Reducing Waste in the Clutch Assembly Pumping Process Case Study: Automotive Air Compressor Factory

Abstract

This research aims to study, analyze, and reduce waste in the process of pumping components for automotive air conditioner clutch assemblies. A case study at a factory and data analysis found that a significant amount of waste was generated from non-standardized pumping processes for automotive air conditioner clutch components. Therefore, the researchers sought to find solutions by applying industrial engineering tools. The prioritization of the problem was done using a Pareto chart. causes were analyzed using the 4M principle, which includes Man, Machine, Material, and Method. A Cause and Effect Diagram was used to visually represent the causes and effects. Brainstorming was conducted to analyze the causes of the problem and compare the research findings. It was discovered that the main cause of the problem was scratches caused by the presence of iron powder or dirt adhering to the mold surface of the metal pumping machine. This resulted in scratches when pumping the clutch assembly components. The improvement method involved having employees clean each product before pumping and conducting cleaning at the mold surface of the metal pumping machine every hour using compressed air and a clean cloth. As a result, before the improvement, the amount of waste was 3,844 pieces with a P_pk value of 0.5754. After the improvement, the amount of was reduced to 23 pieces with a P_pk value of 1.1508, resulting in a reduction of 99.40%.