Application of World Class Manufacturing for the design of a Cold Test in FPT Industrial

The aim of the thesis is to explain how the World Class Manufacturing (WCM) methodology is used in a real application in a company environment. In particular, it is shown how the tools of the Quality Control pillar of this approach are used, with the aim of support the management of issues related to the dimensioning of a Cold Test used to filter functional nonconformities of the product. Thanks to FPT Industrial, it has been possible to elaborate on the following project. The company belongs to CNH Industrial group which started to believe and implement WCM methodology in 2007. With this implementation of methods and tools, the group aims to continuously improve the already high product and process efficiency and to ensure safety inside their plants dislocated worldwide. WCM, studied to eliminate or at least reduce any kind of waste, defects, failures, and injuries, is structured in ten pillars concerning different fields. Each of these pillars is periodically evaluated through an external audit with the assignment of a score which results in a series of awards. The thesis is performed during an internship in the Plant Quality department, and it consists in the dimensioning of a new, and completely automatized, Cold Test which has the capability of check some components of the engine to ensure their functionalities. The dissertation is composed of three chapters: the first is explained what the World Class Manufacturing methodology is, which is its mission, and are described the different pillars from which is composed. In the second chapter is explained the contest in which the thesis is performed; instead, in the last chapter is described the project performed. In particular, it is explained that during the detailed design of the project, the Cold Test showed low reliability in the third phase of functional checks. Using the trial & error approach, it comes out not satisfying results because the bench was not able to detect the anomalies on the trap engines. For this reason, are used WCM tools to face the problem, starting from 5W+1H to have a complete overview of the problem, the DOE and ANOVA to find the correct combination of parameters for the good outcome of the test, and finally the Cost of Quality to estimate the cost savings due to the implementation of the Cold Test.