Quality improvement using lean six sigma in air conditioning products

Cipto Purwanto; Brian Sila Jayanti; Fransiska Sekarlati Bernard; Ardhianiswari Diah Ekawati

doi:10.30811/jpl.v22i5.5408

Quality improvement using lean six sigma in air conditioning products

Cipto Purwanto, Brian Sila Jayanti, Fransiska Sekarlati Bernard, Ardhianiswari Diah Ekawati

Abstract

Air Conditioners (AC) are essential electronic products for residential and industrial buildings in tropical countries or during warm weather in general. The penetration ratio of electronic Air Conditioners (AC) has been increasing every year. Data collection and processing were conducted directly by the author through observation, measurement, and calculation on the heat exchanger production of Air Conditioners (AC). In the production cost of Air Conditioners (AC), the heat exchanger accounts for the second highest cost after the compressor making up 19% of the total cost. The high cost is caused by pipe leaks, with a percentage of 73.7%. This research aims to analyze the improvement of Air Conditioner (AC) production quality using the Six Sigma method. The defect rate in the heat exchanger, evaluated through the Define, Measure, Analyze, Improve, Control (DMAIC) method originating from Six Sigma, was found to be 1,144.8 defects per million opportunities. Further analysis was conducted with the Failure Tree Analysis (FTA) and Failure Mode and Effect Analysis (FMEA) methods. This research was conducted at XYZ company by conducting interviews and observations for 3 months. FMEA and FTA analysis resulted in the top two failure risks based on the Risk Priority Number (RPN): flaring diameter too big and unstable brazing skill. In the manual brazing process, it was found that work by operators with level A certification produced 9% below standard outcomes. An improvement was obtained by changing the punch flaring size to 8.5mm and conducting skill certification and training for brazing operators. The results of the proposed improvement implementation led to a reduction in the DPMO value to 403.35, equivalent to a decrease of 64.7%. The defect ratio in production decreased by 38.1%, exceeding the previous target of 26.2%, equivalent to $31.96/month/unit. The results of this study are horizontal, allowing the implementation of improvements made in the heat exchanger production process to be expanded to other cooling electronic production processes.

Keywords

Six Sigma, air conditioner, heat exchanger, FMEA, FTA.

Full Text:

PDF

References

M. Ghouat, A. Haddout, and M. Benhadou, “Impact of industry 4.0 concept on the levers of Lean Manufacturing approach in manufacturing industries,” Int. J. Automot. Mech. Eng., vol. 18, no. 1, pp. 8523–8530, 2021.

P. Tomov, “The Innovative Development Base of Automation In the Industrial Sphere,” in 2019 International Conference on Creative Business for Smart and Sustainable Growth (CREBUS), 2019, pp. 1–5.

N. Ahmed, M. Wahed, and N. C. Thompson, “The growing influence of industry in AI research,” Science (80-. )., vol. 379, no. 6635, pp. 884–886, 2023.

P. Aghion, A. Bergeaud, M. Lequien, and M. J. Melitz, “The heterogeneous impact of market size on innovation: Evidence from French firm-level exports,” Rev. Econ. Stat., pp. 1–56, 2022.

S. Tissir, S. El Fezazi, and A. Cherrafi, “Industry 4.0 impact on lean manufacturing: literature review,” in 2020 IEEE 13th International Colloquium of Logistics and Supply Chain Management (LOGISTIQUA), 2020, pp. 1–5.

A. K. Möldner, J. A. Garza-Reyes, and V. Kumar, “Exploring lean manufacturing practices’ influence on process innovation performance,” J. Bus. Res., vol. 106, pp. 233–249, 2020.

A. Panwar, R. Jain, A. P. S. Rathore, B. Nepal, and A. C. Lyons, “The impact of lean practices on operational performance–an empirical investigation of Indian process industries,” Prod. Plan. Control, vol. 29, no. 2, pp. 158–169, 2018.

P. Beleya, M. A. A. Bakar, and M. K. Chelliah, “Impact of reverse logistics in the malaysian electrical and electronics industry,” Int. J. Supply Chain Manag., vol. 6, no. 3, pp. 91–101, 2017.

J. G. Zivin and M. E. Kahn, “Industrial productivity in a hotter world: the aggregate implications of heterogeneous firm investment in air conditioning,” National Bureau of Economic Research, 2016.

