Defective Parts Reduction in Automotive Wire Assembly Industry by LEAN theory: A Case study

This research purposed to study the method to reduce defective parts or parts that are detected an error for automotive wire assembly of the factory case study. The objective is to reduce the defective parts or the terminal problems. Starting from studying, surveying, data collecting of details and problems, it was found that the terminal problem arose from the fact that it is hanged with the glove resulting in bending and damage until it is unable to be used. Consequently, the authors must search for the solution of the terminal problem with LEAN theory in order to achieve the objective. The tools in this research included Why Why analysis, Affinity Diagram, and Pareto charts to realize the cause of problem why the terminal hanged with the glove because the glove of wire assembly staffs currently has tiny gaps on the palm which is the reason of the hook. The solution is to change the glove for operation and after the replacement, the mean of the terminal problem from 13.80 pieces per month decreases to 0% as expected.