Visual Inspection As a Screening Method in Assembly Process for Quality Improvement

Journal of Advanced Manufacturing Technology (JAMT) Journal of Advanced Manufacturing Technology (JAMT) Visual Inspection as a Screening Method in Assembly Process for Quality Improvement

VISUAL INSPECTION AS A SCREENING METHOD IN

ASSEMBLY PROCESS FOR QUALITY IMPROVEMENT

A.R. Soufhwee, W. H. W. Mahmood and M. I. H. C. Abdullah

1Faculty of Engineering Technology, 1Faculty of Engineering Technology, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia.

Corresponding Author’s Email: [email protected]

: Received 10 August 2017; Revised 20 October 2017; Article History: Received 10 August 2017; Revised 20 October 2017; Accepted 19 December 2017

ABSTRACT: Kaizen is one of the famous approach in the Japanese manufacturing industries to increase the productivity. There are many techniques applied in Kaizen, but surprisingly the visual inspection ‘point to point checking jig’ is a potential technique to respond customer needs in term of quality issue. This study is performed to detect missing rivet pin during riveting process manually done by operators. The root cause of this the quality issue is due to lack of awareness among the operators. ‘Point to point checking jig’ is apply in order to eliminate waste at production line related to the manually process by operators. Plan, Do, Check and Action or known as PDCA is a method that has been applied in this study. The point to point jig was designed and fabricate with characteristics of mistake proofing. 50 samples were prepared as a pilot run to monitor and validate the progress action. This procedure is to ensure zero percentage (0 %) defect target was achieved in the following months after correction action had been taken. This paper shows the successful of ‘point to point checking jig’ in Kaizen, which gives impact to product quality performance.

: Kaizen; Visual Inspection; Point to Point Checking Jig; PDCA Method KEYWORDS: Kaizen; Visual Inspection; Point to Point Checking Jig; PDCA Method

1.0 INTR ODU CTION 1.0 INTR ODU CTION

To face a big challenge and to survive for excellence in market place, one of the improvement plan can be made is to merge the improvement activities with the quality. Productivity and quality improvement are combined purposely to gain a competitive advantage for most manufacturing industries management. Therefore, a manufacturer should always creative and innovative to apply advanced manufacturingeISSN: 2289-8107 technique Special and Issue skills, iDECON to adopt 2016 better quality343 control for a long run during mass production. And one of the main Journal of Advanced Manufacturing Technology (JAMT)

VISUAL INSPECTION AS A SCREENING METHOD IN ASSEMBLY PROCESS FOR QUALITY IMPROVEMENT

A.R. Soufhwee, W. H. W. Mahmood and M. I. H. C. Abdullah

1Faculty of Engineering Technology, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100 Durian Tunggal, Melaka, Malaysia.

Corresponding Author’s Email: [email protected]

Article History: Received 10 August 2017; Revised 20 October 2017; Accepted 19 December 2017

KEYWORDS: Kaizen; Visual Inspection; Point to Point Checking Jig; PDCA Method

1.0 INTR ODU CTION

To face a big challenge and to survive for excellence in market place, one of the improvement plan can be made is to merge the improvement activities with the quality. Productivity and quality improvementJournal of Advanced areManufacturing combined Technology purposely to gain a competitive advantage for most manufacturing industries management. Therefore, a manufacturer should always creative and innovative to apply Journal of Advanced Manufacturing Technology (JAMT) advanced manufacturing technique and skills, to adopt better quality control for a long run during mass production. And one of the main concerns is the identification of the strategies of change and how is it managed.

Kaizen is a Japanese compound word which means Kai (change) and Zen (for the better). The word has become common in many western companies [1]. Kaizen means continuous improvement (CI) is one of the core strategies for excellence in production. It has become one of the important tools for getting improvement in any field i.e. production, process, quality and maintenance in the manufacturing industry [2-3]. The word Kaizen was introduced by Imai Masaki in 1986 and used by Toyota to improve their performance for waste reduction. Kaizen has many techniques that can be applied to make an improvement in the production line [4-5].

According to several studies, Kaizen apply many types of techniques in forms of umbrella which include Kanban, approach, improvement, zero defects, effectiveness, networking, six sigma, just-in-time, poka- yoke, FMEA and productivity improvement [6-12]. These techniques have been used in many ways, but the aim is the same to improve the productivity, reduce the waste also the cost of the manufacturing process. Kanban is a system that produces only the quantity required by the customer demand. The quantity of the product that been produced is just enough with the customer demand from the customer and it is considerably stockless. Meanwhile, improvement is an updating the product according to a customer that always change from time to time [13]. On the other hand, zero defects refers to making mistakes when doing work. Normally, the good quality of the product can be achieved by practicing zero defects. Effectiveness is also part of the kaizen approach where this method providing the best services to capture customer heart. After the customer confidence has been secure, the connections with customers can be developed through networking. Harry and Schroeder [14] mentioned that six sigma is a process that help company to distribute close to perfect product and services. Poka-yoke is a mistake proofing designed to avoid mistakes and to make it easy to detect any mistake happened.

