Reducing rejection on nickel free plating at finishing line in metal manufacturing company by using Kaizen approach

Zamuri, Amiza Aliyana (2017) Reducing rejection on nickel free plating at finishing line in metal manufacturing company by using Kaizen approach. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Kaizen is a concept that focuses on improving a work area or an organization in incremental methods. Many organizations have begun to incorporate the philosophy of Kaizen through the use of Kaizen Methodology. The most frequently cited proponent of Kaizen has been Imai, who wrote Kaizen book (The Key to Japan’s Competitive Services (1986)). This case study illustrates Kaizen in Metal Manufacturing Company, at Finishing line. The case study is focused on reducing rejection of Nickel Free Plating. Firstly, factors contributing to the rejection of Nickel Free plating is identified and analysed. Based on the analysis, the process capability of switching manual dosing to auto dosing is identified with the number of concentration following the standard limits. Next, improvements are proposed. The improvement only focuses on Ishikawa Diagram. Apart from that, Kaizen was implemented to reduce the rejection of Nickel Free Plating. At the same time, the Standard Operating Procedure (SOP) for the Nickel Free Plating was proposed to standardize the proper method when worker perfoms task. The results show that this implementation helps the company to reduce the rejection of Nickel Free Plating. Improvement on the Nickel Free is evaluated based on the weekly act passes of products. The proposed improvement increases the average percentage of weekly act passes from 67% to 70%. As a conclusion, reduce rejection of Nickel Free Plating at finishing line can be achieved by kaizen Implementation.

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