Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach

In the manufacturing industry, intense competition and more complex customer needs and demands have forced entire industries and organisations to continuously improve the quality of their products, as well as the Small and Medium Enterprise (SME) industry. A good Quality Control (QC) system is the o...

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Main Author:	Mohd Hashim, Nurul Nasreen
Format:	Thesis
Language:	English English
Published:	2019
Subjects:	T Technology (General) TS Manufactures
Online Access:	http://eprints.utem.edu.my/id/eprint/24932/1/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf http://eprints.utem.edu.my/id/eprint/24932/2/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf
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id	my-utem-ep.24932
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Ebrahim, Zuhriah
topic	T Technology (General) TS Manufactures
spellingShingle	T Technology (General) TS Manufactures Mohd Hashim, Nurul Nasreen Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
description	In the manufacturing industry, intense competition and more complex customer needs and demands have forced entire industries and organisations to continuously improve the quality of their products, as well as the Small and Medium Enterprise (SME) industry. A good Quality Control (QC) system is the one of the factors that a company should be taking care of in delivering the best products quality and services in order to overcome the other competitors and gain customer’s loyalty. In this project, the company realises the need to enhance the effectiveness of their Quality Control (QC) system due to inconsistent judgment and repeated problems. Due to this problem, it could lower the production effectiveness and high reject and rework cases. The aim of this project is to enhance the effectiveness of the current Quality Control (QC) system by using Lean Six Sigma approach. In order to achieve the aim, there are two objectives that need to be achieved; (i) To identify the gaps between the current Quality Control (QC) system that used in the company and Quality Control (QC) system in theory and (ii) To enhance the effectiveness of current Quality Control (QC) system by eliminating and reducing the gaps. This project has been conducted using Lean Six Sigma approach which is the DMAIC methodology that consists of five stages DefineMeasure-Analyse-Improve-Control. Analysis of the results shows that (i) Only certain process in the production line of flexible link that have QC inspection, (ii) High potential inspection error based on experience which is absent of standard references for the visual inspection, (iii) Company does not follow the acceptance sampling theory. In conclusion, the effective of current QC system at the company can be enhanced through the implementation of acceptance sampling based on theory. Furthermore, the development of standard references for QC inspection at the production process is essential for the enhancement of QC system.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mohd Hashim, Nurul Nasreen
author_facet	Mohd Hashim, Nurul Nasreen
author_sort	Mohd Hashim, Nurul Nasreen
title	Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
title_short	Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
title_full	Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
title_fullStr	Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
title_full_unstemmed	Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach
title_sort	enhancing the effectiveness of quality control system using lean six sigma approach
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty of Manufacturing Engineering
publishDate	2019
url	http://eprints.utem.edu.my/id/eprint/24932/1/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf http://eprints.utem.edu.my/id/eprint/24932/2/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf
_version_	1747834099800735744
spelling	my-utem-ep.249322021-09-29T11:49:45Z Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach 2019 Mohd Hashim, Nurul Nasreen T Technology (General) TS Manufactures In the manufacturing industry, intense competition and more complex customer needs and demands have forced entire industries and organisations to continuously improve the quality of their products, as well as the Small and Medium Enterprise (SME) industry. A good Quality Control (QC) system is the one of the factors that a company should be taking care of in delivering the best products quality and services in order to overcome the other competitors and gain customer’s loyalty. In this project, the company realises the need to enhance the effectiveness of their Quality Control (QC) system due to inconsistent judgment and repeated problems. Due to this problem, it could lower the production effectiveness and high reject and rework cases. The aim of this project is to enhance the effectiveness of the current Quality Control (QC) system by using Lean Six Sigma approach. In order to achieve the aim, there are two objectives that