All those tools are used to eliminate MUDA that also that may occur in manufacturing area [15-16]. The word “Muda” in Japanese means 344waste [17]. WasteeISSN: is 2289-8107an activity Special that Issuedoes iDECON not add 2016 any value to a product. Beside, waste may lead to a higher manufacturing processing cost due to the unneeded processing process or extra tools required while the product will be sold at the same price. There are many types of waste that occur in the manufacturing process such as overproduction, processing, motion, transportation, rework, defect, Journal of Advanced Manufacturing Technology (JAMT)

concerns is the identification of the strategies of change and how is it managed.

According to several studies, Kaizen apply many types of techniques in forms of umbrella which include Kanban, approach, improvement, zero defects, effectiveness, networking, six sigma, just-in-time, poka- yoke, FMEA and productivity improvement [6-12]. These techniques have been used in many ways, but the aim is the same to improve the productivity, reduce the waste also the cost of the manufacturing process. Kanban is a system that produces only the quantity required by the customer demand. The quantity of the product that been produced is just enough with the customer demand from the customer and it is considerably stockless. Meanwhile, improvement is an updating the product according to a customer that always change from time to time [13]. On the other hand, zero defects refers to making mistakes when doing work. Normally, the good quality of the product can be achieved by practicing zero defects. Effectiveness is also part of the kaizen approach where this method providing the best services to capture customer heart. After the customer confidence has been secure, the connections with customers can be developed through networking. Harry and Schroeder [14] mentioned that six sigma is a process that help company to distribute close to perfect product and services. Poka-yoke is a mistake proofing designed to Visual Inspection as a Screening Method in Assembly Process for Quality Improvement avoid mistakes and to make it easy to detect any mistake happened.

All those tools are used to eliminate MUDA that also that may occur in manufacturing area [15-16]. The word “Muda” in Japanese means waste [17]. Waste is an activity that does not add any value to a product. Beside, waste may lead to a higher manufacturing processing cost due to the unneeded processing process or extra tools required while the product will be sold at the same price. There are many types Journal of Advanced Manufacturing Technology (JAMT) of waste that occur in the manufacturing process such as overproduction, processing, motion, transportation, rework, defect, and waiting. Overproduction usually refer to making something before it is truly needed. This may lead to a finish product waste and it may cause excess inventory. Meanwhile, the processing mean making the part/product more than it is needed compare to what customer requirement. Motion refer to an unnecessary movement of people that does not add any value. Contradict to motion which precisely refer to waste due to human generated, transport is an unnecessary movement of raw materials or work in progress or finished goods. Rework is making corrections or scrapping work that has already been done before it will be sent to customer. Defect can be classify as flawless or refer to mistakes in product manufacturing which happened when production or refer to mistakes in the process that requires rework. Waiting is an idle time happens when waiting for the next step in production. This activity also does not add any value to a product and will cause waste.

In production normally the rejected parts leakage to customers are caused by

i. Insufficient training for the operators ii. Operators do not follow the checking method iii. Bypass checking process during running the production.

Based on the above problems, the purpose of this research is mainly focus to apply point to point checking jig in Kaizen to improve product quality during mass production. It is to solve problems in quality and to support problem solving by the production workers team.

1.1 Company Background

The company that has been selected to make an implementation of continuous improvement is located at Cheng Malacca, Malaysia. It is a

company whicheISSN: is 2289-8107a fully integrated Special Issue iDECONelectronics 2016 manufacturing345 services manufacturer of electronics and computer peripherals. They are able to provide total integration and turnkey services and technology such as plastic injection molding, enclosure and metal stamping, and engineering services. In this factory, it consists of 5 departments which are Press Shop, Secondary Assembly, Powder Coating, Final Assembly and Moulding department. The department that has been placed is Final Assembly Production that produced Chassis Base Assembly. Journal of Advanced Manufacturing Technology (JAMT)

and waiting. Overproduction usually refer to making something before it is truly needed. This may lead to a finish product waste and it may cause excess inventory. Meanwhile, the processing mean making the part/product more than it is needed compare to what customer requirement. Motion refer to an unnecessary movement of people that does not add any value. Contradict to motion which precisely refer to waste due to human generated, transport is an unnecessary movement of raw materials or work in progress or finished goods. Rework is making corrections or scrapping work that has already been done before it will be sent to customer. Defect can be classify as flawless or refer to mistakes in product manufacturing which happened when production or refer to mistakes in the process that requires rework. Waiting is an idle time happens when waiting for the next step in production. This activity also does not add any value to a product and will cause waste.

In production normally the rejected parts leakage to customers are caused by

i. Insufficient training for the operators ii. Operators do not follow the checking method iii. Bypass checking process during running the production.

