Reduction of Total Cost Related to Dent Defect of CD Player Bracket
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Abstract
The objective of this research is to improve production processes of CD Player Bracket, which is used in a car. Which is total dent defects cost amount 221,544 baht in two months or 77.71% of total defects cost. This research has an aim to reduce the defective rate from dent. This research applied the Design of Experiment methodology, consisting of 5 phases, to solve the problem. Define problem, important problem was selected and clearly defined. Analysis, all key process input variables were brainstormed and failure mode and effect analysis, that was found six factors, which are Nominal force of pressing machine, Hardness of urethane rubber, Distance between the edge of work piece and strip, punch and die life , urethane rubber life, and Cutting speed. Design Experiment, specified factors for experiment and designed the design matrix. Experimental Analysis, statistically tested whether they significantly affected the problem. Confirmation Resulted, a confirmatory experiment was performed to confirm the result after improvement. After improvement, the defective cost from dent defects was reduced from 0.675 Baht to 0.110 Baht, or decrease 83.70% .This improvement could save the rework cost of 486,000 baht per year.
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References
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