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  • Author: Krzysztof Knop x
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Analysis and Improvement of the Galvanized Wire Production Process with the use of DMAIC Cycle

Abstract

The article presents the results in the scope of analysis and improvement of the galvanized wire production process with the use of Six Sigma's DMAIC cycle. The basic problem was identified - incorrect wire diameters after galvanizing and specific tools and methods were used to analyze this problem and look for its solution. The potential of Pareto analysis, SPC method, control plan, 5WHY analysis was used. As a result of the analyzes carried out, the source cause was identified - contaminated containers dispensing the preparation maintaining the temperature in the galvanizing unit. To eliminate the problem, maintenance of the machine used to cover the bare wire with zinc was carried out, which allowed to achieve the following results: standstills at the Drawing and Galvanizing Department were eliminated, the duration of the manufacturing process and the percentage of products beyond the specification were significantly reduced.

Open access
Elimination of constraints in the production process of power equipment components and the analysis of the resulting benefits

Abstract

The article presents the results regarding the elimination of constraints in the production process of a power equipment subassembly, a boiler chamber, together with an analysis of the benefits resulting from this, both financial and non-financial. The significance of bottlenecks in the production process, ways of its identification and limitations - in general - are presented. The article is a case-study of an attempt to eliminate the bottleneck in the production process of the boiler chamber, which turned out to be the process of drilling and marking-off, and work stations representing these processes. In order to eliminate the limitation, it was decided to replace the existing tracing and drilling work with a numerically controlled device - a boring machine moved from the liquidated department.. As a result, labor-intensive, manual chambers marking-off and the process of drilling holes with a smaller diameter drill have been eliminated. A number of benefits has been demonstrated resulting from the elimination of the bottleneck in the process, first of all, it was possible to reduce the duration of the marking-off and drilling operations and reduce the costs of the boiler chamber production process.

Open access
Statistical control of the production process of rolled products

Abstract

The article presents the results of the use of SPC tools, i.e. control charts and indicators of the qualitative capability to assess the stability and capability of the production process of rolled products - I-sections. Statistical analysis of the collected data regarding the selected feature of the analysed product - the width of the foot, and the normality of the distribution were done, which showed that the obtained distribution of measurement results is not a normal distribution. As a result, appropriate SPC procedures for non-normal distribution were used. The Pareto-Lorenzo diagram and FMEA method were also used to obtain information about the structure of non-conformities of the analysed product and the level of risk associated with them. This information was used to propose corrective actions and improve the production process of rolled products.

Open access
Evaluation of the Level of Work Safety, Advancement and Efficiency of the Use of Machines and Devices on Labelling and Packaging Line and an Attempt to Compare the Results Using the Modified Mckinsey Matrix

Abstract

The article presents the results of the assessment of the level of work safety, the level of modernity and the efficiency of the use of machines on the labelling and packaging line. The assessment of the level of occupational safety was made on the basis of an interview conducted with machine operators, by direct observation and analysis of historical data. The basis for assessing the level of modernity was the ABC technology method and the 5-stage Parker scale, while the OEE indicator was used to assess the level of efficiency of the use. An assessment of the level of safety, modernity, efficiency and other aspects such as cleanliness, completeness, maintenance, improvements for machines in the line with the use a scale of 0-5 was included and next, based on the validity index, the overall result was calculated. Modified McKinsey matrix was used to evaluate these factors and comparison the obtained results with other lines in the company. As a result of the conducted analyzes, it was pointed out that it is necessary to take improvement measures in the area of the worst-assessed factors.

Open access
Quality Improvement in the Production Company

Abstract

The article discusses the quality improvement concept in terms of companies’ competitiveness and its operations. The research object is a production company located in Silesia province. We analyzed the quality problems occurring in the company based on the selected quality management tools: Ishikawa diagram and the Pareto-Lorenz. It was presented and discussed basic types of waste occurring in the enterprise. It was proposed improvement actions and highlights the importance of immaterial resources - the company's workers.

Open access