1.1 Company Background

The company that has been selected to make an implementation of continuous improvement is located at Cheng Malacca, Malaysia. It is a company which is a fully integrated electronics manufacturing services manufacturer of electronics and computer peripherals. They are able to provide total integration and turnkey services and technology such as plastic injection molding, enclosure and metal stamping, and engineering services. In this factory, it consists of 5 departments which are Press Shop, Secondary Assembly, Powder Coating, Final Assembly and Moulding department. The department that has been placed is Final Assembly Production that produced Chassis Base Assembly. Journal of Advanced Manufacturing Technology (JAMT)

2.0 LITERATURE REVIEW

2.1 Visual Management

Visual management is known as management system that attempts to enhance excellence performance setting through the key performance index (KPI). It is one of management approach that combines all information together such as signalling, limiting or guaranteeing (mistake – proofing/poka yoke) visual devices, so that places become self-explanatory, self-ordering, self-regulating and self-improving [18]. It has been evolving and effectively employed in some manufacturing and service organizations for a long time.

Continuous improvement (or Kaizen in the lean terminology) is a highly dynamic capability and able to be defined as “an organization- wide process of focused and sustained incremental innovation [19]. Visual management serves as a base for continuous improvement and perhaps more important stimulate employee involvement to manage and improve quality [20]. Then, visual management makes the organization listening visual with high ability to respond to people’s ideas. This research study to create a system based on visual management, keeps on organization focused on monitoring, filtering, maintaining of quality performance.

2.2 Kaizen

Kaizen or continuous improvement is one of the lean tools and a 346technique has eISSN:become 2289-8107 popular Specialamong Issue researchers iDECON 2016 because it can increases productivity of the production high quality product with a minimum efforts. These activities are implemented through recognition and elimination of waste (MUDA) throughout the manufacturing process. It involves everyone in the workplace to cooperate together in order to make Kaizen successfully implemented. There are many manufacturing company successfully implemented Kaizen and brought changes to their company. [21] describes that the company that successful in their Kaizen activities such as Nichols Foods manufacturing food products that meet decreasing in their quality rejections, reduction in change over times and increase in manufacturing efficiencies. A small manufacturing designing system had successfully reduces 25% of the unit cost, reduces floor space requirement by 15% and develops better communication network throughout the organization. Other than that, a study on the ‘inventory management Kaizen’ that has been conducted at ‘BAE SYSTEM’ to remove waste shows an improvement was made for the Journal of Advanced Manufacturing Technology (JAMT)

2.0 LITERATURE REVIEW

2.1 Visual Management

2.2 Kaizen

Kaizen or continuous improvement is one of the lean tools and a technique has become popular among researchers because it can increases productivity of the production high quality product with a minimum efforts. These activities are implemented through recognition and elimination of waste (MUDA) throughout the manufacturing process. It involves everyone in the workplace to cooperate together in order to make Kaizen successfully implemented. There are many manufacturing company successfully implemented Kaizen and brought changes to their company. [21] describes that the company that successful in their Kaizen activities such as Nichols Foods manufacturing food products that meet decreasing in their quality rejections, reduction in change over times and increase in manufacturing efficiencies. A small manufacturing designing system had successfully reduces 25% of the unit cost, reduces floor space requirement by 15% and develops better communication network throughout the organization. Other than that, a study on the Journal of Advanced Manufacturing Technology (JAMT) ‘inventory management Kaizen’ that has been conducted at ‘BAE SYSTEM’ to remove waste shows an improvement was made for the process time when it was reduced from 610 hours to 290 hours. Usually to conduct this activity, a team must be form to improve a specific areas that already been identified for an improvement. This team will brainstorm together to find a solution using Kaizen techniques that can be apply as an improvement for the targeted area. The activity consists of Gemba Kaizen and Genchi Genbutsu where the meaning is a shop floor and going to a workplace to identify problem.

To implement Kaizen at production line, there are many approaches that can be use depending on the current situation of the production line. Beside that Kaizen has a form such an umbrella that covered many techniques that can be used in the numerous organizations such as Toyota. There are many tools and techniques available in lean manufacturing that are focuses on eliminating seven waste. But the easiest techniques to use and applied among the other techniques is a Kaizen. It is easy and even the small improvement could also been considered as Kaizen. It can be applied in many other areas and not only focusing on manufacturing industry. As mentioned earlier, Kaizen has many techniques that can be used as a countermeasure for problems at the production line. Through this research, the literature review was doneeISSN: to 2289-8107 study on Special the techniquesIssue iDECON of 2016 Kaizen that are347 available to solve problems occur when searching a countermeasure for the problem arise [22].

According to Basu [4], PDCA (Plan Do Check Action) cycle represents the repeated and continuous nature of continuous improvement. It is obtained by the actual result of an action that is being compared with a target or set point and the difference between those two is then monitored and corrective measures are adopted. PDCA Cycle means continuously looking for better method to make improvement. And each word from PDCA Cycle brought different meaning that represents the basic steps of PDCA Cycle.

