INVESTIGATION OF PRODUCTION LINE DEFECTS USING ROOT CAUSE ANALYSIS: A CASE STUDY ON AN AUTOMOBILE INDUSTRY IN BANGLADESH

RCA is an effective technique for solving production-related problems and used for distinguishing the root causes of significant problems. The present study is conducted to find the root causes of the faulty production line in the automobile industry in Bangladesh that resulted in poor productivity rate and low product quality. Significant QC tools such as Check sheet, Histogram, Pareto diagram, and Cause and Effect diagram are used to collect data and make the analysis to eliminate the defects during the production of Pajero Sport QX automobiles. The outcomes identified that by using Root Cause Analysis (RCA) method, the production line defects can be reduced by about 56.66% on average along with better product quality and productivity.The analysis demonstrated that the procedures can be employed in the automobile assembly plant to mitigate/reduce the faults, in the prioritizing manner. This article presents insight into the possible arisen causes of the faulty production line in an automobile assembly plant and the way to minimize those.