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:
Productivity Improvement by Defect Reduction in Fuel Hose
Case Study:Automotive Part Manufacturer
1 2*
1,2
E-mail: [email protected] E-mail: [email protected]*
Umaporn Pogdang1 Natanaree Sooksaksun2*
1,2Department of Industrial Management, Faculty of Industrial Technology and Management
King Mongkut�s University of Technology North Bangkok Prachinburi
E-mail: [email protected] E-mail: [email protected]*
1) 2)
3) 4)
2.55 2 Cap
4
1.66 65,127.6 781,531.2
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Abstract
The objectives of this research are to study the defect in a process of fuel hose, to analyze the cause and propose the guideline and to use the guideline to solve problems. The methodology of this research
has 5 steps. 1) To study the process of fuel hose. 2) To define the defect in a process of fuel hose and select the significant defect by using pareto principle. 3) To analyze the cause of the significant defect by
using cause and effect diagram and to propose the guideline for reduce the defect. 4) To implement the
guideline and compare the result. From the data collection, the process of fuel hose are extrusion, cutting, pre-curing stock, put in shape, curing, take off mandrel, clean, inline inspection, assemble; after
that, final inspection before packing. From the data collection, the defects in the process equal to 2.55% that is over 2% the limit of company. From the pareto principle, there are 4 significant defect type. 1) The
fuel hose was wrinkled. 2) The cap on the end of a hose. 3) The rubber mouth ulcers. 4) The skin of fuel hose has holes. There are the main causes of four defect types. Employees do not follow the
procedures. The process of put the work piece in shape is wrong. Some machine is the damaged and dirty. Raw rubber is not the standard. The guidelines for solving are training staff, set working standard
and improvement machinery was damaged by cleansing as plan. Moreover, try out the rubber to the
appropriate value. When the guidelines are used, the percentage of defect is decreasing from 2.55% to 1.66% and the cost reduces by approximately 65,127.6 bath per month or 781,531.2 bath per year.
Keywords: Defect, Fuel Hose, QC tools
1.
. .2555
1
1 (Fuel Hose)
2.55
1
( ) ( )
%
Oil cooler hose 43,974 683 1.55
Air condition hose 32,481 532 1.64
Fuel inlet hose 33,252 569 1.71
Water hose 34,394 654 1.90
Water by pass
cover
38,389 814 2.12
Vacuum hose 34,067 759 2.23
Power steering 32,062 715 2.23
Fuel hose 33,849 864 2.55
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2.
2.1
(Kaizen) ( Continual
Improvement) (KAI)
(Change) (ZEN) (Good)
(Participation)
(Return of Improvement)
(PDCA)
7
2.2
(2555) [1]
1.53% 0.53%
(2555) [2]
Magnetic Breaker
1.62% 0.55% 2.0%
0.89% (2555) [3]
(2555) [4]
6.17%
2.30%
3.
3.1
1)
(Genba) 2) (Genbutsu) 3) (Genjitsu)
3.2
(Check
Sheet) (Pareto principle)
3.3
(Cause and effect diagram)
3.4
(P-D-C-A) (Deming Cycle)
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4.
4.1
1
1
4.2
2
2
� � � Cap� � � � �
63.4%
4.3
3
3
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2
2
Mandrel
Cap
Cap
Extrusion
4.4
4.4.1 -
-
Cap
Mandrel Cap
Cap
Cap
One Point Cap
-
Cap
( Cap) Cap Cap
Cap Cap
Cap Cap 3
1, 2 3 1
Cap 2
Cap 3 Cap
Cap 2
One Point Cap
-
21.0 ± 0.2
17.1 ± 0.2
21.0
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17.1 ± 0.2
Cap
0.2 3
20.8, 20.6 20.4
17.1 ± 0.2
20.6 ± 0.2
4.4.2
. . 2555
1 34,750
406 1.16
3
3
( ) ( )
33,849 34,750
864 406
% 2.55 1.16
65,127.6 781,531.2
5.
Cap
2.55 1.66
65,127.6 781,531.2
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