Basic Steps i. P (Plan) stage: It is where comprising the formulation of a plan of action is done based on the analysis of the collected data. ii. D (Do) stage: Implementation of a new ways will be done in this stage. It may involve a mini-PDCA cycle stage until the issue of the implementation is resolved. iii. C (Check) stage: The results of the new implementation that has been done will be checked in this stage and being compared with targets to see if expected performance improvement has been achieved. Journal of Advanced Manufacturing Technology (JAMT)

process time when it was reduced from 610 hours to 290 hours. Usually to conduct this activity, a team must be form to improve a specific areas that already been identified for an improvement. This team will brainstorm together to find a solution using Kaizen techniques that can be apply as an improvement for the targeted area. The activity consists of Gemba Kaizen and Genchi Genbutsu where the meaning is a shop floor and going to a workplace to identify problem.

To implement Kaizen at production line, there are many approaches that can be use depending on the current situation of the production line. Beside that Kaizen has a form such an umbrella that covered many techniques that can be used in the numerous organizations such as Toyota. There are many tools and techniques available in lean manufacturing that are focuses on eliminating seven waste. But the easiest techniques to use and applied among the other techniques is a Kaizen. It is easy and even the small improvement could also been considered as Kaizen. It can be applied in many other areas and not onlyJournal focusingof Advanced Manufacturingon manufacturing Technology industry. As mentioned earlier, Kaizen has many techniques that can be used as a countermeasure for problems at the production line. Through this research, the literature review was done to study on the techniques of Kaizen that are available to solve problems occur when searching a countermeasure for the problem arise [22].

Basic Steps i. P (Plan) stage: It is where comprising the formulation of a plan of action is done based on the analysis of the collected data. ii. D (Do) stage: Implementation of a new ways will be done in this stage. It may involve a mini-PDCA cycle stage until the issue of the implementation is resolved. iii. C (Check) stage: The results of the new implementation that has been done will be checked in this stage and being compared Journal of Advanced Manufacturing Technology (JAMT) with targets to see if expected performance improvement has been achieved. iv. A (Action) stage: If the change made has been successful, then the outcome is consolidated.

3.0 METHODOLOGY

Plan, Do, Check and Action (PDCA) cycle is used in this study. The application of the PDCA cycle is more effective because of the close loop during the analysis process. By using the PDCA cycle continuously looking better improvement.

Plan (P): Implementation of the PDCA method is most appropriate to execute this research where Plan (P) refer to establishing the aim for improvement. In this phase the quality objectives should be identified before start the project.

348Do (D): eISSN: 2289-8107 Special Issue iDECON 2016 Do the action taken based on planning to solve the problem after the brainstorming among the technical group members had been done.

Check (C): Check (C) defined as the determining whether the implementation has produced the planned improvement.

There are several procedures in Check (C) station where several principles in point to point checking jig need to be followed which are:

i. Place parts at the same orientation ii. Using of eye as pointer to guide during the checking process. iii. Apply the method, either zig-zag or up down method. Number was provided at the checking jig as a guideline. iv. Once abnormality was found, rejected part will be separated into reject bin.

Action (A): Action (A) characterizes standardizing as the preventing recurrence of the original problem or setting goals for the new improvement [12]. Point to point checking jig was implemented at station Check (C) as shown in Figure 1.

Journal of Advanced Manufacturing Technology (JAMT) Journa l of Advanced Manufacturing Technology (JAMT)

iv. A (Action) stage: If the change made has been successful, then iv. theA (Action) outcome stage: is consolidated. If the change made has been successful, then the outcome is consolidated.

3.0 METHODOLOGY 3.0 METHODOLOGY Plan, Do, Check and Action (PDCA) cycle is used in this study. The applicationPlan, Do, Check of the and PDCA Action cycle (PDCA) is more cycle effective is used because in this of study. the close The loopapplication during of the PDCAanalysis cycle process. is more Byeffective using because the PDCA of the cycleclose continuouslyloop during lookingthe analysis better improvement. process. By using the PDCA cycle continuously looking better improvement. Plan (P): ImplemenPlan (P): tation of the PDCA method is most appropriate to execute thisImplemen researchtation where of the PlanPDCA (P) method refer isto most establishing appropriate the to aimexecute for improvement.this research Inwhere this phasePlan the(P) quality refer objectivesto establishing should thebe identifiedaim for beforeimprovement. start the In project. this phase the quality objectives should be identified Visual Inspection as a Screening Method in Assembly Process for Quality Improvement before start the project. Do (D): Do (D):the action taken based on planning to solve the problem after the brainstormingDo the action takenamong based the technical on planning group to members solve the had problem been done.after the brainstorming among the technical group members had been done. Check (C): CheckCheck (C):(C) defined as the determining whether the implementation hasCheck produced (C) defined the planned as the improvement.determining wh ether the implementation has produced the planned improvement. There are several procedures in Check (C) station where several Thereprinciples are inseveral point procedureto point checkings in Che jigck need(C) stationto be followed where severalwhich are:principles in point to point checking jig need to be followed which are: i. Place parts at the same orientation ii.i. PlaceUsing parts of eye at as the pointer same orientationto guide during the checking process. iii.ii. UsingApply ofthe eye method, as pointer either to guidezig-zag during or up the down checking method. process. Number iii. wasApply provided the method, at the eitherchecking zig -jigzag as or a guideline.up down method. Number iv. wasOnce provided abnormality at the was checking found, jigrejected as a guideline. part will be separated into iv. rejectOnce abnormalitybin. was found, rejected part will be separated into reject bin.

