DMAIC Cycle for the New Product Launch Process: FMEA and DOE Applications for Built-In Oven

Yıl 2024, Cilt: 58 Sayı: 1, 29 - 44, 31.01.2024

Ezgi Aktar Demirtaş , Gamze Yetimler Kostur , Mehmet Erol Kara

https://doi.org/10.51551/verimlilik.1319240

Öz

Objective: Six Sigma-SS and the DMAIC-Define, Measure, Analyze, Improve, Control cycle are employed to enhance the success of the launch of a new built-in oven with a digital panel.
Method: Following the define and measure phases, to identify and eliminate potential failures, Failure Mode and Effect Analysis-FMEA is conducted and control plans were composed during the analyse phase. In the improvement phase, the Risk Priority Numbers-RPNs obtained through FMEA and recommendations were listed. Using Design of Experiments-DOE, the lifespan of bulbs in ovens was maintained at the target value while reducing procurement costs. In the control phase, the results of validation experiments and the gains were reported.
Findings: After reporting the RPNs related to high-risk failure modes and providing improvement recommendations, DOE and Analysis of Variance were employed to determine which type of oven and brand of bulb could be used. If implemented, the expected annual savings are approximately 20,000 Euros.
Originality: This article focuses on an integrated approach for a product that is set for a new launch. It aims to improve design and production processes using the SS while also targeting cost reduction in procurement processes. To the best of our knowledge, no similar study has been encountered in the literature.

Anahtar Kelimeler

Six Sigma, Built-in Oven, Design of Experiment, Failure Mode and Effect Analysis

Yeni Bir Ankastre Fırını Devreye Alma Sürecinde TÖAİK Döngüsü: HTEA Ve DT Uygulamaları

Öz

Amaç: Altı Sigma Metodolojisi ve TÖAİK-Tanımla, Ölç, Analiz Et, İyileştir, Kontrol Et döngüsü ile ilk kez piyasaya sunulacak olan dijital panelli ankastre bir fırın lansmanının başarısını artırmak hedeflenmiştir.
Yöntem: Tanımlama ve ölçme aşamasını takip eden analiz aşamasında Hata Türü ve Etki Analizi-HTEA ile muhtemel hata kaynakları belirlenip elimine edilmeye çalışılmış, kontrol planları oluşturulmuştur. İyileştirme aşamasında, HTEA ile elde edilen Risk Öncelik Sayıları (RÖS) ve iyileştirme önerileri listelenmiştir. Deney Tasarımı (DT) ile ankastre fırınlarda kullanılan ampül ömrünü hedef değerde tutarak satın alma maliyetlerini düşürmek amaçlanmıştır. Kontrol aşamasında doğrulama deneylerinin sonuçları ile elde edilen kazançlar raporlanmıştır.
Bulgular: Yüksek riskli hata türlerine ilişkin RÖS ve iyileştirme önerileri raporlandıktan sonra DT ve Varyans Analizi ile hangi fırın tipinde hangi marka ampülün kullanılabileceği tespit edilmiştir. Uygulamaya geçilmesi halinde beklenen yıllık kazanç yaklaşık 20.000 Euro civarındadır.
Özgünlük: Bu makale; henüz seri üretime geçmemiş ve yeni devreye alınacak olan bir ürün için, Altı Sigma yaklaşımı ile tasarım ve üretim süreçlerini iyileştirirken, satın alma süreçlerinde de maliyeti azaltmayı hedefleyen bütünleşik bir yaklaşıma odaklanmaktadır. Bilindiği kadarıyla literatürde benzer çalışmaya rastlanmamıştır.

Anahtar Kelimeler

Altı Sigma, Ankastre Fırın, Deney Tasarımı, Hata Türü ve Etki Analizi

Kaynakça

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