Live Case Study
This project focused on improving the automatic welding process to reduce leakage in the condensers of 5,000 BTU window air conditioners, resulting in a reduced return rate of non-cooling products from the market and improved customer satisfaction and experiences. Six Sigma DMAIC methodology was the primary tool used in the problem solving process. Flow charts, SIPOC, CE matrixes, FMEA analysis, measurement system analysis, chi-square test, process capability analysis, DOE experimental design, and control charting are among the tools that were utilized. The project scope and stakeholders were determined by SIPOC chart. 39 inputs affecting the project were found through a detailed flow chart, 13 key factors were found by CE matrix, and 12 important factors were highlighted by FMEA. As a result, 6 quick-win improvements were made, and the remaining 6 factors were analyzed in-depth and improved by updating standards, modifying equipment, and utilizing expert guidance. As a result, the goal of reducing the automatic welding leakage rate of the condenser by 70% was achieved.