Reducing scrap and improving an air conditioning pipe production line

R. M. Lopes, Francisco J. G. Silva, Radu Godina, Raul Campilho, Teresa Dieguez, Luis Pinto Ferreira, Andresa Baptista

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The automotive industry is considered one of the most demanding and competitive sectors in the global market. This increasingly implies having a stable and optimized production process, always with a view to continuous improvement. Therefore, it is very important to be aware of all the waste that is generated in all production and logistics operations and take action to reduce them. In this regard and considering the process of producing air conditioning pipes for the automotive industry, a high scrap value was detected mainly due to soldering process. Therefore, the entire production process is analyzed in order to identify the main causes behind the high scrap value. Several Lean and quality tools are used to reduce not only the amount of scrap but also to increase the line productivity. In order to face this challenge, after elaborating the action plan and corresponding implementation, the scrap value is reduced by 12% in general, and productivity increased by 29%, 55% and 22.5% in three different references produced by the same machine. Although this solution is a bit expensive, the corresponding payback is reduced, so it can easily be applied transversally to other similar machines allowing extremely interesting gains in the short term.

Original languageEnglish
Pages (from-to)1410-1415
Number of pages6
JournalProcedia Manufacturing
Publication statusPublished - 2020
Event30th International Conference on Flexible Automation and Intelligent Manufacturing, FAIM 2021 - Athens, Greece
Duration: 15 Jun 202118 Jun 2021


  • Air conditioning pipes
  • Automotive industry
  • Continuous improvement
  • Lean
  • Production line
  • Quality tools
  • Scrap
  • Waste
  • Welds


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