Quality improvement by implementing Kaizen activities in textile manufacturing company

Mat Nasir, Khairul Azwan (2018) Quality improvement by implementing Kaizen activities in textile manufacturing company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Kaizen is a strategy that normally uses to improve the productivity and quality of an event. It is one of the Lean Manufacturing tools (LMT) that always been uses in manufacturing industry. The purpose of this project conducted is to improve the quality of the products and increase the productivity of the product. This project was conducted in textile manufacturing company located in Tanjung Kling Malacca. The company produce snap fastener which is consist of two different parts that is socket and stud. The major process include in producing this product is stamping process. The main problem in the production is defects products. There are two different process in producing socket and stud for the snap fastener. For stud, the process consist stamping and blanking process. But for the socket, there is more process need to be done. First, producing of preparation-stamping, this preparation-stamping is done by stamping process. The purpose is to construct initial shape. The secondary process is including wire insertion, blanking and folding. The main problem for this product is the product that in smaller size which is 6mm, 7mm, 8mm and 9 mm. This small product are producing loose gap between the stud and the socket. This is cause the quality of the product decrease and not achieves the customer’s satisfactions. The objective of the project is to analyze, observe and eliminate the loosed gap in smaller size snap fastener and improve its production. For the loosed gap problem for the smaller product, every process including in producing the product is identified and observed. Data is collected for both stud and socket from early process to final product to identify the root cause of the problems. The data collected is analyze by using several tools such as brainstorming 5-whys analysis, Ishikawa diagram, cause and effect matrix and FMEA. Based on the analysis, the cause of producing loosed gap is caused by secondary process which is rolling process that increased the height of the stud. The origin of the used of rolling process is because the process of producing neck for small stud can’t be done with stamping process. The small and thin sheet will easily broke and stuck in the mold cause the mold need to be rework and increasing the lead time. Based on the data obtained, the weekly outputs for the products are not achieving the target for 90% passing rate. The focuses for eliminating loose gap defects are by rework and reducing the dies height. Since the rolling process cannot be eliminate, rework the dies is the best solution. The stud specification is reduced by reducing dies 0.5mm of original height. Hence, when the stud undergoes rolling and necking process, the increase of the height will not exceed the product specification. Based on the data after Kaizen implementation, the weekly percentage of passes increase by 14.14% compare to before implementation. Besides, based on the cost analysis, the company saved up to RM 2.81 per kg after the implementation. Finally, to ensure the improvement and prevent others problem in the future, the preventive maintenance and 5S is proposed. Checklist schedule for every two hours period is implement in the production to monitors the condition of the machine and the output. To improve the quality of the product, the KA technique needs to be performed continuously from time to time by the company.

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