Standardizzazione e trasversalizzazione dei metodi di gestione della qualità su di un processo di massa production

In order for companies to survive and stay competitive in today's market, it is very important to ensure consistency in their operations because it increases efficiency. However, because of different ways of executing the same process by different workers, due to different skill levels, education or experiences, it is hard to maintain the required consistency and that might result in variations in the produced products or services. The aim of this project is to study the creation of standardized work according to Lean, as well the training process of unskilled personnel to perform production tasks in an efficient way. This thesis will concentrate on creation of work instructions making standards of different kinds of condensers in order to have efficient work and mainly to decrease the percentage of internal and external scarps which costs the company huge amount of money every year. The idea is to implement this work instructions to all the phases related to the production of the condensers starting from the first phase, procedure of making the tubes needed for the condenser, till the last phase which is packaging in order to have the products ready for the shipment. The work instructions must be part of closed cycle which consists of control plan, Fmea, Process flow to have complete information needed for the worker to make efficient work and also for the supplier to make them comfort about the products they are buying. The work instructions done were approved from the head of the quality department, the health and safety executive responsible and from production area manager Moreover the work instructions were discussed by the suppliers of Denso Thermal Systems (GENERAL MOTORS, IVECCO, RENAULT,PSA, MASERATI) where I had the opportunity to participate in the meetings when considering the audit visits to take some notes and improve the work instructions. Our project is not just to reduce the percentage of scraps in the internal company but also to have the satisfaction of the customers which is one of the main goals of the quality.