Name: PowerPoint Presentation
Uploaded: 2022-10-03
Duration: 7 min 26 s
Description: KAIZEN ACTIVITY ENGINEERING DEPARTMENT. A close up of a machine Description automatically generated with low confidence.

KAIZEN ACTIVITY ENGINEERING DEPARTMENT. A close up of a machine Description automatically generated with low confidence. 

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A close up of a machine Description automatically generated with low confidence

EXPERT TEAM PLASTIC GROUP DIANA-NAJWA-HAFIZ

BACKGROUND STUDY. 1. During FEP preparation there were no major problem occurred. Engineering had improved the tooling and part condition before PP started.. 

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During FEP preparation there were no major problem occurred. Engineering had improved the tooling and part condition before PP started.

However, many defects were found during PP and not following approval sample.

This is because approval sample condition is too good and not yet run for long run production.

Usually, plastic part defects comes out after long run period production.

KAIZEN TARGET OUTCOMES. To reduce PP part rejection. 

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To avoid PP schedule delay due to plastic part defects

STUDY CASE 1. BG799 (FS-1-WL). FEP qty = 20 sets  no major part issue. 

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Impact to RMM  Cannot proceed PP (line stop).

4/July- PP start but line stop due to weldline & sink mark confirmation

FEP qty = 20 sets  no major part issue

RE: INFO: 5100080542 - FS-I -WL TOP CASE - WELD LINE - FORMOSA PROSONIC INDUSTRIES - NEW MODEL
Muhammad Hjis Faisli Hasanuddin
MH
To O Muhamad Hafiz Hazizan; "Muhammad Aizzat Abu Bakari: Mahmi Shaari; O Chin Lok Ming; Makoto Ohnuma; Masakazu Sato: O Yasushi Morib
Cc O Tsuyoshi Ishiwa: V Muhammad Fadhli Ismail: O Koichi Sakai' O Nordiana Mom} Hana: O Hanin Najwa Mohayan; j; Noryusly Md.Yusof
Dear Mr Hafiz,
Good day,
Regarding below issue, IQC member already complete sorting for model FS-I-WL TOP CASE.
Below the result sorting:
Qty Sorting: 168 pcs
Qty 0K: 87 pcs
Qty 81 pcs
Percentage: 48.2%
We already return 0K part to production.
For NG part, need to claim supplier or waiting new information from Engineer side?
Please advise for this issue.
If you have anything unclear, please do not hesitate to contact me.
Thank you.
Best Regards,
Muhammad Hjis Faisli
(IQC DEPARTMENT)
Roland Manufacturing Malaysia

IQC rejection = 48.2% TOP CASE (NG appearance)

Supplier’s reason: Cannot control the injection parameter after long run production.

STUDY CASE 2. PC240 (TD-02). FEP qty = 26 sets  no major part issue. 

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Description automatically generated

FEP qty = 26 sets   no major part issue

æR01and
Roland Manufacturing Malaysia Sdn.Bhd
Corrective Action Report (CAR)
RMM.QAQC-QAC-F007(ROO)
DATE:- 13/9/2022
APPUCATION NO CAR2022342
DEFECT DESCRIPTION
PART NO. : 5100079439
PART NAME : TD-02 BOTTOM CASE
MODEL : TD-02
SYMPTOM : APPEARANCE NG
DEFECT CAUSE : SHORT MOULD
QTY INCOMING : 448 pcs
QTY NG FOUND : 87 pcs
PERCENTAGE : 19.4%
DLR NO. : 96259
"INCOMING LOT"
RMM.IQC
CASE
R244-TD0201a-R0
uuu
R602

Impact to RMM CAR issuance record due to more than 3% part rejection

IQC rejection= 19.4% BOTTOM CASE (NG appearance)

Supplier’s reason: due to unstable injection. They will monitor on next PO injection and their QA has noted this as caution point.

Current practice. DEVELOPMENT FLOW. .u•uualdul! 0000 d5Ö. 

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Sample
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improæment
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PP & MP

Engineer could detect and mitigate the problems before PP start.

Many defects come out after long run production

 Part delivered not same as approval sample

Production need to wait for Engineering to confirm part

PRE-PRODUCTION (PP) PART QUALITY CONTROL. Early -Middle-End part quality check. 

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Collect several samples at the  MIDDLE  injection & compare with approval sample

Collect several samples at the  EARLY  injection & compare with approval sample

PRE-PRODUCTION (PP)  PART QUALITY CONTROL

If defect occurred, engineer have time to counter or discuss with RJA

Collect several samples at the  END  injection & compare with approval sample

KAIZEN ACTIVITY OUTCOMES. 1) FS-1WL (TOP CASE) for PP. 

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EARLY injection MIDDLE injection END injection OK OK OK

 No PP part rejection due to plastic defect  PP will run on schedule

EARLY injection MIDDLE injection END injection OK OK OK END

KAIZEN ACTIVITY EFFECT TO RMM & SUPPLIER. SUPPLIERS. 

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Part delivery & Production planning is on track

Less part rejection & increase plastic part quality

Production schedule no delay due to plastic part quality issue

Aware of potential plastic part defects will come out after long run production

Educate supplier to judge OK part (no special accept)

“Prevention is always better than cure”

THANK YOU! ありがとうございました！. ENGINEERING DEPARTMENT PLASTIC GROUP. 

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