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PROBLEM SOLVING TECHNIQUE WORKSHOP

PROBLEM SOLVING TECHNIQUE WORKSHOP. PT. MINDA ASEAN AUTOMOTIVE. JULY 2011 By Suntoro Assembly Department. COMPANY PROFILE. JL. Permata Raya Lot CA/7 KIIC Karawang , West Java, Indonesia. Indonesia. PT. MINDA ASEAN AUTOMOTIVE INDONESIA. COMPANY PROFILE.

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PROBLEM SOLVING TECHNIQUE WORKSHOP

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  1. PROBLEM SOLVING TECHNIQUE WORKSHOP PT. MINDA ASEAN AUTOMOTIVE JULY 2011 By Suntoro Assembly Department

  2. COMPANY PROFILE JL. Permata Raya Lot CA/7 KIICKarawang, West Java, Indonesia Indonesia PT. MINDA ASEAN AUTOMOTIVE INDONESIA

  3. COMPANY PROFILE MINDA FACTORY INTRODUCTIONNAME : PT. MINDA ASEAN AUTOMOTIVEQUALITY SYSTEM : ISO/TS 16949 : 2002ESTABLISHED ON : FEBRUARY 2005FIRST PRODUCTION : OCTOBER 2005FIRST SUPPLY : DECEMBER 2005TOTAL NO OF EMPLOYEES : + 450 NosPRODUCTS : a. SWITCHES : - SWITCH HANDLE BAR - NEUTRAL SWITCH - BRAKE SWITCH - MODULAR SWITCH b. LOCKS : - IGNITION SWITCH LOCK - SEAT LOCK - FUEL TANK KIT ASSY c. LIGHT : - FOG LAMP - LAMP ASSY LICENCE - REFLECTOR

  4. OUR PRODUCTS & CUSTOMERS CUSTOMERS:A. YAMAHA : - INDONESIA - MALAYSA - THAILANDB. SUZUKI : - INDONESIA - THAILAND - VIETNAMC. KAWASAKI: - INDONESIA - FILIPHINED. ASTRA DAITHATSU MOTOR INDONESIA

  5. COMPANY QUALITY POLICY Quality to accorded high priority to ensure market competitiveness and to enable supply of cost effective products to the customers. “This shall be reflected by our commitments, action products and services to our internal and external customer”. For this, we shall create an environment to encourage all our employees & suppliers to prevent defects and strive for excellence. “ QUALITY POLICY “

  6. PROBLEM EXPLANATION DEFINITION a. Problem statement, “Elimination Solder defect in Switch SW-0657AH b. Team : Leader : Suntoro (Assembly) Member : Ika ( Assembly ), M azis ( PE ) c. Objective : To eliminate the process rejection of soldering come out d. U.O.M. PPM Earlier Status : 4537 ppm ( Before Improvement ) Now : 0 ppm ( After Improvement ) e. Explanation of the problem Technical Phenomenon : Soldered wire is come out during wire arrangement at assembly process to case lower. (One problem was found on customer line of horn not function due to solder come out)

  7. DATA COLLECTION : REJECTION DATA

  8. DATA COLLECTION : CUSTOMER CLAIM DATA

  9. DATA COLLECTION : CYCLE TIME OF CASE LOWER ASSY • Gemba observation : • Have difficulty of assembly process plate horn to lower • case due to sometimes edged of plate horn stuck with boss of case lower. On this process operator do more one times fixed plate horn to case lower. • B. Take data of tact time: Assembly W/h to case lower

  10. PROCESS FLOW SWITCH HANDLE ASSY Plate Horn Rivetting Plate Horn Soldering Wire Harness Assy Complete Case Upper Assy Complete Case Lower Assy Complete Manual Testing Batch Code & Continuity Testing Packing Lever Starter Assy Note : Problem found at case lower assy complete station

  11. FLOW PROBLEM OCCURANCE Soldering Assembly W/h to case lower Base Horn assy Found solder come from base during wire arrangement Black wire solder come out

  12. OBSERVATION -1 of soldering strength test Soldering strength test Solder come out Note : Ideally, good soldering will breakage on wire after pull test Wire breakage

  13. Comparison of soldering wire position with others model COMPARISON WITH W/H 0574 SOLDERING STRENGTH DATA Solder wire position on “U” cut on terminal

  14. Comparison of same type soldering with other model. SW-0683 SW-0684 Wire position put a “U “shape profile of terminal

  15. OBSERVATION -2 Soldering Process Note : * Found inconsistency preheating process from 28 April 2011 until 30 April 2011, bit solder was not properly touching the plate horn ( finding qty 2 ~ 4 times )

  16. ANALYSIS Base on Observation No.1: “SOME QTY, SOLDER STRENGTH IS LESS ”

  17. Plate horn stuck with case lower boss for mounting screw

  18. ANALYSIS Base on Observation No.2: “ SOLDER COME OUT ”

  19. ACTION

  20. AFTER IMPROVEMENT PART BEFORE AFTER Angle of plate horn 30º Angle of plate horn 90º

  21. AFTER IMPROVEMENT PART BEFORE AFTER Solder & wire lay on top of plate horn. Solder strength of wire 3.8 – 7 kgf Solder & wire lay on “U” cut of plate horn. Solder strength of wire 12 – 15 kgf Edge of plate horn stuck to screw boss & wire folding made wire having more stress Edge of plate horn is free & wire having more space to be routed

  22. CHECK Improvement on 06 May 2011

  23. Productivity Improvement Improvement on 06 May 2011 Up 39%

  24. Productivity Improvement Improvement on 06 May 2011 Reduced 39%

  25. STANDARDIZATION. • Part drawing is updated as per ECRN. • b. Tool drawing is updated as per revision last part drawing. • c. Master sample of part assembly updated. • d. OGS and PQCS updated.

  26. PT. MINDA ASEAN AUTOMOTIVE “GO AHEAD WITH QUALITY” CONCLUSION. • BENEFITS: • Rejection on account solder come out reduced from 4537 ppm • to zero ppm. • b. No customer complain for solder come out. • Productivity increased by 39 % from 900 pcs/day to 1320 pcs/day

  27. THANK YOU

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