Quality improvement through lean practice

Talib, Nurazliana (2015) Quality improvement through lean practice. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Providing a good quality in manufacturer products is important in order to obtain customers’ trust. Furthermore, manual skill by Operator does not guarantee a good quality in manufacturing process especially when working with fragile material. Therefore, company has to reduce the quality defects by improving the worker skill and use appropriate tools. In this study, Lean Manufacturing (LM) practice has been proposed to reduce the quality defects for Lay-up Bonded A320 Spoiler Project at one of aerospace manufacturing company. The aim of this project is to reduce monthly quality defects at Lay-up Bonded Process from 17% to 5%. The aim is supported by three objectives: (i) to identify the critical quality defects at Lay-up Bonded Process, (ii) to analyse the root causes of the critical quality defects, and (iii) to propose solution using appropriate Lean Manufacturing tools and techniques. Ishikawa, 5W1H, Quick Survey, and Pareto Chart were used to identify the root cause of critical quality defects. Results of the first objective show that the critical quality defects are; (i) Delam, (ii) Disbond NCR and (iii) CPL. In the second objective, Man factor and Machine factor are the main root-cause of the critical quality defects. For the third objective, improvements of current 5S implementation system at Lay-up Bonded A320 Spoiler Project has been proposed as solutions for the main root cause. In this case, three types of 5S activities have been proposed; (i) Tooling Storage, (ii) 5S Daily Checksheet, and (iii) Red Tag. As a conclusion, the proposed solution need to be implemented in order to reduce the monthly critical quality defect from 17% to 5%. In this regard, continuous improvement of the proposed solutions may needed.

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