Title: Quality enhancement through first pass yield using statistical process control

Authors: Sukrut Nataraj; Mohammed Ismail

Addresses: Department of Industrial and Production Engineering, The National Institute of Engineering, Mananthody Road, Mysuru – 570008, Karnataka, India ' Department of Industrial and Production Engineering, The National Institute of Engineering, Mananthody Road, Mysuru – 570008, Karnataka, India

Abstract: The purpose of this study was to improve the first pass yield (FPY) and reduce the defect rate of inner tubes used in motorbikes (two-wheeler). Data regarding quantity of products produced, accepted and rejected respectively was compiled and a preliminary FPY was calculated. Further, Pareto chart analysis was carried out to identify the most significant defect types. Fishbone analysis was used to highlight the possible causes of defects and hence determine the causes which had the greatest effect. An action plan for improvement was recommended to increase average FPY from 96.35% to 97.25% indicating a decline in defectives by 6,000 parts a month.

Keywords: first pass yield; FPY; fishbone diagram; Pareto analysis; root cause analysis; improvement action plans; quality improvement; statistical process control; SPC; defect rate; motorcycle inner tubes; motorbikes; motorcycles; inner tube defects.

DOI: 10.1504/IJPQM.2017.081482

International Journal of Productivity and Quality Management, 2017 Vol.20 No.2, pp.238 - 253

Received: 28 Mar 2015
Accepted: 05 Jun 2015
Published online: 10 Jan 2017 *

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