The Improving and Defect Prevention in Production Process of Car Window Trim Seal Parts Case study: Company for Plastic Components

Abstract

The case study company is a manufacturer of plastic parts in the automotive and electrical industries. From the study, it was found that the product with the IG43-0 number, which is the car window trim seal, had the highest number of defects. The most common type of defect found was the "injection marks" on the surface of the workpiece, with a total of 2,089 pieces. This caused the proportion of defects to increase to almost reach the threshold values. From studying the production process and analyzing the cause of the problem using the 7 Quality Control Tools and the Why-Why Analysis, it was found that the cause of the problem was a blockage in the air vent system of the injection mold. Therefore, corrective actions were taken by making a work instruction manual for preparing the injection mold, which specifies that it must be cleaned before using in production and the air vent system must be washed and checked the distance between the air vent grooves to ensure compliance with the specified standard. The results showed a reduction in defects by 1,171 pieces or 56.06% of the defects were reduced.