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Quality Control Circles Technique for Reducing Fine Bored Parts Rejects After Tool Change
Abstract
This study aims to assess reduction of rejects after tool change in a crankshaft manufacturing industry using Quality Control Circles (QCC) technique. Four months production data of crankshaft was collected and analyzed in 2022 in one of the largest automotive industries in Indonesia. Fine boring process was identified as the largest contributor of rejects. QCC activities were conducted to streamline the type of rejects in fine boring. QCC introduced a new intermediate action in calibrating machine setting after tool change. The results show a significant reduction in the level of rejection from 35% to just 5% of total rejects in the fine boring process after this QCC method was implemented. This result shows that this QCC method, by brainstorming among employees, can continuously improve and solve the problem in the workplace. This QCC method not just reduce the reject rate but also increasing morale, safety maintenance for employee, smoothness in supplying the next process, and reducing the cost (QCDSM). The limitation of this method is high dependency to the knowledge, experience and skill of the QCC team. Development of QCC team in term of new knowledge may lead to future improvement opportunity through development of quality control techniques with incorporation of internet of things or smart devices.
... Dari data diatas menunjukan dominasi terbesar adalah defect Center, tetapi untuk menyelesaikan kegagalan yang berkorelasi harus diselesaikan 80%, dan faktor-faktor yang harus diselesaikan antara lain: 1) Center; 2) Ukuran tidak standar (UTS); 3) Deformasi b. ANAKONDA(Analisa Kondisi Yang Ada) Fungsi dari tahap ini adalah untuk mendapatkan sejumlah gambaran rinci dari permasalahan yang ada (Sulaeman et al., 2024). Pada tahap ini dapat diperoleh banyak data aktual yang terjadi pada setiap proses yang mempengaruhi masalah yang dihadapi (Nurhayani et al., 2023) data dapat dilihat pada Tabel 2. (Sutawijaya, 2022), hal ini dilakukan untuk mengetahui apakah segala perbaikan yang dilakukan memberikan hasil penurunan jumlah NG (defect) atau tidak (Dahniar, 2018), perbandingan data dapat dilihat pada tabel 6 dan tabel 7 berikut. ...
Perusahaan manufaktur PT. KMIL, yang mengkhususkan diri dalam pengolahan metal, konsisten dalam menjaga kepercayaan konsumen dengan menghasilkan produk berkualitas dan kompetitif. Meskipun telah melakukan pengendalian kualitas, masih terdapat defect pada Produk Collect. Penelitian ini bertujuan untuk mengoptimalkan kualitas produk dengan mengurangi jumlah defect yang terjadi menggunakan metode Quality Control Circle (QCC) dengan konsep PDCA (Plan, Do, Check, Action). Hasil analisis menunjukkan bahwa terdapat tiga jenis defect tertinggi pada proses produksi collet, yaitu center, ukuran tidak standar, dan deformasi, yang disebabkan oleh faktor-faktor seperti mesin, manusia, material, metode, dan lingkungan. Dengan penerapan metode Quality Control Circle (QCC), hasil penelitian menunjukkan penurunan defect pada Defect Center sebesar 72%, Defect UTS (Ukuran Tidak Standar) sebesar 81%, dan defect deformasi sebesar 76%. Implikasi dari temuan ini adalah peningkatan signifikan dalam kualitas produk Collect, yang diharapkan dapat meningkatkan kepuasan pelanggan dan reputasi produk. Komunikasi aktif antara pemimpin dan bawahan serta pendekatan personal yang dilakukan dengan menerapkan Quality Control juga dianggap penting untuk meningkatkan produktivitas karyawan.
PT. Pajitex is one of the textile industries that produce sarongs and continues to strive to fulfill customer desires through quality sarong products. During the sarong production process, there are still various product defects that can reduce consumer confidence in the resulting sarong products. Therefore, PT. Pajitex strives to reduce the number of defects that occur in the sarong manufacturing process by exploring various causes of defects. The purpose of this study was to analyze the defective edge on the CR3082 plate using the Quality Control Circle (QCC) method. The QCC method is a quality control system through the 8-step method with a continuous improvement system. At the defect search stage, use quality control tools such as Pareto diagrams and fishbone diagrams, and use the Failure Mode Effect Analysis (FMEA) method to obtain the highest RPN value which is a priority in the improvement proposal, and in determining the improvement proposal using the PDCA Methods. Based on the results of the analysis obtained, the cutter cutting and the needling process are not perfect and the tuck-in setting is not precise has the highest RPN value, which is equal to 120, so this activity needs to be monitored and followed up.
Background:
To report a quality control circle (QCC) activity on the theme of reducing the incidence of catheter-associated urinary tract infection (CAUTI), and used an interrupted time series analysis to evaluate the impact of the QCC.
Methods:
In a general tertiary hospital in Shenzhen, China, we carried out a QCC activity with the theme of reducing CAUTI from April 2017 to December 2017. Before the QCC, we carried out the routine measures; during the QCC, we implemented usual measures and the countermeasures of QCC, and after the QCC, we performed the routine measures and adhered to the core measures of QCC. The interrupted time series analysis method was used to analyze the changes in the CAUTI incidence during the 3 stages.