Action (A): Journal of AdvanceActiond Manufacturin (A)(A): characterizes g Technology (JAMT) standardizing as the preventing recurrence of theAction original (A) characterizes problem or standardizingsetting goals foras thethe preventingnew improvement recurrence [12]. of

Journal of Advanced ManufacturinPointthe original gto Technolog point problemy (JAMT) checking or jigsetting was goalsimplement for theed newat station improvement Check (C) [12]. as Journal of Advanced ManufacturinPoint tog Technologpoint y checking(JAMT) jig was implemented at station Check (C) as shown in Figure 1.

shown in FigurePlan 1o. Do Check Action

Plano Plano DoDo CheckCheck ActionAction

Point to point

checking jig

Point to point Figure 1: PointPoint to topint point checking jig checkingchecking jig jig

Figur Figuree 11:: PointPoint to pint checkingchecking jig jig

Table 1 shows the PDCA action and activities in resolve the problems. There are four steps which are Plan, Do, Check, and Action Phase. TableTable 1 1showsPDCA shows the thecycle PDCA PDCA represents action action andand the activitiesactivities repeated inin resolve resolveand continuousthe the problems. problems. nature of ThereThere are arecontinuous four four steps steps improvement which which areare Plan,Plan, and Do,idea Check, implementation andand ActionAction PDCA Phase. Phase. in Kaizen PDCAPDCA cycle hadcycle been representsrepresents applied previouslythethe repeatedrepeated. and continuouscontinuous naturenature ofof continuouscontinuous improvement improvement andand ideaidea implementationimplementation PDCAPDCA in in Kaizen Kaizen had been applied previouslyTable. 1: Action and activities in PDCA had been applied previouslyeISSN: .2289-8107 Special Issue iDECON 2016 349 Step Phase Action/Activities Step 1 PlanTable 1- : AimAction quality and objectives activities to bein achieved.PDCA Table 1: Action and activities in PDCA Step Step Phase2 Do Action/Activities- Countermeasure action on the problematic process. Step Phase Action/Activities Step 1 Plan - Aim quality objectives to be achieved. Step 1 StepPlan 3 Check- Aim quality- Check objectives the effectivenessto be achieved. of the countermeasure by using point to point Step 2 Do - Countermeasure action on the problematic process. checking jig. Step 2 Do - Countermeasure action on the problematic process. Step 3 StepCheck 4 Action- Check the- Implementeffectiveness the of thecountermeasure countermeasure which by using after point improvement to point had been Step 3 Check - Checkchecking the jig.effectivenessdone. of the countermeasure by using point to point Step 4 Action checkingImplement jig. the countermeasure which after improvement had been - Step 4 Action - Implementdone. the countermeasure which after improvement had been done.

The PDCA cycle is used to detect lacking in the riveting process. And The PDCApoint cycle to point is used checking to detect jigs lacking was designed in the riveting according process. to problem.And And Thepoint PDCA tothe point cycleprocess checking is used must tojigs detectbe was full designed lacking monitor inaccording theto rivetingensure to problem. process.the improvement And And of pointthe toprocess productpoint mustchecking quality be fulljigsis achieved. wasmonitor designed to ensure according the improvementto problem. Andof theproduct process quality must is achieved.be full monitor to ensure the improvement of product 4.0quality RESULTS is achieved. AND DISCUSSION 4.0 RESULTS AND DISCUSSION 4.1 Plan (P) 4.04.1 RESULTS Plan (P) AND DISCUSSION

The study was conducted at final assembly line in one of 4.1 Plan (P) The studymanufacturing was conducted company at infinal Malaysia. assembly The waste’sline in dataone areof collected

manufacturing company in Malaysia. The waste’s data are collected The studyand evaluatedwas conducted for improvement at final assemblypurpose. Theline company in one offersof many and evaluated for improvement purpose. The company offers many manufacturingservices company as sheet inmetal Malaysia. stamping, The plasticwaste’s injectiondata are molding,collected powder services as sheet metal stamping, plastic injection molding, powder and evaluatedcoating for and improvement assembly. This purpose. study onlyThe focusescompany on offers assembly many process of coating and assembly. This study only focuses on assembly process of services productas sheet XYZ.metal To stamping, produce oneplastic complete injection product, molding, the powderproduction line product XYZ. To produce one complete product, the production line coating andwill assembly.receive the This part study from onlymolding focuses and on press assembly shop department. process of will receive the part from molding and press shop department. product XYZ. To produce one complete product, the production line

will receive the part from molding and press shop department.

