Reduce power energy cost using Hybrid Six Sigma based on fuzzy MADM: A case study in mechanical factory

Abstract

Production costs are always the top concern of company managers in improving production and business efficiency. The cost of energy is one of the major costs that manufacturing companies must pay. This research paper proposes a Hybrid Six Sigma method based on fuzzy Multi-Attribute Decision Making (MADM), Industry 4.0, and digital numerical control (DNC). A fuzzy MADM method to select problems to improve and build an Industry 4.0 system with Internet of Things (IoT) devices, calling for automatic machining programs using Radio Frequency Identification (RFID) systems and management. Manage production equipment maintenance system using a digital numerical control (DNC) system. Measuring industry 4.0 system user satisfaction in manufacturing using Partial Least Squares Structural Equation Modeling (PLS-SEM). The results of research on applying industry 4.0 techniques to the induction heat treatment process eliminate the dependence on worker skills and simplify the operation of the induction heat treatment process. Improve employee satisfaction with process operating conditions. Reduce the cost of electrical energy arising due to the coil maintenance system by applying the Industry 4.0 system. The result after the improvement is that the defect rate decreased from 47.2% to 4.9%. In terms of money, the reduction in losses due to defects is reduced from 6,593 USD per year to 549 USD per year. This research paper builds a sample continuous improvement model to apply to other production processes at other manufacturing companies in terms of applying industry 4.0 systems with IoT devices such as RFID and barcode readers in operations. automatically call the machining program of the machining machine and build an autonomous and preventive maintenance system using the industry 4.0 system to make improvements in process automation, smart data management, and analytics, using Internet of Things (IoT) to connect devices in the production process create a flexible production process.