Reducing Defects from the Production Line by Total Productive Maintenance Principles and Six Sigma Techniques : A Case Study of ABC Automotive Parts Manufacturer in Nakhon Ratchasima Province

Abstract

This study aimed to reduce the defects in the welding process of the shock absorber and reduce the cost of manufacturing car shock absorbers. The principles of Total productive maintenance, and the Six Sigma techniques have been applied. By setting up a group to carry out activities to improve the work, and defect reduction in the ABC automotive parts manufacturing industry in the Nakhon Ratchasima province. The results showed that this activity can reduce the amount of defects in the process of welding the shock absorber from 2.17% to 1.05% or a decrease of 48.3%.The value of Six Sigma, which is a measure of confidence, increased from 2.3 to 2.5 by reducing defects in the process, resulting in a reduction in defects in the final inspection process from 0.17% to 0.08%, or 47.01%, rednced the rework cost from 124,830 baht per month to 62,415 baht per month, or a 50% reduction, It saved rework cost 748,980 baht per year. As well, The Mean Time Between Failure (MTBF) increased from 65 hours to 283 hours and the Mean Time to Repair (MTTR) decreased from 75 minutes to 30 minutes.