Journal of Advanced Manufacturing Technology (JAMT)

Journa l of Advanced Manufacturing Technology (JAMT) Journa l of Advanced Manufacturing Technology (JAMT)

Journal of Advanced Manufacturin g Technology (JAMT) Plano Do Check Action

Plan o Do Check Action Plano Do Check Action

Plano Do PointCheck to point Action

checking jig Point to point Pointchecking to point jig Figure 1: Point to pint checking jig checkingPoint to point jig checking jig Figure 1: Point to pint checking jig Figure 1: Point to pint checking jig Figure 1: Point to pint checking jig

Table 1 shows the PDCA action and activities in resolve the problems.

There are four steps which are Plan, Do, Check, and Action Phase. Table 1 shows the PDCA action and activities in resolve the problems. PDCATable 1 showscycle representsthe PDCA actionthe repeated and activities and incontinuous resolve the natureproblems. of ThereTable are 1four shows steps the PDCAwhich actionare Plan, and activitiesDo, Check, in resolve and Action the problems. Phase. There are four steps which are Plan, Do, Check, and Action Phase. PDCAcontinuousThere cycle are improvement fourrepresents steps which andthe idearepeatedare Plan,implementation Do,and Check, continuous andPDCA Action naturein Kaizen Phase. of PDCA cycle represents the repeated and continuous nature of continuoushad beenPDCA app improvementcyclelied previouslyrepresents and . the idea repeated implementation and continuous PDCA innature Kaizen of continuous improvement and idea implementation PDCA in Kaizen had beencontinuous applied improvement previously . and idea implementation PDCA in Kaizen Journal of Advanced ManufacturingTable 1: Action Technology and activities in PDCA had hadbeen been app appliedlied previously previously. . Step Phase Action/Activities Table 1: Action and activities in PDCA Step 1 Plan - AimTable quality 1: Action objectives and to beactivities achieved. in PDCA Step Phase Action/ActivitiesTable 1: Action and activities in PDCA StepStep 12 Step PhasePlanDo Phase - AimCountermeasure Action/Activities quality Action/Activities objectives action to on be the achieved. problematic process. Step 1 Plan - Aim quality objectives to be achieved. StepStep 31 CheckPlan -- CheckAim quality the effectiveness objectives to of be the achieved. countermeasure by using point to point Step 2 Do - Countermeasure action on the problematic process. Step 2Step 2 Do Do - checkingCountermeasure- Countermeasure jig. action action on onthe the problematic problematic process. process. Step 43 ActionCheck - ImplementCheck the effectivenessthe countermeasure of the countermeasure which after improvement by using point had to pointbeen Step 3 Check - Check the effectiveness of the countermeasure by using point to point Step 3 Check - checkingCheck the jig. effectiveness of the countermeasure by using point to point done.checking jig. Step 4 Action - Implementchecking jig. the countermeasure which after improvement had been Step 4 Action - Implement the countermeasure which after improvement had been Step 4 Action - done.Implement the countermeasure which after improvement had been done. done.

The PDCA cycle is used to detect lacking in the riveting process. And point to point checking jigs was designed according to problem. And The PDCAThe PDCA cycle cycle is used is used to detectto detect lacking lacking in in the the riveting riveting process. process. AndAnd theThe processPDCA cycle must is beused full to detectmonitor lacking to ensure in the rivetingthe improvement process. And of pointpoint to point to point checking checking jigs jigs was was designed designed according according to to problem. problem. AndAnd point to point checking jigs was designed according to problem. And theproduct theprocess qualityprocess must ismust achieved. be befull full monitor monitor to toensure ensure the the improvementimprovement of the process must be full monitor to ensure the improvement of productproduct quality quality is achieved. is achieved. 4.0product RESULTS quality is AND achieved. DISCUSSION

4.0 4.0RESULTS RESULTS AND AND DISCUSSION DISCUSSION 4.1 Plan (P)

4.0 RESULTS AND DISCUSSION 4.1 4.1 Plan Plan (P) (P) The study was conducted at final assembly line in one of 4.1 Plan (P) The study was conducted at final assembly line in one of Themanufacturing study was company conducted in Malaysia. at final The assembly waste’s dataline arein collectedone of The manufacturingstudy was companyconducted in Malaysia.at final Theassembly waste’s dataline arein collectedone of manufacturingand evaluated forcompany improvement in Malaysia. purpose. The Thewaste’s company data areoffers collected many manufacturingand evaluated company for improvement in Malaysia. purpose. The waste’sThe company data are offers collected many andservices evaluated as sheet for metal improvement stamping, purpose. plastic injectionThe company molding, offers powder many and servicesevaluated as forsheet improvement metal stamping, purpose. plastic The injection company molding, offers powder many coatingservices andas sheetassembly. metal This stamping, study only plastic focuses injection on assembly molding, process powder of productservicescoating XYZ.as andsheet To assembly. producemetal stamping, This one study complete plastic only focusesproduct, injection on the assembly molding, production process powder line of coatingproduct and assembly.XYZ. To produce This study one completeonly focuses product, on assembly the production process line of willcoating receive and theassembly. part from This molding study only and pressfocuses shop on assemblydepartment. process of productwill receiveXYZ. To the produce part from one molding complete and pressproduct, shop the department. production line Journal of Advanceproductd Manufacturin XYZ.g ToTechnolog producey (JAMT) one complete product, the production line will receive the part from molding and press shop department. will receive the part from molding and press shop department.