need to be achieved; (i) To identify the gaps between the current Quality Control (QC) system that used in the company and Quality Control (QC) system in theory and (ii) To enhance the effectiveness of current Quality Control (QC) system by eliminating and reducing the gaps. This project has been conducted using Lean Six Sigma approach which is the DMAIC methodology that consists of five stages DefineMeasure-Analyse-Improve-Control. Analysis of the results shows that (i) Only certain process in the production line of flexible link that have QC inspection, (ii) High potential inspection error based on experience which is absent of standard references for the visual inspection, (iii) Company does not follow the acceptance sampling theory. In conclusion, the effective of current QC system at the company can be enhanced through the implementation of acceptance sampling based on theory. Furthermore, the development of standard references for QC inspection at the production process is essential for the enhancement of QC system. 2019 Thesis http://eprints.utem.edu.my/id/eprint/24932/ http://eprints.utem.edu.my/id/eprint/24932/1/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf text en public http://eprints.utem.edu.my/id/eprint/24932/2/Enhancing%20The%20Effectiveness%20Of%20Quality%20Control%20System%20Using%20Lean%20Six%20Sigma%20Approach.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=118082 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Ebrahim, Zuhriah 1. Anonymous, 2012. PDCA Problem Solving Technique & Tools by Operational Excellence Consulting. 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Assessing acceptance sampling application in manufacturing electrical and electronic products, 31(2), pp. 622–628. 13. Forbes, L.H. and Ahmed, S.M., 2010. Modern construction: lean project delivery and integrated practices. 14. Govindaraju, K. and Ganesalingam, S., 1998. Zero Acceptance Number Quick Switching System For Compliance Sampling, pp. 1–12. 15. Khasawneh, M. T. et al., 2003. The Effects of Eye Movements on Visual Inspection Performance Department of Computer Science, pp. 1–6. 16. Harry, M. and Schroeder, R., 2000. Six Sigma: The breakthrough management strategy revolutionizing the world's top corporations. 17. Juran, M., and Godfrey, A.B., 1998. Juran’s quality handbook (5th ed.). Washington, DC: McGraw-Hill Companies, Inc. 18. Koning, H. and de Mast, J., 2006. A rational reconstruction of Six-Sigma’s breakthrough cookbook, International Journal of Quality and Reliability Management, Vol. 23 No. 7, pp. 766-787 19. Liker, J. k., 2005. Toyota Way Fieldbook: A Practical Guide for Implementing Toyota's 4Ps. The McGraw-Hill Companies. 20. Luke, K., 2019. Best Excel Tutorial: Pareto Diagram. [online] Available at: https://best-excel-tutorial.com/56-charts/77-pareto-chart [Accessed on 30 April 2019]. 21. Magar, V. M. and Shinde, V. B., 2014. Application of 7 Quality Control ( 7 QC ) Tools for Continuous Improvement of Manufacturing Processes, 2(4), pp. 364–371. 22. Montgomery, D.C., 2007. Introduction to Statistical Quality Control. John Wiley & Sons. 23. Muhammad, S., 2015. Quality Improvement Of Fan Manufacturing Industry By Using Basic Seven Tools Of Quality : A Case Study, 5(4), pp. 30–35. 24. Nave, D., 2002. How to Compare Six Sigma, Lean and The Theory Of Constraints. Quality progress, 35(3), pp. 73-80. 25. Okerekehe, O. S., 2014. The Impact of Inspection on the Quality Assurance and Reliability of Projects , Manufacturing , Operations and Maintenance, 4(27), pp. 3884–3901. 26. Paritosh, 2019. 5 Principles of Lean Management [online] Available at: https://soft2share.com/5-principles-of-lean-management/ [Accessed on 30 April 2019]. 27. Penfield, D., 2007. Control Chart [online] Available at: https://commons.wikimedia.org/wiki/File:ControlChart.svg [Accessed on 30 April 2019]. 28. Penfield, D., 2010. Check Sheet of Motor Assembly [online] Available at: https://commons.wikimedia.org/wiki/File:Check_sheet_for_motor_assembly.svg [Accessed on 30 April 2019]. 29. Peter Hines and Nick Rich, (1997). The Seven Value Stream Mapping Tools, Published by International Journal of Operations and Production Management. 30. Rawabdeh, I. A., 2005. A model for the assessment of waste in job shop environments. International Journal of Operations & Production Management, 25(8), pp. 800-822. 31. Sandra, K. G., Brian. J. M., Anand. K. G., 2001. The effects of per-lot and per-item pacing on inspection performance, International Journal of Industrial Ergonomics, 27, pp. 291–302 32. Stephen, P. (2004) Application of DMAIC to integrate Lean Manufacturing and Six Sigma. 33. Tetteh, E. G., Jiang, S. and Lafayette, W., 2006. The Effects of Search Strategy, Task Complexity and Pacing on Visual Inspection Performance , (1), pp. 2–7. 34. Vijayarangam, J. et al., 2017. Implementation Of Seven Tools Of Quality In Educational Arena : Implementation Of Seven Tools Of Quality In Educational Arena : A Case Study.

Enhancing The Effectiveness Of Quality Control System Using Lean Six Sigma Approach

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