Synergizing QCC and PDCA Approaches to Foster Kaizen Practices in Wingbox Production at Karoseri

Fredy Sumasto; Muhamad Eryl Saputra Syaeful; Edwin Sahrial Solih; Finna Suroso; Astriyani Sandya Paramita

doi:10.22441/ijiem.v5i2.22816

Authors

Fredy Sumasto Department of Automotive Industrial Engineering, Politeknik STMI Jakarta, Jakarta Pusat 10510, Indonesia http://orcid.org/0000-0001-9429-6241
Muhamad Eryl Saputra Syaeful Department of Automotive Industrial Engineering, Politeknik STMI Jakarta, Jakarta Pusat 10510, Indonesia http://orcid.org/0009-0006-9329-3456
Edwin Sahrial Solih Department of Automotive Engineering Technology, Politeknik STMI Jakarta, Jakarta Pusat 10510, Indonesia http://orcid.org/0000-0003-1093-298X
Finna Suroso Department of Automotive Industry Information Systems, Politeknik STMI Jakarta, Jakarta Pusat 10510, Indonesia
Astriyani Sandya Paramita Department of Automotive Business Administration, Politeknik STMI Jakarta, Jakarta Pusat 10510, Indonesia http://orcid.org/0000-0001-8308-1536

DOI:

https://doi.org/10.22441/ijiem.v5i2.22816

Keywords:

Automotive parts, Kaizen, PDCA, QCC, Quality management

Abstract

This research applies the Quality Control Circle (QCC) method and the PDCA (Plan-Do-Check-Action) approach to overcome problems in hydraulic cylinder bracket mounts in a manufacturing company. At the "Plan" stage, a defect classification analysis, matrix diagram for problem classification, analysis of existing conditions, setting quality, cost, and morale targets, as well as Why-Why and 5W+1H analysis were conducted. At the "Do" stage, the cylinder bracket mounts was redesigned using UNP 5.4 material as a solution to the existing problems. At the "Check" stage, measurements of the improvement results were made to ensure the achievement of the planned targets, including the reduction of damage frequency and repair costs. The results of overcoming the problem of broken hydraulic cylinder bracket mounts showed a decrease in complaints during the 2-month period after implementation. The application of the QCC method and PDCA approach not only effectively addressed the problem, but also increased customer confidence, company sustainability, and worker morale. The next step is “Action” stage to ensure process continuity by standardizing through the creation of operation standards for the manufacture and installation of hydraulic cylinder bracket mounts. As a result, the material change from SPHC 6.0 to UNP 5.4 successfully resolved the damage problem and eliminated complaints within two months after implementation. After implementation, the company can reduce the cost expense of repair by IDR 1,413,510. This success had a positive impact on customer confidence, cost efficiency, and worker morale.

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