AT CUSTOMER SITES: A CASE STUDY ON METAL PIPES

Abstract

This research presents the creation of artifacts to solve a problem regarding the external diameter exceeding the maximum tolerance of welded steel tubes, reported by a customer. Two artifacts were developed, with characteristics of Poka-Yoke tools, manufactured by Additive Manufacturing, and used in the dimensional detection of the external diameter of the claimed and lots of other parts in customer stock. The increase in sales, accompanied by increased competition, has made on-time delivery and good quality two essential requirements for competitiveness. Basically, in the quality control process, all supplies and production processes are inspected, but there are many products with defects that are passed on to the consumer. Therefore, the objective of this research is to apply Poka-Yoke concepts to the complaining customer's stock, in addition to proposing a commercial agreement, to bring to the factory floor justifications for implementing inspection on 100% of the items. The theme: application of error-proof devices, has grown significantly in companies, especially those that follow the Zero Defects philosophy or with specific programs to improve manufacturing processes. Applying the concepts of the Poka-yoke method to 100% of products can prevent defective products from reaching customers, and this type of dissatisfaction does not occur later. The research successfully met its objective since artifacts were created capable of measuring the external diameter and classifying many parts into approved and disapproved, at the customers' sites, without the need for excessive handling.