Research On Optimization Of Iron Scrap Cleaning In Bearing Production Of Company A Based On DMAIC

The problem of insufficient cleaning of iron filings in Company A has led to a series of negative impacts.From the perspective of external complaints of OEM customers,there were 25 complaints about iron filings from April 2021 to March2022,far exceeding the complaint quantity standard set by the company.Complaints in this respect will not only cause financial losses,but also have a negative impact on customer loyalty.From the point of view of the company’s internal production,iron filings attached to automobile hub bearings may lead to their scrapping,whether surface scratches or problems caused by assembly detection are worthy of attention.In addition,excessive accumulation of iron filings in the conveyor belt will also reduce the actual use time of the conveyor belt.Excessive iron filings are also 5S problems.In order to solve this problem,starting from the actual production,this dissertation studies the iron scrap cleaning problem in the production of automobile hub bearing of company A.Considering a series of consequences caused by insufficient cleaning of iron scraps,it was decided to adopt Lean Six Sigma management method for optimization and apply DMAIC process to the cleaning and optimization of iron scraps.In the D(definition)stage,the core process of iron scrap cleaning and optimization is defined.In the M(measurement)stage,MSA analysis and process capability analysis were carried out on the iron filings related measurement data.In the A(analysis)stage,the insufficient cleaning of iron scraps in the tooth drawing,runout turning and cleaning processes is deeply discussed.Three fishbone diagrams are respectively used to analyze the three processes from five dimensions of human-machine material process,and then factors are screened according to the actual situation and the difficulty of operation,laying a foundation for the next step of cleaning and improving iron scraps.In the I(improvement)stage,a rubber ring was added for the tooth drawing process,which improved the iron filings attached to the ABS ring.In the aspect of runout turning,the application of Z-axis positioning makes the adhesion of iron filings produced in this process improved;In terms of cleaning machine,the cleaning effect of this process is measured by single factor test,and the straight-through cleaning machine with better cleaning effect is introduced.In the C(control)stage,the optimization results of iron filings cleaning are controlled.Through the DMAIC process,the situation of iron filings attached to automobile hub bearings is reduced,and iron filings related complaints are solved.The successful application of Lean Six Sigma in iron scrap cleaning not only reduces complaints and improves production level,but also serves as a good example for the implementation of Lean Six Sigma in the company.