A Scientific Approach of using the DMAIC Methodology to Investigate the Effect of Cutting Tool Life on Product Quality and Process Economics: A Case Study of a Saudi Manufacturing Plant
One of the major priorities for manufacturing companies in the globalized economy is the ability to offer high-quality products to customers at the lowest production cost. Globally, process improvement methods and techniques are used to reduce waste and improve product and service quality. This paper aims to propose a systematic model based on process improvement methodologies and tools to help the manufacturing companies decide on cutting tool life and other manufacturing issues. This research seeks to prove that some common industry practices, such as changing cutting tools in machining processes, can significantly affect the economics of production and the overall performance of the plant. The research is mainly based on analyzing real field data using the DMAIC methodology to identify improvements in order to achieve a balance between economy and quality in a Saudi manufacturing plant. Although the study was concerned only with changing cutting tools in the machining process in an air conditioning plant, its findings and conclusions can be generalized to all manufacturing processes.
Keywords:manufacturing process improvement, DMAIC methodology, cutting tool life, machining operations
F. S. S. Staff 1162, "Cutting Tool Consumption Up 10.8% Year-to-Date," American Machinist, Aug. 13, 2018. https://www.americanmachinist.com/cutting-tools/article/21902825/cutting-tool-consumption-up-108-yeartodate (accessed Aug. 26, 2020).
A. E. Bonilla Hernández, "On cutting tool resource management," Ph.D. dissertation, University West, Trollhättan, Sweden, 2018.
E. Ferrell, "Analysis of Tool Wear and Tool Life of Cutting Tool Inserts using Statistical Process Control Charts: A Case Study," M.S. thesis, Morehead State University, Morehead , KY, USA, 2017.
A. Al-Harbi, "Performance management framework for research and development activities in Saudi Arabia Oil and Gas Sector," Ph.D. dissertation, Universiti Teknologi Malaysia, Johor, Malaysia, 2016.
S. Al-Otaibi, "The relationship between service and organizational culture on students' satisfaction at UMM-Al-Qura university," Ph.D. dissertation, Universiti Teknologi Malaysia, Johor, Malaysia, 2019.
"Saudi Vision 2030," Vision 2030. https://www.vision2030.gov.sa/en (accessed Jan. 26, 2021).
"Saudi Arabia's $7+ Billion HVAC/R Market 2014-2024: Competition, Forecast and Opportunities - ResearchAndMarkets.com," Business Wire, May 13, 2019. https://www.businesswire.com/news/home/2019051300
/en/Saudi-Arabias-7-Billion-HVACR-Market-2014-2024 (accessed Jan. 26, 2021).
Ž. Vagnorius, "Reliability of metal cutting tools:: Stochastic tool life modelling and optimization of tool replacement time," Ph.D. dissertation, Norwegian University of Science and Technology, Trondheim, Norway, 2010.
M. H. Doroudyan, A. Asgari, A. Amiri, and M. Bashiri, "Multi-objective Efficient Design of np Control Chart Using Data Envelopment Analysis," International Journal of Engineering, vol. 26, no. 6, pp. 621-630, Jun. 2013. https://doi.org/10.5829/idosi.ije.2013.26.06c.07 DOI: https://doi.org/10.5829/idosi.ije.2013.26.06c.07
E.-A. Attia, K. Khader, and O. Nada, "Mistake Proofing Cam Mechanism Through Six-sigma Process: Case Study on Clothes Printing Machines," International Journal of Engineering, vol. 32, no. 3, pp. 438-444, Mar. 2019. https://doi.org/10.5829/ije.2019.32.3c.12 DOI: https://doi.org/10.5829/ije.2019.32.3c.12
S. E. Black, "Using Basic Quality Tools to Improve Production Yields and Product Quality in Manufacturing," M.S. thesis, East Tennessee State University, Johnson City, TN, USA, 2015.
I. Hrvacic, "Design and implementation of SPC systems in defense industry manufacturing process," Periodicals of Engineering and Natural Sciences, vol. 6, no. 1, pp. 27-40, Feb. 2018. https://doi.org/10.21533/pen.v6i1.163 DOI: https://doi.org/10.21533/pen.v6i1.163
P. Li, P. Jiang, and G. Zhang, "An Enhanced DMAIC Method for Feature-Driven Continuous Quality Improvement for Multi-Stage Machining Processes in One-of-a-Kind and Small-Batch Production," IEEE Access, vol. 7, pp. 32492-32503, 2019. https://doi.org/10.1109/ACCESS.2019.2900461 DOI: https://doi.org/10.1109/ACCESS.2019.2900461
I. Elbadawi, M. Aichouni, and N. A. Messaoudene, "Developing an Innovative and Creative Hands-on Lean Six Sigma Manufacturing Experiments for Engineering Education," Engineering, Technology & Applied Science Research, vol. 6, no. 6, pp. 1297-1302, Dec. 2016. https://doi.org/10.48084/etasr.838 DOI: https://doi.org/10.48084/etasr.838
I. A. Memon, A. Ali, M. A. Memon, U. A. Rajput, S. a. K. Abro, and A. A. Memon, "Controlling the Defects of Paint Shop using Seven Quality Control Tools in an Automotive Factory," Engineering, Technology & Applied Science Research, vol. 9, no. 6, pp. 5062-5065, Dec. 2019. https://doi.org/10.48084/etasr.3160 DOI: https://doi.org/10.48084/etasr.3160
A. B. E. Aichouni, F. Ramlie, and H. Abdullah, "Process improvement methodology selection in manufacturing: A literature review perspective," International Journal of Advanced and Applied Sciences, vol. 8, no. 3, pp. 12-20, Mar. 2021. https://doi.org/10.21833/ijaas.2021.03.002 DOI: https://doi.org/10.21833/ijaas.2021.03.002
A. Trimarjoko, D. S. Saroso, H. H. Purba, S. Hasibuan, C. Jaqin, and S. Aisyah, "Integration of nominal group technique, Shainin system and DMAIC methods to reduce defective products: A case study of tire manufacturing industry in Indonesia," Management Science Letters, vol. 9, pp. 2421-2432, 2019. https://doi.org/10.5267/j.msl.2019.7.013 DOI: https://doi.org/10.5267/j.msl.2019.7.013
M. Touahmia, M. Aichouni, A. Alghamdi, L. Kolsi, and H. Alzamil, "A Foresight Study about the Skills and Competencies Needed for Quality Professionals in 2030: An Empirical Study of Saudi Arabia," Engineering, Technology & Applied Science Research, vol. 10, no. 5, pp. 6176-6182, Oct. 2020. https://doi.org/10.48084/etasr.3713 DOI: https://doi.org/10.48084/etasr.3713
L. S. Tavassoli, N. Sakhavand, and S. S. Fazeli, "Integrated Preventive Maintenance Scheduling Model with Redundancy for Cutting Tools on a Single Machine," Engineering, Technology & Applied Science Research, vol. 10, no. 6, pp. 6542-6548, Dec. 2020. https://doi.org/10.48084/etasr.3903 DOI: https://doi.org/10.48084/etasr.3903
How to Cite
MetricsAbstract Views: 264
PDF Downloads: 165
Copyright (c) 2021 Authors
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.