Ge mba walk had been done when entering the production line to

familiarize with the process involved in the production line and to analyze the wastes. Gemba was done after the problematic model/product was identified. After analyzing the data for the month of August, September and October, 2017; it is found that the highest defect is missing rivets.

Figure 2 shows the overall defects that happened in three (3) month which are August, September, and October. Missing rivets was the highest defects for three accumulate months, followed by the broken rivet and dented.

350 eISSN: 2289-8107 Special Issue iDECON 2016

Figure 2: Total defects in 3 particular months

4.2 Do (D)

After the problem of defect had been identified, the countermeasure was made to overcome the defect that affect to the quality of the product. A riveting jig was made as a guidance for the operators to make their process easier, by using this jig the operator only followed the hole that needed to be riveted in that process. Moreover, this jig has Poke Yoke characteristics in which it tells the operators that the part is wrongly positioned on the jig. The riveting jig is shown in Figure 3. The location for both riveting jig is different, thus it guides the operators during when part positioning.

Figure 3: Point to point checking jig Journal of Advanced Manufacturing Technology (JAMT) Journal of Advanced Manufacturing Technology (JAMT) Journa l of Advanced Manufacturing Technology (JAMT)

Gemba walk had been done when entering the production line to GeGembamba walk walk had had been been done done when when entering entering the the production production line line to to familiarize with the process involved in the production line and to familiarizefamiliarize with with the the process process involved involved in in the the production production line line and and to to analyze the wastes. Gemba was done after the problematic analyzeanalyze thethe wasteswastes. . GembaGemba waswas donedone afterafter thethe problematicproblematic model/product was identified. After analyzing the data for the month model/productmodel/product was was identified. identified. After After analyzing analyzing the the data data for for the the month month of August, September and October, 2017; it is found that the highest ofof August August, September, September and and October, October, 2017; 2017; it itis is found found that that the the highest highest defect is missing rivets. defectdefect is is missing missing rivets. rivets. Figure 2 shows the overall defects that happened in three (3) month FigureFigure 2 2shows shows the the overall overall defects defects that that happened happened in in three three (3) (3) month month which are August, September, and October. Missing rivets was the whichwhich are are August, August, September, September, and and October. October. Missing Missing rivets rivets was was the the highest defects for three accumulate months, followed by the broken highesthighest defects defects for for three three acc accumulateumulate months, months, followed followed by by the the broken broken rivet and dented.Visual Inspection as a Screening Method in Assembly Process for Quality Improvement rivetrivet and and dented. dented.

Figure 2: Total defects in 3 particular months FigureFigure 2 :2 Total: Total defects defects in in 3 3particular particular months months

4.2 Do (D) 4.24.2 DoDo (D) (D)

After the problem of defect had been identified, the countermeasure AfterAfter the the problem problem of of defect defect had had been been identified, identified, the the countermeasure countermeasure was made to overcome the defect that affect to the quality of the waswas made made to to overcome overcome the the defect defect that that affect affect to to the the quality quality of of the the product. A riveting jig was made as a guidance for the operators to product.product. A A riveting riveting jig jig was was made made as as a aguidance guidance for for the the operator operators sto to make their process easier, by using this jig the operator only followed makemake their their process process easier, easier, by by using using this this jig jig the the operator operator only only followed followed the hole that needed to be riveted in that process. Moreover, this jig thethe hole hole that that needed needed to to be be riveted riveted in in that that process. process. Moreover, Moreover, this this jig jig has Poke Yoke characteristics in which it tells the operators that the hashas Poke Poke Yoke Yoke characteristics characteristics in in which which it ittells tells the the operators operators that that the the part is wrongly positioned on the jig. The riveting jig is shown in partpart is is wrongly wrongly positioned positioned on on the the jig. jig. The The r ivetingriveting jig jig is is shown shown in in Figure 3. The location for both riveting jig is different, thus it guides FigureFigure 3 .3 The. The location location for for both both riveting riveting jig jig is is different, different, thus thus it itguides guides the operators during when part positioning. thethe operators operators during during when when part part positioning. positioning.

