Designing a Cowl Template with DFSS Methodology

Abstract

This paper illustrates the application of modern ideas along with the integration of new techniques to achieve optimum process cycle efficiency. The paper uses design for six sigma (DFSS) methodology in designing a metal template for tack welding of brackets on the cowl. The cowl is a part of the fork truck located near the driver’s position. The design uses six sigma methodology, considering five steps known as DMADV, which resembles define, measure, analyze, design and verify. Lean and six sigma tools, 3D modeling software, finite element analysis, jigs and fixtures theories were utilized to determine and eliminate bottlenecks with the help of the proposed methodology. The sample readings were recorded and analyzed. A detailed comparison showed a surge of 27% in the process cycle efficiency resulting in savings of manpower cost and reduction in time required for the overall process.