Defects in Manufacturing Process: A Case Study P. S. Atigre 1 1 Assistant Professor, Department of Mechanical Engineering, Sanjeevan Engineering and Technology Institute, Panhala, India. A. P. Shah 2 2 Associate Professor, Department of Mechanical Engineering, Dr. J. J. Magdum College of Engineering, Jaysingpur, India. V. R. Patil 3 3 B.E. Student, Department of Mechanical Engineering, Sanjeevan Engineering and Technology Institute, Panhala, India. Abstract - This paper has focused on two objectives. The first objective is to study the 8D methodology which is an 8 disciplinary approach. It consist of 8-steps to be followed by quality improvement team for problem solving as well as for product and process improvements. The second objective is to apply the 8D methodology and to analyze its effectiveness. In order to apply the 8D methodology and to analyze its effectiveness a case study was conducted in a small scale manufacturing industry (ISO 9001:2000 certified). The results of the case study show that the 8D methodology is effective. After applying 8D methodology the total rejection for coupling disc part was reduced to 6.57% from 37.95 %. Keywords: 8D Methodology, Problem Solving Techniques, Quality Control Tools, Rejection Analysis. 1. INTRODUCTION Improvement in quality of product and process is necessary for any company in order to survive and to grow in competitive market. Quality plays an important role in an organization to become more efficient and effective in the global market. Also it helps to improve the productivity, customer loyalty along with the market share [1]. To maintain the quality of product or process there is need to solve all the problems systematically which arises during entire manufacturing process and which affects quality of product or process. In order to solve these problems 8D methodology can be used. According to Chen H.R. and B.W. Cheng [4] the 8D method has been widely applied in automotive industries for problem solving regarding manufacturing process deviations, defects, maintenance, customer complaints, returned purchases and for supplier qualification confirmation. Ford made 8 D popular in the automotive manufacturing by introducing standardized set of steps to be followed by quality improvement teams [5]. Basically 8D methodology is 8 disciplinary approach for problem solving. It consist of 8-steps to be followed by quality improvement team for problem solving as well as for product and process improvements. In this paper, first the 8D methodology is studied and then its effectiveness is analyzed through a case study. The remainder of this paper is structured as follows: After introduction, section 2 reviews pertinent literature on 8D methodology, application of 8D methodology and various quality control tools. Section 3 first introduces 8D methodology and then provides in-depth description of the steps involved in 8D methodology. Section 4 presents the case study which is carried out to analyze the effectiveness of 8D methodology. Section 5 presents the results of the case study. Section 6 concludes with a discussion of the results. 2. LITERATURE REVIEW This point reviews the past research that serves as the foundation for this work. Following will be the review of literature on 8D methodology, its application in problem solving, and application of various quality control tools to reduce the rejection level in various manufacturing organizations. Wan Ahmad Najmuddin Wan Saidin et al. [2] conducted a case study on application of 8D methodology for defective product named as left hand side mirror at trim assembly line in automotive company. Their study proved that 8D methodology had succeeded to fulfil the expectation of the quality team by reducing the major defect of part at trim assembly line. Through a case study Marjanca Krajnc [3] observed that the 8D methodology is an excellent tool for preventing defects from reoccurring. He supported his observation not only by PPM results but also by related costs. Chen H.R. and B.W. Cheng [4] used 8D methodology and Kanos model in their case study. With the help of these methods they solved the problem and reduced the defect rate from 28% to 0.5%. According to Rambaud [5] 8D methodology was applied to military standards and was referred to as the Army Directive 1520 'Remedies and disposal of non-conforming material. To reduce the rejection level of single cylinder head V.V.Yadav and S.J.Shaha [6] used various quality control tools such as pareto analysis, cause and effect diagram, and why-why analysis. With the help of these quality control tools they reduced the rejection from 7.74% to 1.81% as well as they improved productivity by 8.60%. Ashwini A. and Avinash K.S. [7] carried out rejection analysis of piston with the help of various quality control tools such as check sheet, pareto chart, cause and effect diagram and control charts etc. With the application of these tools they reduced the overall rejection rate in production line from 10% to 7 %. Many researchers have International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 http://www.ijert.org IJERTV6IS090053 (This work is licensed under a Creative Commons Attribution 4.0 International License.) Published by : www.ijert.org Vol. 6 Issue 09, September - 2017 123 Application of 8D Methodology for Minimizing the