Journal of Advance d Manufacturing Technology (JAMT)

Figure 3: Point to point checking jig FigureFigure 3 :3 Point: Point to to point point checking checking jig jig

4.3 Check (C)

After fabricating process was completed, the riveting jig is transferred to the production line for trial session. 50 samples were tested whether the jig is able to overcome missing rivet problem. The missing rivet defect was 100% eliminated during the implementation as shown in Figure 4.

eISSN: 2289-8107 Special Issue iDECON 2016 351

Figure 4: Eye was used as a pointer during implementing visual inspection

4.4 Action (A)

The countermeasure can be reviewed over time because PDCA is cyclical and not linear. Although, the improvements have been put in place and effective improvements are found to be consistent, process management must not end at this stage. Figure 5 shows that an improvement is achieved through the adoption of point to point checking jig to reduce quality problem. There was 0 defect result after implementing this PDCA method in production line.

Figure 5: Results after improvement plan

JournaJournal of Advancel of Advanced Manufacturind Manufacturing Technologg Technology (JAMT)y (JAMT)

4.3 4.3 Check Check (C) (C)

AfterAfter fabricating fabricating process process was was completed, completed, the rivetingthe riveting jig is jig transferred is transferred to theto theproduction production line linefor ftrialor trial session. session. 50 samples50 samples were were tested tested whetherwhether the thejig isjig ableis able to overcometo overcome missing missing rivet rivet problem. problem. The The missingmissing rivet rivet defect defect was was 100% 100% eliminated eliminated during during the impthe implementationlementation Journal of Advanced Manufacturing Technology as shownas shown in Figure in Figure 4. 4.

FigureFigure 4: Eye 4: wasEye wasused used as a aspointer a pointer during during implementing implementing visual visual inspection inspection

4.4 4.4Action Action (A) (A)

The Thecountermeasure countermeasure can canbe reviewedbe reviewed over over time time because because PDCA PDCA is is cyclicalcyclical and andnot notlinear. linear. Although Although, the, improvementsthe improvements have have been been put putin in placeplace and andeffective effective improvements improvements are foundare found to be to consistent, be consistent, process process managementmanagement must must not notend endat thisat thisstage stage. Figure. Figure 5 sho 5 wssho wsthat that an an improvementimprovement is achievedis achieved through through the theadoption adoption of pofoint point to pointto point checkingchecking jig to jig reduce to reduce quality quality pro blem.problem. There There was was 0 defect 0 defect result result after after implementingimplementing this thisPDCA PDCA method method in production in production line. line.

FigureFigure 5: Results 5: Results after after improvement improvement plan plan

352 eISSN: 2289-8107 Special Issue iDECON 2016 Journal of Advanced Manufacturing Technology (JAMT) Journa l of Advanced Manufacturing Technology (JAMT)

Visual Inspection as a Screening Method in Assembly Process for Quality Improvement

5.0 CONCLUSION 5.0 CONCLUSION This paper has discussed the processes and implementation of Kaizen Tconceptuallyhis paper has and discussed empirically. the Theprocesses focus andof theimplementation paper has been, of Kaizen more conceptuallyspecifically, on and how empirically. organization The embedding focus of of the quality paper and has productivity been, more in specifically,solving the onproblems how organization at production embedding line. The of intangible quality and benefits productivity from the in solvingKaizen activitiesthe problems increase at production the motivation line. The of eachintangible operator benefits in doing from the Kaizenverification activities during increase the process. the motivationBeside the jobof enrichmenteach operator, the inawareness doing the of verificationthe product during quality the also process. impro ved.Beside As the a conclusion,job enrichment the, objectivesthe awareness of this of thestudy product are achieved quality wherealso impro the ved.main As objective a conclusion, of this theresearch objectives is to ofapply this studyKaizen are techniques achieved in where the process the main area objectivein the same of thistime researchto improve is to product apply Kaizenquality . techniquesThrough thein the improvement, process area inthere the samewas zerotime todefect improve results product after qualitymethod. implementedThrough the wasimprovement, achieved through there wasthe adoptionzero defect of point results to pointafter methodchecking implemented jig after 3 months was usingachieved the method.through theContinuous adoption improvement of point to point can checkingalways be jig made after 3to months achieve using good the target method. in productContinuous quality improvement performance. can Thus,always the be study made shown to achieve point goodto point target checking in product as visual quality inspection performance. method inThus, assembly the study process shown is point a relevant to point approach checking asto visualsimultaneously inspection enhancemethod inproduct assembly quality process performance. is a relevant approach to simultaneously enhance product quality performance. A CK NOWLEDGMENTS A C K NOWLEDGMENTS The author would like to appreciate Universiti Teknikal Malaysia TheMelaka author and wouldCOE- AMClike to(Advanced appreciate Manufacturing Universiti Teknikal Center) Malaysia under MelakaFaculty ofand Manufacturing COE-AMC (Advanced Engineering Manufacturing for supporting Center) this research under Facultyunder grant of Manufacturing PJP/2014/FTK(11C)/S01321. Engineering for supporting this research under grant PJP/2014/FTK(11C)/S01321.

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