decreasing total amount of defects at the rectification

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By Heinrich Putra

11407013

BACHELORS DEGREE IN

INDUSTRIAL ENGINEERING

FACULTY OF ENGINEERING AND INFORMATION TECHNOLOGY

SWISS GERMAN UNIVERSITY The Prominence Tower

Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia

AUGUST 2018

Revision after the Thesis Defense on July, 20^th 2018

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STATEMENT BY THE AUTHOR

I hereby declare that this submission is my own work and to the best of my knowledge, it contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.

Heinrich Putra

_____________________________________________

Student Date

Approved by:

Ir. Setijo Awibowo, MM

_____________________________________________

Thesis Advisor Date

Anton Royanto Ahmad, S.T, M.Sc

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Thesis Co-Advisor Date

Dr. Irvan Setiadi Kartawiria, S.T., M.Sc.

_____________________________________________

Dean Date

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DECREASING TOTAL AMOUNT OF DEFECTS AT THE RECTIFICATION AREA BY IMPROVING REPARATION PROCESS. A CASE STUDY AT PT. XYZ

By Heinrich Putra Ir. Setijo Awibowo, MM Anton Royanto Ahmad, S.T, M.Sc

SWISS GERMAN UNIVERSITY

Defect is one of the most problems in car manufacturer especially in PT. XYZ. Paint Problem, Scratch, Dent, Shortage, Gap and Transition are some problems which usually found in the assembly process. Those problems are caused by many factors: shipment, logistic or even assembly process itself. Thus, there must be some ideas or ways to be developed to decrease total problems in the assembly process. The purpose of decreasing total defects in the assembly line is because there are too many cars park and wait at the rectification area to get repaired. Therefore, this research is one of many ways that can reduce the amount of defects in the cars by developing In-Line and Shadow Station Rework concept which means to repair or rework light defect such as small scratch and paint problem. For In-Line Rework, workers will do polishing only not painting process. Small or light painting process will be done in the Shadow Station where it is located outside the assembly line. Polishing also can be done in the Shadow Station. In addition, there is supporting tools called B-Pillar protector to prevent damages at the most problematic part (B-Pillar) at the station which contributes the most damage. With this method and supporting tool, PT.XYZ hopes total defect cars at the end of assembly line will reduce.

Keywords: In-Line Rework, Shadow Station, Defect, Rectification, Polishing, Painting, PDCA, B-Pillar Protector

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DEDICATION

I dedicate this thesis to PT. XYZ.

To my family and lecturers who gave me many lessons and knowledge to me.

And the last is to all my friends who support me to finish the thesis.

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ACKNOWLEDGEMENTS

Foremost, the author would like to thank to God for His blessing, support, strength and guidance to finish this thesis.

The author also thank to Ir. Setijo Awibowo, M.M as the author’s thesis advisor and Anton Royanto Ahmad, S.T, M.Sc as the author’s thesis co-advisor who spare time, patience and support the author to finish the thesis.

The author also thank to Mr. Wahyu Ricardo, Mr. Mukti Hartono as the author’s supervisors in the company who always help and guide the author to finish the thesis.

Thanks to the author’s parents and siblings who always support and pray for the thesis work.

Morover, the author also thank to all Industrial Engineering 2014 students who always supporting and inspiring especially to the author’s colleague in PT.XYZ, Felix, Juan, Kenny, Ronaldi and Steve.

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LIST OF FIGURES ... 10

LIST OF TABLES ... 12

CHAPTER 1 – INTRODUCTION ... 13

1.1. Background ... 13

1.2. Problem Identification ... 14

1.3. Research Objectives ... 15

1.4. Significance of Study ... 15

CHAPTER 2 – LITERATURE REVIEW ... 16

2.1 Definition ... 16

2.2 Lean Manufacturing ... 17

2.3 PDCA ... 19

2.4 Kaizen ... 20

2.5 Automotive Manufacturing ... 20

2.5.1 Assembly Line ... 21

2.5.2 Rectification Area ... 23

2.6 Takt Time ... 24

2.7 Automotive Paint ... 24

2.7.1 Primer Coat ... 25

2.7.2 Base Coat ... 25

2.7.3 Clear Coat... 25

2.8 Polishing ... 25

2.9 In-line Rework ... 26

2.10 Visual Management ... 26

2.11 Ishikawa Diagram ... 27

CHAPTER 3 – RESEARCH METHODS ... 28

3.1 Problem Identification ... 29

3.1.1 Field Observation ... 33

3.1.2 Product Overview... 34

3.1.3 Root Cause Analysis ... 34

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3.2 Literature Review ... 35

3.3 Methodology ... 35

3.4 Data Acquisition... 35

3.5 B-Pillar Protector ... 35

3.6.1 In-Line Rework ... 36

3.6.2 Shadow Station Concept ... 36

3.6.3 Paint Shop ... 36

3.7 Result and Analysis ... 37

3.8 Conclusion and Recommendation... 37

CHAPTER 4 – RESULT AND DISCUSSION ... 38

4.1 Company Profile ... 39

4.2 Problem Identification ... 40

4.3 Data Acquisition... 42

4.3.1 Field Observation ... 43

4.3.1.1 Cabin Area ... 43

4.3.1.2 Panorama Station ... 44

4.3.1.3 Trimming Line ... 44

4.3.1.4 Mechanical Line ... 45

4.3.2 Current Condition ... 46

4.3.2.1 Existing Process ... 46

4.3.2.2 Defect Cars Reparation Process ... 49

4.3.2.3 Red Dot Sticker ... 52

4.3.2.4 Car Zone ... 52

4.3.2.5 Reparation Lead Time Process ... 53

4.3.2.6 Damage Percentage ... 56

4.3.2.7 Overtime ... 56

4.4 Improvement : B-Pillar Protector ... 57

4.4.1 Material Consideration ... 59

4.4.2 Design and Material Consideration ... 60

4.4.3 Trial Result ... 62

4.5 Improvement : In-line Rework Concept ... 64

4.5.1 Procedure... 64

4.5.2 Three Colors Sticker Indicator ... 66

4.5.3 Tools and Equipment Requirement ... 68

4.5.4 Concept Location ... 69

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4.5.6 Car Zone for Rework ... 72

4.5.7 Example of Implementation ... 73

4.5.8 Chip, Dirt and Scratch Form ... 76

4.5.9 Research Contribution for In-Line Rework ... 81

4.5.10 Result ... 83

4.6 Improvement : Shadow Station ... 87

4.6.1 Procedure... 87

4.6.2 Difference between In-line Rework, Shadow Station and Paint Shop... 88

4.6.3 Proposal Location... 89

4.6.4 Type of Damage ... 91

4.6.5 3-D Visual Conceptual ... 92

4.6.6 Tools and Equipment ... 93

CHAPTER 5 – CONCLUSION AND RECOMMENDATION ... 95

5.1 Conclusion and Recommendation... 95

5.2 Further Improvement ... 96

5.2.1 B-Pillar Protector ... 96

5.2.2 In-line Rework System ... 97

REFERENCES ... 99

APPENDICES ... 100

A.Defect Catalogue ... 100

B. Tools and Equipment ... 115

CURRICULUM VITAE ... 118