Reduction of assembly time in ball valve manufacturing using DMAIC methodology

摘要

In this present scenario the reduction of cycle time and lead time of a component is essential to uplift the business and to satisfy the customer. The case study was taken in the assembly section of ball valve manufacturing, during the study and observation it was found that more time is consumed to assemble a single ball valve. Hence the DMAIC methodology was applied to investigate the causes to get the solution to overcome it. The various tools and techniques such as SIPOC tool, time study, brain storming, 5S have been applied under DMAIC phases. The reasons are arrived through TIMWOOD method of waste identification and solutions are suggested. The synergic approach of DMAIC and 5S have results a good solution. Finally, the time taken to assemble one ball valve i.e.2.4 min is reduced to 1.8 min and this in turn reduced the lead time of 30 days to 26 days to produce 6000 valves.