Two-wheeler automobile manufacturers in India are currently facing a big pressure to reduce the overall manufacturing cost in order to sustain the position in hypercompetitive domestic and global market. The manufacturing conversion cost is one part of the overall manufacturing cost. It consists of three major components i.e. product or parts scrap cost, consumables cost and tool cost. The scrap cost is the cost of defective products, which are not produced in accordance with standard and can't be sent to market. The consumables cost is the cost of other than basic raw material used in manufacturing i.e. filters, filler materials, fuel, gases, chemical, coolant and lubricants etc. This study has tried to emphasise role of conversion cost in making organisations cost competitive. Case study-based approach is used in this study. The case manufacturing system comprises three main processes: machine shop, frame plant (weld and paint shop) and assembly shop. In frame plant, paint shop and weld shop are the two main sub sections of this automobile manufacturing. More than 50% of overall manufacturing conversion cost is consumed in these two areas. This study attempts to illustrate the reduction of the manufacturing conversion cost by prioritizing and analysing the cost factors using DMAIC (define-measure-analyze-improve-control) approach using quality control (QC) tools like Pareto chart, Cause & effect diagram and digitization of real time data. Authors have identified eighteen elements of conversion cost in this study. It has been observed from this study that even small saving in conversion cost per vehicle i.e. INR 24.18 (0.35 US$) per vehicle has resulted in annual saving of 2.2 millionUSD.Initiatives taken by this organisation for cost saving has also resulted in cleaner production and more sustainable manufacturing processes. Findings will be motivating to other manufacturers for reducing manufacturing cost using QC tools on smaller and insignificant activities.

中文翻译：

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使用质量控制工具和实时数据数字化降低制造转换成本


印度的两轮汽车制造商目前面临着降低总体制造成本的巨大压力，以维持在竞争激烈的国内和全球市场中的地位。制造转换成本是总制造成本的一部分。它由三个主要部分组成，即产品或零件报废成本、消耗品成本和工具成本。报废成本是指未按标准生产、无法投放市场的有缺陷产品的成本。消耗品成本是制造过程中使用的基本原材料以外的成本，即过滤器、填充材料、燃料、气体、化学品、冷却剂和润滑剂等。本研究试图强调转换成本在使组织具有成本竞争力方面的作用。本研究采用基于案例研究的方法。箱体制造系统包括三个主要工序：机械车间、车架车间（焊接和喷漆车间）和装配车间。车架厂中，涂装车间和焊装车间是汽车制造的两个主要分工段。总体制造转换成本的 50% 以上消耗在这两个领域。本研究试图通过使用 DMAIC（定义-测量-分析-改进-控制）方法，使用帕累托图、因果图和数字化等质量控制 (QC) 工具，对成本因素进行优先排序和分析，来说明制造转换成本的降低的实时数据。作者在这项研究中确定了转换成本的十八个要素。这项研究表明，即使每辆车的改装成本节省很少，即每辆车 24.18 印度卢比（0.35 美元），每年也能节省 220 万美元。该组织为节省成本而采取的举措也带来了更清洁的生产和更可持续的制造工艺。研究结果将激励其他制造商在较小和无关紧要的活动中使用质量控制工具来降低制造成本。