Results:
Before, during, and after the QCC activities, the catheter use ratios and mean indwelling time both had a downward trend; meanwhile, the compliance rate of CAUTI prevention measures showed an upward trend. After the interventions, the CAUTI incidence decreased by 1.317‰ immediately, then gradually decreased by 0.510‰ per month. After the completion of QCC, the CAUTI incidence increased by 0.266‰ immediately and increased by 0.070‰ over time, but the difference was not statistically significant.
Conclusions:
The CAUTI incidence is reduced through QCC, providing a useful reference for the prevention of CAUTI and the development of medical quality improvement activities.
Currently, manufacturing industry competes in improving the quality of
products produced, High demand leads to competition in similar manufacturing industries.
Therefore, it becomes a challenge for companies to reduce product abnormality. Six sigma
is a very early and potential ideology in this field. In production sector accross the
world, six sigma is well known and its asset is being taken for improving capacity and
character achievement and also to make the course sturdy to quality alteration. The
effectiveness of Six Sigma is well supported by anecdotal evidence. However, academic
research on Six Sigma is still in its early stage. The review of Six Sigma and Grey FMEA
case studies that is achieved in modest scale corporation, service company and product
construction is showed in this paper.
- The ‘kerem’ production process is the earliest process of the entire process in iron casting. The brake itself is a mandatory thing in an iron foundry company because it functions as a limiter of the inner diameter of an iron casting product or more simply as a hole in iron casting products. With the analysis carried out using seven tools, it is expected to be able to obtain actual data to improve the quality of brake production, look for factors that affect brake quality, control the number of rejects, countermeasures, repairs, and standardization. The biggest problems with defects in the production of brakes are porous, broken, cracked and not full sand. From the aspect of 4M + 1E, the Man factor is the dominant cause of brake defects. Meanwhile, the number of rejects outside the 2.5% AQL limit was 6 times, namely on 8 July 2021 as many as 16 pcs (AQL 2.5% was at 10 pcs). Then on July 17, 2021 as many as 15 pcs (2.5% AQL at 13 pcs) on July 18 2021 as many as 30 pcs (2.5% AQL at 2 pcs) on July 20 2021 as many as 25 pcs (AQL 2.5% was at 12.63) on 27 July 2021 as many as 20 pcs (AQL 2.5% was at 19 pcs) and finally on August 5, 2021 as many as 30 pcs (AQL 2.5% was at 12.6 pcs).
PT. Toyota Boshoku Indonesia merupakan perusahaan asing yang bergerak dibidang komponen otomotif dengan produk utama yang dihasilkan adalah kursi mobil.Dalam proses pembuatan produk kursi mobil tersebut sering terjadi produk cacat atau kurang sempurna. Untuk meminimalisir terjadinya produk dengan kualitas yang kurang baik, pihak perusahaan melakukan analisa kegiatan dengan menggunakan metode QCC(Quality Control Circle), metode analisa yang dilakukan adalah dengan menggunakan pareto dan fishbone. Dengan kegiatan yang dilakukan diharapkan perbaikan kualitas akan terus berlangsung, dan kualitas semakin membaik. Untuk meminimalisir terjadinya pembuatan barang yang kurang berkualitas pihak perusahaan mewajibkan setiap operator untuk menjaga 3M (Tidak menerima, Tidak membuat, Tidak meneruskan), serta apabila terjadi upnormal pada saat proses berlansung, maka operator diharuskan untuk melakukan tindakan SCW (Stop, Call, Wait).Kata Kunci : Kualitas, QCC, 3M, SCW
In this modern world, there are always pressure on the designers and the manufacturers to respond to the consumer needs. Engineering involves designing, manufacturing, constructing, and maintaining of products, systems, service and structures. In this paper, an attempt has been made to derive all the parameters, which are necessary for designing the components of an engine using reverse engineering. Even though lots of methods are available for redesigning, the reverse engineering is selected. Computer aided modeling using CATIA and optimization analysis of crankshaft is used to study was to evaluate and compare the fatigue performance of three different materials of automotive crankshafts, namely forged steel, ductile cast iron and aluminium alloy. In this study a dynamic simulation was conducted on three crankshafts, cast iron and aluminum alloy forged steel; from similar single cylinder four stroke engines. The dynamic analysis was done and was verified by simulations in ANSYS. Geometry, material and manufacturing processes were optimized considering different constraints, manufacturing feasibility and cost.The maximum stress point and dangerous areas are found by the deformation analysis of crankshaft. Possible weight reduction options and their combinations were considered. Thus durability of feasible material and analysis is carried after weight reduction carried to the feasible material. Thus more possibilities of feasible crankshaft are found out.
Pengendalian Kualitas Cacat Scrap Blown Ban Tbr 11R22 . 5 dengan Metode QCC dan Seven Tools pada PT . Gajah Tunngal Tbk Pendahuluan Pesatnya kemajuan teknologi membawa dampak terhadap tatanan kehidupan di dunia ke arah globalisasi . Perubahan terjadi di p
- E Supriyadi
- R Effendi
- Taufik
Supriyadi, E., Effendi, R., & Taufik. (2021). Pengendalian Kualitas Cacat Scrap Blown Ban Tbr 11R22
. 5 dengan Metode QCC dan Seven Tools pada PT. Gajah Tunngal Tbk Pendahuluan Pesatnya
kemajuan teknologi membawa dampak terhadap tatanan kehidupan di dunia ke arah
globalisasi. Perubahan terjadi di p. Jurnal Polimesin, 19(1), 22-27.