Application of QC Story for Improving Defect Reduction of Polyurethane Foam Insulated Metal Roofing Sheet Production
Keywords:
QC story, improvement, defectAbstract
This study is a survey and experimental research. The objectives of this research were to: 1) study the working process and production of insulated metal roofing sheets; 2) study and analyze the causes of waste in the insulated metal roofing sheet production; and 3) reduce waste generated in the production process by at least 5%. Waste data were collected from January 2021 to October 2021 before improvement. To solve the waste problem, employee brainstorming was carried out, and a causes and effect diagram was used as a tool. Then, causes of problems were prioritized using three factors: the likelihood of a solution, the severity of the problem, and the frequency of the problem. Problems that resulted in the most waste in the production process were selected for improvement. The results showed that the causes of the problem were man, machine, raw materials, and environment. Several methods were used to solve problems, such as the principle of Eliminate Combine Rearrange and Simplify--ECRS and the use of a check sheet after measuring. After improvement, data were collected from December 2021 to January 2022. The amount of waste generated in the process was reduced after improvements. Before improvement, the average waste was 889 meters per month, whereas after improvement it was 705 meters per month, indicating a 20.7% reduction in waste.
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