Research On Product Quality Improvement Of Company A Based On Lean Six Sigma

With the arrival of " Industry 4.0" and big data era,more and more enterprises realize that data-based analysis and decision-making has obvious advantages.Statistic-based six Sigma is a systematic and considerable quality control method.Lean production is a management approach that focus on reducing waste.Lean Six Sigma has advantages over two aspects of the speed and the process robustness,and the competitors should never underestimate the gaining competitive advantages.In that,many enterprises have payed much attention to the implementation of Lean Six Sigma.This thesis summarized published research in both domestic and abroad,and suggested the related methods,concepts and implementations of Lean Production,Six Sigma,Lean Six Sigma.On the basis of the published investigation,we analyzed the situation of quality management of company A,including low customer satisfaction,low product quality level,cost of poor quality,inadequate personnel quality awareness and knowledge together with skills,and lack of quality improvement project,improper management which needs to be standardized,insufficient corrective action and preventive action,etc.To address mentioned problems,we proposed specific implementation approaches of Lean Six Sigma in the company.The shampoo viscosity improvement of company A was taken as a case and the tool DMAIC of lean six sigma was used to improve it.Key quality characteristics were identified in the definition phase and the improvement scope,project objectives,project team and project schedule were determined.After analyzing Y's measurement system,process capability,C&E and FMEA in the measurement phase,the simple influencing factor X was improved quickly with lean improvement,while the complex influencing factor X was introduced in the analysis phase.In the analysis phase,for the key factor(the amount of tackifier)that was selected in the previous phase,we applied the method of linear regression and hypothesis test to prove the certain linear relationship between the tackifier and viscosity,and there was no difference of the viscosity adjustment due to the order of viscosity addition after D component to be added.In the improvement phase,the best factor parameters were obtained by quantifying DOE experiments and RSM analysis methods,and were verified to be in line with expectations by trial production.In that,we determined the best improvement scheme.In control phase,X and Y were monitored and controlled.Finally,the optimal process was conclude,namely the tackifier in time from the initial viscosity test,after the completion of change to the D components after completion of feeding,control add tackifier added quantity and the moisture,at the same time made for the amount of tackifier and viscosity changes corresponding to the table,to guide the workshop viscosity adjustment when addition amount of tackifier.The improvement of shampoo viscosity case had evaluated in the actual effects from the initial viscosity yield of shampoo production,the number of times to adjust the viscosity of each batch,the production time occupied by the viscosity adjustment of each batch,and the process capability of the final viscosity.Due to the positive improvement effect,it was obvious that the approach could be used as a promotion to other daily chemical products of the company.On the basis of the implementation of Lean Six Sigma,Company A had achieved a promising improvement results in customer satisfaction,finance,quality indicators,production performance,human resources,corporate culture and management changes,and had successfully implemented Lean Six Sigma for domestic daily-use chemical companies as well.