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my.uniten.dspace-20418 |
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my.uniten.dspace-204182023-05-04T17:41:40Z Overcome CBC line defect by applying dmaic method Wan Amirul Shazzuan bin Wan Saiful Bahri Dmaic Sipoc Pfmea Interim sem 2020 / 2021 This thesis explains on the use of DMAIC methodologies towards the defects occurred at CBC production line in SIME DARBY, Pasir Gudang, Johor. DMAIC methodologies is one of the best methods in lean manufacturing to tackle out problems as well as making improvement towards a specific area. DMAIC stands for define, measure, analyze, improve and control. In addition, the defects found are by using the define, measure and analyze phase in which some of 7 QC tools takes place. In define phase, tools such as SIPOC diagram has been used in order to define the problems occurred at CBC production line. In term of measuring phase, QC tool such as Pareto chart takes place in which to measure its problem indicator on the defects that affect the most towards the process of finishing goods. There are four main defects that has been measured and identified which are material waste, product defect waste, waiting waste and machine defect waste. Next, tools such as COPQ and WHY-WHY analysis are the catalyst to analyze the problems occurred at CBC production line. COPQ shows the cost area which shows the most problematic area in the production line. The total cost for single error is RM 24, 229.00 with the percentage shows in the result and discussion chapter is quite high in term of tissue usage with a staggering of 97.51%. This shows that almost a hundred percent defect of tissue usage. According to the WHY-WHY analysis, it could be found that there are two root causes based on the four defects which are the causes of old machine and also no quality control at the first stage of CBC production process. These root causes are crucial in proceeding to the next stage which is improvement phase. Improvement phase will give out the idea of improving as well as tackling the defects occurred at the production line. Based on brainstorming session with the engineers, the quality control has been implemented at the first stage of the process which results in decreasing of tissue usage. Other than that, the top management has taken initiative on purchasing the new oil filling machine from Singapore. The improvement from the action taken shows a formidable result which can be found by implementing the PFMEA method. The RPN numbers from all of the four defects decreases with a satisfactory value. Cost of Poor Quality (COPQ) for the process have being reduced from RM 24, 229.00 to RM 7, 523.50, a significant reduction of RM 16, 705.50 (68.9%). The improvement made can be conclude as beyond satisfactory level as it reaches higher than half percentage. Last but not least, the control phase is a stage in which the management controls the improvement implementation. This phase is crucial so that the management could make a corrective action whenever the process improvement experiencing out of control situation. The control limit has been set up depends on the improvement made from the brainstorming session with the engineers. The conclusion, limitations of projects and as well as recommendation for this project has been made in order show the fulfillment of the objective set at the early stage of the project and also to make an improvement plan in the future for the process of CBC production line. 2023-05-03T15:00:24Z 2023-05-03T15:00:24Z 2020-09 https://irepository.uniten.edu.my/handle/123456789/20418 application/pdf |
| institution |
Universiti Tenaga Nasional |
| building |
UNITEN Library |
| collection |
Institutional Repository |
| continent |
Asia |
| country |
Malaysia |
| content_provider |
Universiti Tenaga Nasional |
| content_source |
UNITEN Institutional Repository |
| url_provider |
http://dspace.uniten.edu.my/ |
| topic |
Dmaic Sipoc Pfmea |
| spellingShingle |
Dmaic Sipoc Pfmea Wan Amirul Shazzuan bin Wan Saiful Bahri Overcome CBC line defect by applying dmaic method |
| description |
Interim sem 2020 / 2021 |
| format |
|
| author |
Wan Amirul Shazzuan bin Wan Saiful Bahri |
| author_facet |
Wan Amirul Shazzuan bin Wan Saiful Bahri |
| author_sort |
Wan Amirul Shazzuan bin Wan Saiful Bahri |
| title |
Overcome CBC line defect by applying dmaic method |
| title_short |
Overcome CBC line defect by applying dmaic method |
| title_full |
Overcome CBC line defect by applying dmaic method |
| title_fullStr |
Overcome CBC line defect by applying dmaic method |
| title_full_unstemmed |
Overcome CBC line defect by applying dmaic method |
| title_sort |
overcome cbc line defect by applying dmaic method |
| publishDate |
2023 |
| _version_ |
1806425770842652672 |
| score |
13.211869 |