IJE TRANSACTIONS C: Aspects Vol. 32, No. 3 (March 2019) 438-444   

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Khaled M. Khader, E. Attia and O. Nada
( Received: September 13, 2018 – Accepted in Revised Form: January 17, 2019 )

Abstract    Controlling the occurrence of defects is a major challenge for manufacturing organizations that are seeking to enhance their competitive position in today’s global market. This paper considers the process of screen-printing T-shirts using hydraulic and pneumatic printing machines. Several defects in the output of this printing process have been observed, especially with multi colors printing as well as maintenance problems. The six-sigma DMADV approach has been implemented to improve the process performance. Modifications of the current printing machine design using mistake proofing principles that have been proposed to prevent or diminish the occurrence of defects. The analysis indicates that manipulation of wrong oriented products of T-shirts printing machines can be considered as the main effective problem results from machines that are driven by hydraulic or pneumatic systems. Consequently, the quality level and productivity are affected. Moreover, some stained products with leakage fluid from the hydraulic systems can appear. Relying on the DMADV process, an effective mechanical mechanism using Geneva cams was used for diminishing these problems. Geneva cams prototype is manufactured to be used in printing machines instead of the hydraulic or pneumatic systems. A prototype of the cams mechanism is used for testing and validating the presented idea.


Keywords    Six-sigma process, DMADV process, Cams Mechanism, Printing Machines, Quality improvement



کنترل وقوع نقایص یک چالش عمده برای سازمان های تولیدی است که در جستجوی بهبود موقعیت رقابتی خود در بازار جهانی امروز هستند. این مقاله روند چاپ تی شرت های چاپی را با استفاده از ماشین های چاپی هیدرولیک و پنوماتیک در نظر می گیرد. چندین نقص در خروجی این فرایند چاپ مشاهده شده است. رویکرد DMADV شش سیگما برای بهبود عملکرد پردازش اجرا شده است. تغییرات طراحی ماشین چاپ کنونی با استفاده از اصول تصحیح اشتباه که برای جلوگیری یا کاهش وقوع نقص پیشنهاد شده است. تجزیه و تحلیل نشان می دهد که دستکاری محصولات غلط چاپ ماشین های تی شرت می تواند به عنوان اصلی ترین مشکل موثر از ماشین آلات که توسط سیستم های هیدرولیک و پنوماتیک هدایت می شود. علاوه بر این، برخی از محصولات رنگ شده با مایع نشت از سیستم های هیدرولیک می توانند ظاهر شوند. با تکیه بر فرایند DMADV، مکانیسم مکانیکی موثر با استفاده از کامپوننت های ژنو برای کاهش این مشکلات استفاده شد. نمونه اولیه کامپوزیت ژنو برای استفاده در ماشین های چاپی به جای سیستم های هیدرولیک یا پنوماتیک تولید می شود. نمونه اولیه مکانیزم کامپوزیت برای آزمایش و اعتبار دادن ایده ارائه شده مورد استفاده قرار می‌گیرد


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