Application of Quality Function Deployment (QFD) in Die Redesign to Lowering Rework of Stamping Parts

In this work, QFD was utilized in die redesign to solve burrs and incorrect dimension defects in the stamping part. Because of these defects, almost 87% of processed parts were reworked in one industrial case. Based on root cause analysis, the burrs and incorrect dimension defects resulted in the cam piercing, piercing, and separating on compound dies of the existing stamping process. Dies configuration is indicated as the cause of these defects. This study aims to decrease the defects. The work consists of problem identification, RCA, die planning using the House of Quality of QFD phase 1, die design using QFD phase 2, and fabrication and assembly using QFD phase 3. Finally, QFD phase 4 tests the design die with 1,000 tons load and 30 samples in regular production and then analyzes. The result shows that reworked parts decreased from 87% to 0%. It concluded that QFD can be applied effectively in this work.