Non-conformities and Scrap Costs Reduction in a 3D Printing Workshop

The aim of this study is to reduce non-conformities and scrap costs in a Tunisian 3D printing workshop. Therefore, we performed a resolution of problems methodology. We started by defining the problem. According to a preliminary diagnosis of the 3D printing workshop, it was impossible to conduct a numerical analysis due to the lack of indicators and non-conformities registration. So, we began our work by establishing key performance indicators to gain insights into the different machines of this workshop. Then, we developed a non-conformities registration document. This document was essential to realize the Pareto Analysis which revealed that” low extrusion density” is the main non-conformity. After identifying its main causes through a root cause analysis, we implemented improvement actions consisting principally of the optimization of printing parameters. In the last step ‘‘review of results’’, we noticed an average of 15% reduction in the non-conformity rate and scrap cost. We showed also, through this article, that low extrusion density non-conformity exists regardless of the generation of the machine and that key performance indicators are essential and can be adapted to reflect the real state of 3D printing workshops in a Tunisian industry.