Improving the Paint Appearance in the E-Coat System Utilizing Six Sigma Methodologies

Abstract

ABC Manufacturing had several E-coat process related problems, which resulted in paint appearance variations and defects. These defects and variations contributed to a high level of cost associated with rework and customer dissatisfaction. The purpose of this study was to identify the root causes of the variations in the paint appearance and implement practical solutions to improve the E-coat process capabilities using Six Sigma methodology. The study emphasized the importance of Six Sigma as a problem-solving tool; a tool, which could be used to resolve real problems such as the E-coat paint appearance variations presented in this study. Various statistical tools such as control charts, PFMEA, and DOE were used to help the team reach the correct decision before moving on to a different step in the DMAIC methodology.