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Open AccessFeature PaperArticle

Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

Department of Industrial Engineering, Tecnológico Nacional de México/Instituto Tecnológico de Tijuana, Calzada del Tecnológico S/N, Tijuana, Baja California 22414, Mexico
Chemical Sciences and Engineering Faculty, Universidad Autónoma de Baja California, Calzada Universidad #14418, Parque Industrial Internacional, Tijuana, Baja California 22390, Mexico
Author to whom correspondence should be addressed.
Appl. Sci. 2018, 8(11), 2181;
Received: 16 October 2018 / Revised: 2 November 2018 / Accepted: 5 November 2018 / Published: 7 November 2018
(This article belongs to the Special Issue Applied Engineering to Lean Manufacturing Production Systems)
Defects are considered as one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects that are generated during the welding process. In addition, it is intended to increase 20% the capacity of three double production lines where electronic boards are processed. As method, the Plan-Do-Check-Act (PDCA) cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79%, and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help to decrease the number of defective components. View Full-Text
Keywords: lean manufacturing; Plan-Do-Check-Act (PDCA); defects; pareto chart; flowchart lean manufacturing; Plan-Do-Check-Act (PDCA); defects; pareto chart; flowchart
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Realyvásquez-Vargas, A.; Arredondo-Soto, K.C.; Carrillo-Gutiérrez, T.; Ravelo, G. Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study. Appl. Sci. 2018, 8, 2181.

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