The current research study aimed to explore the utility of selected problem-solving tools and techniques in root-cause analysis to demonstrate their practical application. An experimental research design adopting a positivist empirical approach with a deductive strategy was followed to assess the effectiveness of a combined (8D & Six Sigma) problem-solving approach in reducing a high defects rate of a mixer shower assembly line. A novel application of the 8D framework in combination with Six Sigma and other analytical tools was found highly effective in reducing the reject rate from 11.84% to 0.11%. Successful identification of the root cause led to the implementation of permanent corrective action ensuring a long-term stable assembly process. The research study provided a problem-solving framework that was found effective in resolving a complex problem and implementing long-term corrective action in an assembly production line. However, this framework can be used in other industries. The research study provides a solution to a high number of leak rejects in a sub-assembly where "O-seals" are used between mating parts. It also provides analytical tools that were found highly effective during the problem-solving process.
The research study aims to evaluate the precision of the measurement system using Gauge R&R. An experimental research design adopting a positivist empirical approach with deductive strategy was followed to assess the effectiveness of Crossed Gauge R&R technique for validating a measurement system using destructive testing. Crossed Gauge R&R technique in Minitab was found to be highly effective in quantifying different components of measurement variation relative to process variation. Clue generation from the Crossed Gauge R&R study combined with manufacturing and measurement process know-how helped in identifying and eliminating the root causes for measurement variation. Overall Crossed Gauge R&R proved successful in validating the burst strength test equipment. However, it should be noted that manufacturing and test equipment played an equally important part in developing and executing the gauge R&R study and accurately analysing the results. So, Crossed Gauge R&R should be used as an aid rather than the solution for measurement system validation.
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