Application of kaizen to prevent slip of defective products to internal customer in automobile manufacturing

Mani, Nirmessini Maselah (2016) Application of kaizen to prevent slip of defective products to internal customer in automobile manufacturing. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

In quality improvement, optimum controlling condition is determined by balancing control with cost of quality. This approach is widely applicable in all manufacturing process especially in automobile manufacturing industry. The study reports improvement effort that applied in a vehicle parts manufacturing factory with aim of preventing slip of defective vehicle parts to internal customer. The major cause of problem identified through field study and quality control session. In order to eliminate major causes of problem, a new in- house inspection operation known as Quality Filter proposed to prevent supply of defective parts. Besides, an effective and comprehensive quality control sticker introduced to enhance self-discipline among quality assurance staffs. The effectiveness of preventive actions evaluated by testing implementation at operation field for one month duration. Rate of rejection of vehicle parts from internal customers before and after implementation compared statistically. The solutions then further analyzed in term of operational and economic feasibility. The action research managed to solve the productivity problem within short period of time.

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