Quality control and loss reduction in the front side fender model assembly process using Poka-Yoke techniques

Abstract

This study aimed to use Poka-Yoke techniques to help prevent errors and reduce loss in Front Side Fender Model assembly process. The researchers used four tools in the 7QC tools which were Check Sheet, Cause-and-Effect Diagram and Graphs to search for causes and ways to solve problems and Cause and Effect Matrix and ECRS Techniques. The study revealed that the main cause of the problems was that the incorrect assembled side fenders were submitted to another department. This mistake had bad effects on time and workforce spent for correcting work including more expenses. The mistakes occurred because there was no tool for detecting errors in the work piece. Therefore, the researchers use Poka-Yoke techniques in order to decrease errors by designing a control system for target detection while it was moving through the process. After collecting data, the study showed that before the improvement during January to August 2019, the number of problems caused by the process were 0.093. However, the number of problems after the improvement during September to December 2019 reduced to 0. It was obvious that this improvement reduced the loss from the front side fender assembly process up to 100.