The global air conditioning systems market size was valued at USD 119.36 billion.* We’ll look at the applications of Lean and Six Sigma in air conditioner manufacturing and finish with a video of air conditioner manufacturing processes.

*Source

Integrating Value Stream Mapping and DMAIC for Air Conditioner Assembly Improvement

In a case study titled “Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line” authors Wei Guo and others discuss  a case study using their proposed VSM-DMAIC model.

The case study includes:

  • Three Models for Integrating VSM and DMAIC
  • VSM-DMAIC Framework
  • Relationships Among Waste, Production Problems, Production Resources, And Resources Attributes
  • Kaizen Events Based On DMAIC
  • Production Line Layout Of Air-Conditioner Outdoor Unit
  • Production Line Task Description
  • Assembly Line Line of Balance Rate
  • Current VSM of Air-Conditioner Assembly Line
  • Motion Analysis Of Fixing Cut-Off Valve Station
  • Assembly Line Identified Wastes and Production Problems
  • Cause and Effect Diagram for Imbalance
  • Pareto Chart for Imbalance Factors
  • Evaluation Factors Before and After Concurrent Lean-Kaizen

You can access the case study here.

Lean Six Sigma and DMAIC in Air-Conditioner Manufacturing

In a paper titled “Impact of Stakeholders on Lean Six Sigma Project Costs and Outcomes during Implementation in an Air-Conditioner Manufacturing Industry” authors Jawad Sarwar and others discuss the application of Lean Six Sigma and DMAIC to enhance production capacity and reduce per-unit cost in air-conditioner manufacturing.

The paper includes:

  • Advantages of Lean, Six Sigma, and Lean Six Sigma
  • Lean Six Sigma Flowchart
  • Outdoor Unit Testing Flow
  • Key Stakeholders
  • Fishbone Diagram for Power Cord Process
  • Fishbone Diagram for Expanding Machine
  • 5-Why Analysis for Power Cord Process
  • Machine Expansion Modifications
  • Power Cord Design Improvement Results
  • Results of Expanding Machine Improvement

To access the paper, use the following link.

Increasing First Pass Yield Through the Use of Six Sigma

In a paper titled “Optimization of Flow Test Quality Indicators in a PIM Air Conditioner Line” authors Marcio Bilby Barbosa discuss the use of Six Sigma and First Pass Yield with the objective of optimizing the quantity of products reworked internally. 

The paper includes:

  • First Pass Yield Before Implementation
  • Performance Failure Categories
  • Problem Causes
  • First Pass Yield After Implementation

Link here.

Air Conditioner Manufacturing Processes

See air conditioner manufacturing at a Gree air conditioner factory in this video from Forever Tech.

You can watch the video here.