Track: Lean Six Sigma

Abstract

During the wheelset maintenance process, the number of the axles is reduced by scrapping and make it difficult to comply with the wagon maintenance plan. To re–establish the number of wheelsets, it is necessary to purchase new axles at a cost U$ 2.386,36 per unit. The average number of scrap axles is 26,44 units or 5,4% per month, which raises the costs of maintaining wagons. Thus, it was identified the problem, defined goal based on history, was stratified with tree diagram, pareto and sequential graph, boxplot and histogram. From the tree diagram, we identified componentes involved with the problem of the high scrap rate of axle 6.1/2x12 by groove in the sleeve. Then, the brainstorm of the causes of the groove was elaborated, they were prioritized for study by correlation, q-square test, boxplot, histogram and soft flexion test. Then, the proven causes for treatment, elaboration and effective action plan were prioritized. The result was that, while 3,03% of the groove axes studied were scrapped up to 5,47 months, 35,43% of the tested axles (127 units) went through this period without groove. 1.Expenditure avoided with the 127 axles of the sample: = U$ 223.810,98. Projected avoided expenditure 4 years (large scale application) = U$ 1.562.583,81 ie annual average of U$ 390.646,06. The result was approved by management and economic management. Drafted standard and trained team. The completion of the work was by the pilot test and serves as a basis for large-scale application of the solution in the fleet.