. . 2556 16-18 2556

Defects and Waste Reduction with Lean Six Sigma Concept in

the Motorcycle Spare Parts Manufacturing Plant

1*, 2, 3 4

. 73170

E-mail: amp.d@hotmail.com*

Atiphon Dansatien1*, Supawit Assavarungsrikul2, Arthit Nakbun3 and Ronnachai Sirovetnukul4

1,2Department of Industrial Engineering, Faculty of Engineering, Mahidol University, Putthamonthon, Salaya, NakhonPathom 73170

E-mail: amp.d@hotmail.com*

DMAIC (Process Mapping)

(Failure Mode and Effects Analysis; FMEA) (Measurement System Analysis; MSA)

(Preventive Maintenance) (Standardized Work)

(Work Instruction)

2 47 5,300 6,800 3.00-3.14

10,000 15,000 2.70-2.91 36,743.35

Abstract

The purpose of this research is toreduce defects and wasteby using Lean Six Sigma concept in the

motorcycle spare parts manufacturing plant. Lean and Six Sigma benefits are used to solve the problems. DMAIC is the track of the problems solving. Failure Mode and Effects Analysis(FMEA) is used in gathering

the problem information. Measurementsystem analysis(MSA) is used in measurement phase. Lean tools are

used afterwards. Preventive Maintenance and standardized work are used in improvement phase and work instruction is updated to be a present state. After Lean Six Sigma concept is applied, the result are

. . 2556 16-18 2556

categorized into defects and cost reduction. The number of defects aredecreased to 47 percent. They reduce approximately from 10,000 - 15,000 pieces per month to 5,300 - 6,800 pieces per month. Quality level

increase from 2.70-2.91 to 3.00-3.14 . Direct labor and direct material cost are reducted to 36,743.35 baht.

Keywords: Lean Six Sigma, Motorcycle Spare Parts, Quality Level, Defects, Waste

1.

Weight Handle 6401(WH6401)

. .2554 . .2555

WH6401 1

[1], [2]

[3] [4]

1 WH6401

2.

2

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2

2.1 (Define)

WH6401

3

. . 2555

3 2555

80 Ø20

(Process 2) Ø30 (Process 2)

2

2.2

(Measurement)

2

2

(Man-

Machine Chart) (Flow Process Chart)

2 CNMG TNMG 2

8

80-90

8 NCL003

4 10

5

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5 2

2.3

FMEA [5]

NCL003 6

6

. . 2556

6 7

7 6

1

4

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7 [3] (Defects)

1

(Inappropriate

Processing)

[6]

2.4 (Improvement)

(Black

Belt) (Green Belt)

5 . [3]

.1

2 1) Ø20

2) Ø30 3) 4) Ø20

8

8

.2

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88

.3

1)

2)

3)

3

.4

.5

.

(QC)

(Preventive Maintenance) [7]

(Planned Maintenance) [7]

2 6 (

6-8 ) (Autonomous

Maintenance) [7]

1) 2

40-100

30

30

1.1)

8.00 . 1.2)

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9 10 PM

NCL003

4

4 2 10

10 2

11

11

. . 2556

2.5 (Control)

(DMAIC)

(Six Sigma) [4]

3.

57 2 ( )

47

10,000-15,000 2.70-

2.91 5,300-6,800

3.00-3.14

. . 2556 16-18 2556

6.50-6.98 6.45

23,368.35

13,375

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http://healthcare.isixsigma.com/library/ content/c031126a.asp

[3] . �

(Introduction to Lean Manufacturing System). 4. :

( - ); 2549. [4] . Quality

Control. : ) (;2551.

[5] . FMEA . Industrial

Technology Review. 73. 2543.

101-105.

[6] , . Six Sigma .

4. : ; 2548. [7] . .

: ; 2545.