Manufacturing problem solving methodology analytic. A case study of leakage current in a production company

Abstract

Product end-user and customer satisfaction are critical for the success of organisations. This paper presents a case study of a design company and manufacturing supplier that faces customer complaints due to defective temperature sensors integrated into fridge freezers. This research aims to find the root cause of the issues and implement a solution to the problem and to ensure that prevent its recurrence by implementing the lean eight disciplines methodology as an analytics step: (1) 5 Whys analysis based on cross-functional team finding, (2) problem descriptions confirmation, (3) containment actions, (4) root cause analysis of occurrence, (5) permanent corrective actions, (6) implementation of permanent corrective action, (7) actions to prevent a recurrence, and (8) closure with eight disciplines report and congratulate cross-functional teams from the design, engineering, and suppliers production sites. High-quality product design, development, production processes and manufacturing require a problem-solving framework for the life cycle assessment. This study develops the Eight Disciplines (8D) investigation tool for cross-functional teams, internal and external work together to solve issues to improve the product life cycle in the field. Shows how to conduct root cause investigation analysis of issues with five whys of the problems for crucial processes. If necessary, integrate the 8D, and Six Sigma approaches to identify answers. It enables corrective and preventive actions and customer reports with executed fixes and measures timelines to prevent similar issues from recurring in businesses. This study deals with product managers and practitioners of manufacturing and product design companies using the 8D analytics tool and framework to solve problems for quality improvements throughout the life cycle of products. For manufacturing problem-solving, use 8D tool analytical challenges (e.g., high warranty cost, high production failures, the unreliability of products, resources, and different scopes) and opportunities (e.g., to solve product issues, improve production processes, and reduce warranty cost). In this case study, a circuit is susceptible to leakage current, cleaning all components following solder assembly. Specific solvents are needed to effectively clean boards because "no-clean" solder flux is used, which does not require cleaning. Therefore, different flux chemistry is necessary for this situation, which can be cleaned using a water-based solvent as a long-term fix, as revealed by the 8D analytics template.