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Article

Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company

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Department of Industrial Engineering, Tecnológico Nacional de México/Instituto Tecnológico de Tijuana, Calzada del Tecnológico S/N, Tijuana 22414, Baja California, Mexico
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Chemical Sciences and Engineering Faculty, Universidad Autónoma de Baja California, Calzada Universidad #14418, Parque Industrial Internacional, Tijuana 22390, Baja California, Mexico
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Department of Industrial and Manufacturing Engineering, Autonomous University of Ciudad Juarez, Ave. del Charro 450 Norte. Col. Partido Romero, Ciudad Juárez 32310, Chihuahua, Mexico
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Department of Electrical Engineering, University of La Rioja, Edificio Departamental—C/San Jose de Calasanz 31, 26004 Logroño, La Rioja, Spain
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Author to whom correspondence should be addressed.
Appl. Sci. 2020, 10(7), 2433; https://doi.org/10.3390/app10072433
Received: 31 January 2020 / Revised: 19 March 2020 / Accepted: 30 March 2020 / Published: 2 April 2020
(This article belongs to the Special Issue Design and Management of Manufacturing Systems)
Customer satisfaction is a key element for survival and competitiveness in industrial companies. This paper describes a case study in a manufacturing company that deals with several customer complaints due to defective custom cable assemblies that are integrated in an engine. The goal of this research is to find a solution to this problem, as well as prevent its recurrence by implementing the eight disciplines (8Ds) method in order to: (1) develop a team, (2) describe the problem, (3) develop an interim containment action, (4) determine and verify root causes, (5) develop permanent corrective actions, (6) define and implement corrective actions, (7) prevent recurrences, and (8) recognize and congratulate teamwork as well as individual contributions. Therefore, a software tool is proposed to conduct a functional test on assembly lines. After the test, the problem was successfully reduced and detected, because from 67 engines that were identified with problems, 51 were redesigned before being sent to customers, consequently decreasing the number of defective products by 75%, whereas the remaining 16 engines were replaced by new engines. In conclusion, the research goal was accomplished, and the 8Ds method proved to be a helpful model with which to increase employees’ motivation and involvement during the problem-solving process. View Full-Text
Keywords: 8 disciplines method; custom cable assemblies; defects; functional test; customer satisfaction 8 disciplines method; custom cable assemblies; defects; functional test; customer satisfaction
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MDPI and ACS Style

Realyvásquez-Vargas, A.; Arredondo-Soto, K.C.; García-Alcaraz, J.L.; Macías, E.J. Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company. Appl. Sci. 2020, 10, 2433. https://doi.org/10.3390/app10072433

AMA Style

Realyvásquez-Vargas A, Arredondo-Soto KC, García-Alcaraz JL, Macías EJ. Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company. Applied Sciences. 2020; 10(7):2433. https://doi.org/10.3390/app10072433

Chicago/Turabian Style

Realyvásquez-Vargas, Arturo, Karina C. Arredondo-Soto, Jorge L. García-Alcaraz, and Emilio J. Macías 2020. "Improving a Manufacturing Process Using the 8Ds Method. A Case Study in a Manufacturing Company" Applied Sciences 10, no. 7: 2433. https://doi.org/10.3390/app10072433

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