAL SUPERVISOR
    • Engr. Rano Khan Wassan (Lecturer at DUET)

    EXTERNAL SUPERVISOR
    • Engr.Rehan Afzal (Quality Manager at IMC)
    TABLE OF CONTENETS

    Introduction
    INTRODUCTION
    About company
     Indus Motor Company Limited (IMC) is a joint venture of House of Habib of
    Pakistan, Toyota Motor Corporation and Toyota Tsusho Corporation of Japan.
     The Company manufactures and markets Toyota brand vehicles in Pakistan.
    Products
     The main product offerings include several variants of the flagship ‘Corolla’
    in the passenger cars category
     ‘Hilux’ in the light commercial vehicles segment
     ‘Fortuner’ in the Sports Utility Vehicle.
    Location
     The manufacturing facility and offices are located at a 105 acre site in Port
    Qassim, Karachi
     While the product is delivered to end customers nationwide through a
    strong network of 45 independent 3S Dealerships spread across the country.
     Lean Six Sigma DMAIC Methodology
    DEFINE PHASE
     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
     Project Charter
    Project Title Minimization of repair rate by using lean six sigma

    Methodology Using DMAIC approach (define, measure, analyze ,improve ,


    control )

    Business case Repairing of vehicles is a very critical process in 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

    Project scope Assembly section, welding section, and paint section


    department’s head should be involve during different phases of
    the project.
     Project Objectives
     Reduce defects

     Reduce man power

     POSSIBLE OUTCOMES

     Decrease repair rate

     Improve productivity
     Scope Of Project

    This project is focused on the quality improvement of

     Paint Repair Shop and

     Assembly
     Flow process chart of IMC
     Voice Of Customer
     SIPOC(Supplier Input Process Output Customer)
    SUPPLIER INPUT PROCESS OUTPUT CUSTOMER

    Engineering Latest drawing/ Vehicle map Detail of vehicle Production


    Department specification preparation manufacturing department

    Production
    Details of vehicle and Preparation of Select production
    Engineering Press shop
    design requirements assembly parts line and define routing

    Press Shop Detail drawing of Select doors of


    Body manufactured Weld shop
    vehicle body vehicle

    Welding Welding of job


    All welding Vehicles body
    Engineer according to Paint shop
    parameters prepared
    parameter
    Paint
    Color material Execution of paint Body painted Assembly shop
    Engineering
    Assembly Material handling of Fitting assembly in Fitted all parts in
    Department Quality control
    parts painted body body

    Quality Third party


    Vehicle requirements Visual testing Verified

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