Quality improvement of production line by using Hikarimono activity for automobile industry

Abstract

The most important department in industry is the production department. The smooth in production flow beginning from the raw material to the product is important and need to maintain it. There are several improvements can be done in the production line to increase productivity and then maintain the production. The objectives of this project are to reduce the application of the racking, to reduce working area or space, to reduce the time taking parts and to preserve the quality of the parts. In this project, there are several production terms and Japanese terms has been used for facilitate the production user such as Cycle Time, Takt Time, Hikarimono, Kaizen, Pokayoke, and Mieruka. In this project, the application of Lean Manufacturing principles such as Process Flow and Non Value Added ratio is use to calculate and analysis the result. The REBA method is use to design an ergonomic workplaces. Beside that, the used of CAD design software such as AutoCAD software and IRONCAD software is good for visualization the method and results. The other software that also has been used in this project is Microsoft Excel 2007 which use as an assistant method during the calculation and small part of design. The Kaizen or improvement that has been done form this project was applied in industry. For example, the process of redesign of layout arrangement, the application of Set Part Supply (SPS) tray and Pokayoke racking system in the production site has been introduced into the line to be one of the improvement items. For more facilitate during the improvement process, the using of some equations such as Non Value Added ratio and time taking part method have been used as the analysis process. From this project, the improvement in the production line has been done successfully especially in reduction of space area and time taking part, the achievement of clear Mieruka concept and preserve the part quality in production line.