AN EMPIRICAL STUDY ON THE CONROL OF REJECTION RATE IN INSTRUMENT CLUSTER ASSEMBLY LINE BY USING QUALITY CONTROL TOOLS AND KAIZEN

In today's competitive world, any organization has to do mass production but mass production has both advantages and disadvantages. More rejection and more waste formation occurs in mass production. Further wastage leads to decreases in productivity and improvements. Lean production leads to minimizing the wastes and also improving the productivity. Hence profits would be considerably increased and further improvements takes place. Lean production has several benefits over mass production. It reduces the storage area and also helps in cost savings. Quality control tools played an important role in industrial engineering. They use 7 different tools to find the root cause for the defects and also prioritize it. Why – why analysis used to find the causes for the problem in accurate manner. Lot of questions arises which paved the way for the solutions to solve the problems. Kaizen culture should be encouraged. We must conduct Kaizen event weekly to motivate the workers by providing increments and gifts and also share the new ideas among our industrial peoples. Lean manufacturing brings less inventory, less material wastage than other methods. Flow of materials should be properly maintained. This paper discuss about how to control the rejection rate in instrument cluster assembly line by using the seven Quality control tools and the famous Kaizen (Lean technique).