EVOLUTIONARY APPROACH IN PROCESS IMPROVEMENT — A CASE STUDY IN AUTO ELECTRICAL ALTERNATOR MANUFACTURING

Abstract

Evolution is "understanding and overcoming current constraints in small steps toward optimum." "Understanding" requires elucidation of facts and corroborating theories that can explain those facts in a coherent manner. "Overcoming" requires self-development to suit the environment. In this paper, a case study about how a manufacturing process is improved in terms of productivity and quality using evolutionary improvements is explained. Here "Understanding" is achieved through use of Shainin Technique, PM analysis, Affinity Diagram, and the engineer's ingenuity, along with Relations diagram. "Overcoming" is achieved through Geometrical Analysis and Designed Experiments. The Study has set a new benchmark in the Stator riveting process by proving it can yield the desired results, and the need to adapt welding process is avoided.