K. Lundgren-Kownacki, E. D. Hornyanszky, T. A. Chu, J. A. Olsson, and P. Becker, “Challenges of using air conditioning in an increasingly hot climate,” Int. J. Biometeorol., vol. 62, pp. 401–412, 2018.

K. S. Ong, “Review of heat pipe heat exchangers for enhanced dehumidification and cooling in air conditioning systems,” Int. J. Low-Carbon Technol., vol. 11, no. 3, pp. 416–423, 2016.

H. Weiguo, Y. Tingting, Y. Chun, and P. Dengke, “Leakage Analysis of Copper Pipe for Air Conditioner,” in 2019 4th International Conference on System Reliability and Safety (ICSRS), 2019, pp. 166–170.

N. O. Erdil, C. B. Aktas, and O. M. Arani, “Embedding sustainability in lean six sigma efforts,” J. Clean. Prod., vol. 198, pp. 520–529, 2018.

A. Chiarini and M. Kumar, “Lean Six Sigma and Industry 4.0 integration for Operational Excellence: evidence from Italian manufacturing companies,” Prod. Plan. Control, vol. 32, no. 13, pp. 1084–1101, 2021.

T. Immawan, W. Sutrisno, and A. K. Rachman, “Operational risk analysis with fuzzy FMEA (Failure Mode and Effect Analysis) approach (case study: optimus creative bandung),” in MATEC Web of Conferences, 2018, vol. 154, p. 1084.

J. Sarwar et al., “Impact of Stakeholders on Lean Six Sigma Project Costs and Outcomes during Implementation in an Air-Conditioner Manufacturing Industry,” Processes, vol. 10, no. 12, p. 2591, 2022.

R. Lu, C. C. Chao, and Y. Cheng, “To improve the measure fail rate on SEM through six sigma DMAIC methodology—Chien-Hui Lu,” in 2017 Joint International Symposium on e-Manufacturing and Design Collaboration (eMDC) & Semiconductor Manufacturing (ISSM), 2017, pp. 1–4.

A. Kania, K. Cesarz-Andraczke, and J. Odrobiński, “Application of FMEA method for an analysis of selected production process,” J. Achiev. Mater. Manuf. Eng., vol. 91, no. 1, pp. 34–40, 2018.

R. Godina, B. G. R. Silva, and P. Espadinha-Cruz, “A DMAIC integrated fuzzy FMEA model: a case study in the Automotive Industry,” Appl. Sci., vol. 11, no. 8, p. 3726, 2021.

J. Ji, Y. Pan, X. Deng, J. Zhang, and P. Liu, “Research on the heat transfer performance of an improved elastic tube bundle heat exchanger under fluid-induced vibration,” Case Stud. Therm. Eng., vol. 49, p. 103184, 2023.

A. Garg, K. Raina, and R. Sharma, “Reducing soldering defects in mobile phone manufacturing company: A DMAIC approach,” in IOP Conference Series: Materials Science and Engineering, 2020, vol. 748, no. 1, p. 12027.

N. Kaoudom, T. Yimtrakarn, and N. Choomrit, “Using DMAIC Methodology to Reduce Defects in Sport Bar Products,” in 2019 IEEE 6th International Conference on Industrial Engineering and Applications (ICIEA), 2019, pp. 852–855.

D. M. Zaman and N. H. Zerin, “Applying DMAIC methodology to reduce defects of sewing section in RMG: a case study,” Am. J. Ind. Bus. Manag., vol. 7, no. 12, p. 1320, 2017.

K. A. O. Sergey, Scherbin, “A Method For Increasing The Efficiency Of A Propane Air Condenser,” Mod. Technol. Sci. Technol. Prog., 2022, doi: 10.36629/2686-9896-2022-1-89-90.

J. Cartwright and C. Santamarina, “Seismic characteristics of fluid escape pipes in sedimentary basins: Implications for pipe genesis,” Mar. Pet. Geol., vol. 65, pp. 126–140, 2015.

S. P. Sawant and S. V Pataskar, “Applying six sigma principles in construction industry for quality improvement,” Int J Sci Eng Res, vol. 117, no. 4, pp. 129–139, 2014.

H. Harisupriyanto, Y. Prasetiawan, and M. F. R. Supri, “Improving The Quality Of Manufacturing Products With The Application Of Lean Six-Sigma,” in Conference SENATIK STT Adisutjipto Yogyakarta, 2019, vol. 5, pp. 231–240.

DOI: http://dx.doi.org/10.30811/jpl.v22i5.5408