Waste reduction of safety pin by implementing Kaizen activities in textile manufacturing company

Lee, Sing Chi (2018) Waste reduction of safety pin by implementing Kaizen activities in textile manufacturing company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Wastes in manufacturing industries are one of the major environmental sustainability issues in Malaysia. Kaizen Activities (KA) is one of the Lean Manufacturing (LM) tools usually widely used to eliminate or reduce waste, improve quality and reduce cost in manufacturing industries. KA is a powerful continuous improvement method which selected in this project to solve the defect safety pin issues in the assembly process of a textile manufacturing company which is located in Malacca. Currently, the textile manufacturing company is facing high rejection of low quality safety pin which contributed to the high sorting cost. Hence, the goal of this study is to reduce the rejection of safety pin by implementing KA. There are many type of defect safety pin which contributed to rejection. By following the KA methodology, the major defects that occur in the assembly process of safety pin are identified by using Pareto diagram that is Top Wire Showing. Various statistical tools were used such as Pareto Chart, Cause-and-Effect Diagram and Failure Mode and Effect Analysis (FMEA). The root causes of the critical defect were identified and solution to reduce the defect was provided. The use of Plan, Do, Check and Act (PDCA) cycle has determine the bottleneck machine in assembly process that contributed to the high rejection of defect safety pin as well as provide correction action to reduce the rejection. Based on the results, the rejection of safety pin was reduced 32.76% and the sorting cost was reduced 31.48% per month. An estimation of RM13202 sorting cost can be saved annually after the improvement. For continuous improvement, the KA should be continuously implemented in the assembly process in order to find the best solution.

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