With the development of national economic construction becoming more and more reasonable and stable, the standard load of road vehicle transportation is also deepening and standardizing. The concept of lightweight is gradually recognized by users, and lightweight dump trucks have caused a revolution in the field of automobile manufacturing and transportation. Major OEMs have launched suitable new models to seize the market, and the leading models in Shanxi, which focus on dump trucks, have quickly occupied most of the market share in strict control, basically occupying the living space of the original old products.

Second, enterprises to implement the benefits of six sigma

Six Sigma can reduce operating costs, improve turnaround time, reduce material waste, better understand customer needs, improve customer satisfaction and enhance the reliability of products and services.

Third, Zhang Chi Company pays attention to Six Sigma, Lean Six Sigma and design for six sigma.

1. Six Sigma training is divided into: green belt, black belt and green belt and black belt.

2. The training cost of Zhang Chi Liusima open class is between 8,000 and 40,000 yuan. There are fixed courses every month.

3. There are three training methods: open class, internal training and consulting (project counseling).

Four, the automobile industry to implement six sigma project improvement case

However, the market share of our products is not high. In order to regain the market share of road dump trucks and compete in this strategic market segment nationwide, according to market research and analysis, enterprises decided to introduce six-sigma management to improve the overall operation quality and reduce costs. After an all-round comparison, the Group chose Zhang Chi Consulting Company to provide it with six overall consulting services. This project mainly started with loading light dump trucks, and improved the design of the Group's light 8×4 dump trucks. Through half a year's efforts, the lightweight will be increased by 24%, reaching the advanced level of the industry.

1 Project target setting:

1. The vehicle is lightweight by 22%.

2. Users can get more use benefits, enhance the recognition of the group's products and win the potential market.

3. Accumulate technical and manufacturing strength and experience for lightweight dump truck products.

2 Project implementation process:

At the initial stage of the introduction of Six Sigma, Zhang Chi consulting experts conducted a systematic investigation within the group, and determined the improvement area in combination with the annual business plan and the problems faced by the enterprise. When the project and personnel are selected, the first phase of training and project implementation of the six black belts in Malaysia officially begins. This form of training and learning students by projects is called "action learning method". It is characterized by the close combination of theoretical study and solving practical problems. Through the in-depth discussion of specific issues and the wonderful comments and guidance of Zhang Chi's consultant, the students have established a strong interest in the six horses. After a week's study and classroom practice, students have a clear and systematic understanding of the implementation logic and process of the six horse-adapted projects. According to the project implementation roadmap given by the teacher, the students officially started the operation of six horse-suitable projects.

The operation steps of the improvement project are divided into five stages, namely, definition stage, measurement stage, analysis stage, improvement stage and control stage.

design development phase

Definition of problem: One of the important reasons for the low efficiency and high repetition rate of traditional problem-solving methods is that they are eager to solve problems before they are clearly defined. Zhang Chi Consulting attaches great importance to the definition of problems and guides students to correctly define and state problems. After in-depth discussion, the project team finally decided to take lightweight as the project index. Determination of project scope: By drawing SIPOC diagram, the team determined the scope of this project, and the subsequent project operation will be analyzed and improved around the following processes. Status quo and target setting: Zhang Chi consultant instructed the trainees to determine the current body weight of the project as the status quo benchmark, and set the lightweight target as 22% in combination with the industry benchmark and their own process conditions.

2. Measurement stage

The main task in the measurement stage is to determine the current situation of project indicators and initially determine the direction of finding the cause of the problem. In order to achieve this goal, the project team needs to make data collection plan, measurement system analysis and confirmation, and process capability analysis of project indicators. After data analysis, the process ability of the project team to calculate the target weight is Cp=0.49, Cpk=0.32, Ppk=0.25, which has great room for improvement. Through process analysis, causality matrix, FMEA and other analysis and screening, it is preliminarily determined that five factors, such as product structure design, CAE analysis, verification and evaluation process, research data and material properties, are the suspected key factors leading to the lightweight problem of car body. Through rapid improvement, the verification and evaluation process, investigation data analysis and material properties are optimized.

3. Analysis stage

In the analysis stage, the project team deeply analyzed the rationality of structural design and the accuracy of CAE analysis, and further refined it into several factors such as container form, deck thickness, deck material, critical conditions and parameter setting. According to these factors, the best structure/material combination is determined by theoretical analysis, CAE comparative analysis, load and working condition analysis, bending and torsion analysis and other technologies.

4. Improvement stage

According to the two key factors "structural design and CAE analysis" determined in the analysis stage, the improvement scheme is put forward. By implementing corresponding improvement measures, such as formulating evaluation and control criteria and processes in product development stage, formulating workflow for product design verification CAE analysis, verifying material performance, setting analysis boundary conditions, etc., the project team confirmed through data verification that after implementing comprehensive improvement measures, the body weight loss rate reached 24%. Exceeding the target set in the definition stage by 2 percentage points.

Step 5 control the phase

After the project team achieves the project objectives in the improvement stage, the main task in the control stage is to pursue victory and maintain and maximize the project results for a long time. In the control stage, the project team mainly did the following work: (1) Solidify the improvement results through documents and quality control plans; Through discussion, the promotion plan of the improvement scheme will be made, and the knowledge and experience gained from this project will be directly or indirectly extended to other models of the group to expand the benefits; Conduct employee training, transfer the knowledge and scheme obtained by the project team to the front-line operators, and make them master new methods through training and assessment; For the long-term control of the project, the project team set up a single-value moving range control chart to monitor the change of car body weight and identify and eliminate abnormal fluctuations in time.

3 project results

1. The lightweight rate target set at the project establishment stage was 22%, but it actually reached 24%, exceeding the target by 2 percentage points.

2. The project income is about 2 million yuan per year. Due to the light weight of the car body, the fuel consumption is reduced, saving users 30-36 thousand yuan of fuel every year.

3. Practice the joint open mode of the technology center and its subsidiaries, develop lightweight loading new products of dump trucks, and improve the product competitiveness of the Group in this market segment.

4. Take the dump truck as the breakthrough point, and establish the technical platform for loading light special vehicles of the Group.

5. Through the project operation, a group of black belt talents have been trained.