Automotive component manufacturers are some of the organizations that are faced with a lot of complexities in their manufacturing streams. These complexities require a number of changeovers on the lines according to the sequences and derivatives that are required by customers. One of the challenges that component manufacturers face is the outflow of defective parts post their changeovers which hinders the ability to deliver and reduces capacities. An automotive component manufacturer which manufactures various bedliners was concerned about the outflow of defective parts after every changeover on their Thermoforming line. This pointed directly to a lack of built-in-quality in their changeover processes. This was primarily reflected in their approach of frequently adjusting the moulding machine and relentless reworking of the work being done in the moulds after changeover completion. This resulted in multiple destructive tests, high defect rates, and major delays in their ability to run the line and deliver to their customers. Given the magnitude of the problem in the organization, the aim of this study was to utilize the Lean Six Sigma Define, Measure, Analyse, Improve, and Control (DMAIC) methodology to bring about significant improvement in driving built-in-quality in the changeover process execution for the line. The results of the study were a streamlined approach to this problem, reduced defect occurrences after changeovers, and an overall changeover process that encompasses a built-in-quality approach in its execution.

Keywords: DMAIC methodology, Changeover, Automotive component manufacture, Built-in-quality, defect rates