ABSTRACT
This research work is carried out in an industrial gearbox manufacturing plant. It is observed that the variations in the critical dimensions of the output in the worm gearbox manufacturing process unit are very high. The worm shaft and worm wheel are the two main components of the worm gearbox. It is observed that the variations were not natural variations and hence, these variations were due to the assignable causes. This leads to the process out of statistical control and as a result produces non-conforming products, which in turn, increases the cost of the worm gearbox. In the present paper, detailed process analysis is carried out for the worm gearbox manufacturing unit to bring the manufacturing process of worm shaft and worm wheel under statistical control by eliminating assignable causes, rejection, rework, cycle time and scrap.
