Reducing an Indonesian Auto Part Production Cycle Time using the PDCA Approach: A Case Study
Received: 2 May 2024 | Revised: 7 October 2024 | Accepted: 5 December 2024 | Online: 11 December 2024
Corresponding author: Jonny
Abstract
Constituting the biggest challenge in any manufacturing company’s product delivery, operational excellence can be accomplished by obtaining the best Quality, Cost, and Delivery (QCD). The delivery parameter has been an issue for the ABC Company, an Indonesian auto part manufacturer, having automotive manufacturers as customers, since its cycle time has been found to be lower than its takt time. This could jeopardize the company’s status in that it could degrade its customer service level. Thus, the company immediately initiated a quality control circle, especially when it was revealed that its production cycle time in Core Assy Line 3 was 49 s more than its targeted 41.7 s takt time. The team was then committed to reducing it to 39.2 s, accounting for a 20% reduction. A method named 8 steps and 7 tools was deployed under the Plan-Do-Check-Act (PDCA) approach to solve the specific problem. This method guided the team to find five root causes of the problem, while five solutions were equivalently provided. As a result, the achieved cycle time reduction was from 49 to 38.9 s, that is, a 21% decrease, capable of securing the company’s relationship with its customers and granting an order increase.
Keywords:
quality control circle, PDCA, 8 steps and 7 tools, cycle time, takt timeDownloads
References
S. Manojkumar and M. Kumar, "Elimination of visor defects using 7 QC tools," Materials Today: Proceedings, vol. 45, pp. 8203–8206, Jan. 2021.
M. D. Phalane and K. Gupta, "An integrated framework for improving safety, quality, and stewardship standards in manufacturing: A case study," Reports in Mechanical Engineering, vol. 4, no. 1, pp. 213–224, Oct. 2023.
V. Shivajee, R. K. Singh, and S. Rastogi, "Manufacturing conversion cost reduction using quality control tools and digitization of real-time data," Journal of Cleaner Production, vol. 237, p. 117678, Nov. 2019.
V. M. Magar and D. V. B. Shinde, "Application of 7 Quality Control (7 QC) Tools for Continuous Improvement of Manufacturing Processes," International Journal of Engineering Research and General Science, vol. 2, no. 4, pp. 364–371, Jul. 2014.
N. Abbas, "Homogeneously weighted moving average control chart with an application in substrate manufacturing process," Computers & Industrial Engineering, vol. 120, pp. 460–470, Jun. 2018.
W.-H. Ho, Y.-H. Chiu, and Y. J. Chen, "Multi-objective Pareto adaptive algorithm for capacitated lot-sizing problems in glass lens production," Applied Mathematical Modelling, vol. 53, pp. 731–738, Jan. 2018, https://doi.org/10.1016/j.apm.2017.09.030.
F. A. Fernandes, S. D. Sousa, and I. Lopes, "On the Use of Quality Tools: A Case Study," in Proceedings of the World Congress on Engineering 2013, UK, Jul. 2013, vol. 1.
S. Muhammad, "Quality Improvement Of Fan Manufacturing Industry By Using Basic Seven Tools Of Quality: A Case Study," Sulaman Muhammad Int. Journal of Engineering Research and Applications, vol. 5, no. 4, pp. 30–35, Apr. 2015.
S. H. Bambharoliya, H. Thakkar, G. H. Patel, and V. Nagar, "Reducing Rejection Rate in Small Scale Machining Unit Using 7 Quality Control Tools - A Review," International Journal of Engineering Development and Research, vol. 3, no. 4, pp. 582–586, Dec. 2015.
. D., "Application of Quality Control Tools in a Bicycle Industry: A Case Study," International Journal of Research in Engineering and Technology, vol. 05, no. 07, pp. 119–127, Jul. 2016.
Handbook for TQM and QCC Vol. I. Inter-American Development Bank, 2003.
I. A. Memon, Q. B. Jamali, A. S. Jamali, M. K. Abbasi, N. A. Jamali, and Z. H. Jamali, "Defect Reduction with the Use of Seven Quality Control Tools for Productivity Improvement at an Automobile Company," Engineering, Technology & Applied Science Research, vol. 9, no. 2, pp. 4044–4047, Apr. 2019.
I. A. Memon, A. Ali, M. A. Memon, U. A. Rajput, S. a. K. Abro, and A. A. Memon, "Controlling the Defects of Paint Shop using Seven Quality Control Tools in an Automotive Factory," Engineering, Technology & Applied Science Research, vol. 9, no. 6, pp. 5062–5065, Dec. 2019.
A. B. E. Aichouni, H. Abdullah, and F. Ramlie, "A Scientific Approach of using the DMAIC Methodology to Investigate the Effect of Cutting Tool Life on Product Quality and Process Economics: A Case Study of a Saudi Manufacturing Plant," Engineering, Technology & Applied Science Research, vol. 11, no. 1, pp. 6799–6805, Feb. 2021.
Downloads
How to Cite
License
Copyright (c) 2024 Jonny
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.
