Using quality tools to identify cost saving opportunities in hand layup process
Abstract
The hand layup process is used for producing the composite sandwich panels by
laying different composite materials on and bottom of the core to make a sandwich
structure of the panel. Vacuum bagging process is one of the process involved in
completing layup process. This process is important in order to ensure no air trapped
between the plies, allow plies to be drawn together perfectly by creating secure bond
between them. In this process, perforated release film is also used to accomplish the
vacuum bagging process. It plays the role to act as a contact material to avoid the
contact occur between the breather and the matrix resin during compaction and
autoclave processes. Non-perforated release film among the high cost material that used
frequently for every layup process. Material waste occur by the excessive use of this
material will ultimately affect the cost expenditure. This study will focused on the hand
layup process area because this area is requiring high cost for its operation. Finding the
cost saving opportunities on activities performed along this process that use nonperforated
release film will give high profit and cost balance. Based on the data
collection, several potential causes and problem are identified which can lead to the
difficulty in finding cost saving opportunities. In order to study this problem, the 8D
Method, Cause and Effect diagram, Five Why’s Method, and other quality tools are
used. From the potential causes that identified, the above stated quality tools are used to
find the solution to save the cost intelligently by finding the root cause and solution of
the problem. The improvement is implemented at the hand layup process like used
again the same FEP Red for the second time, and the data on quality level of composite
panel fabricated using recycle FEP Red also gathered and analysed and showing good
results.