Quality improvement through lean six sigma approach at wooden picture frame moulding company

Abdul Muhaimin, Mohd Yusri (2015) Quality improvement through lean six sigma approach at wooden picture frame moulding company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Every manufacturing organization seeks for a solution to increase productivity in their company. One of the factor that contributes to low productivity in manufacturing process is high of workers turnover. For processes in the factory that manufacture customized products, it is difficult to maintain a high productivity level. The experts are needed to cope with the fluctuated demands. This study done at a furniture Company that produces customized products. The company faces low productivity due to high of workers turnover. Ultimately, quality defects and rework continually increase. Moreover, overtimes has also increased to meet the production target. Thus this study aims to propose solution for productivity improvement at Compo department process. The aim is supported by three objectives: i) to identify the critical problems that cause high rate of defect at Compo process, ii)To analyses the root causes of the critical problem at the Compo process, and iii) to propose appropriate lean tools and techniques for the solution of the critical problem at Compo process. The critical problem has been identified as finger join effect on the compo layer surface. Ishikawa diagram, quick survey method and majority minor-concept have been used to analyse the root causes of the finger join effect. There are eight main root causes identified: (i) Inconsistent temperature at compo storage; (ii) inconsistent humidity at compo storage; (iii) missing of standard operating procedure; (iv) variation of wood structure before joining process; (v) poor compo material quality content; (vi) careless while performing the process; (vii) less attention from new workers, and (viii) vibration producing by the machines. This study proposed (i) storage room, (ii) standard operating procedure, (iii) Andon light system (iv) separation box (v) glue filter and (vi) training. In conclusion, productivity in Compo department can be improved by using Andon, Poka Yoke, Zero defects techniques and training. The proposed solutions were based on the identified causes.

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