PRODUCT DESIGN PROCESS IMPROVEMENT FOR A JEWELLERY MANUFACTURER

Abstract

The major purpose of this thesis is to improve the product design process for a jewellery manufacturer by utilisation of Lean Six Sigma DMAIC Methodology. The case is the operations of a jewellery manufacturer in Thailand. In Define phase, a product design process improvement team was formed and current problem which is delay in delivery and product not as per customer specifications were identified. During Measure phase, Cause and Effect Analysis was performed in order to determine root causes, RPNs were defined and prioritised by utilisation of FMEA, and the root causes were graphically summarised using Pareto Chart. In Analyse phase, the solutions for eliminating the problem were discussed. In Improve phase, action plan was created with an integration of the daily planning system using an ERP software, CAD programme and development of product prototype using 3D Printer, and Concurrent Engineering. Lastly, in Control phase, APQP system was integrated in order to monitor and control the product design process. After the improvement, there is a reduction in the average percentage of the product rejection from the customers and the average percentage of design quality was also increased. Furthermore, there was a reduction of the design error items found at the launch phase. Lastly, it allowed the company in delivering product as per customer specifications as the results revealed that the degree of customer satisfaction with adherence to the delivery schedules and product as per specifications were increased.