DECREASING DEMERIT VALUE IN TORSO ASSEMBLY PROCESS IN TOY’S MANUFATURING BY USING INTEGRATED FIRST ARTICLE INSPECTION PROCESS (A CASE STUDY IN PT.XYZ)

Abstract

In the modern definition, quality is defined as proportionally inverse of variability. Since then decreasing variability is considered as a main factor in quality management. PT.XYZ that produces around 300 types of product a year has piloting project’s failed rate of 38 percent. From the initial observation 72.7 percent of the demerit value is come from torso assembly process. To improve the quality PT.XYZ tries to use first article inspection (FAI) in torso assembly process. From the initial observation products that been through FAI have less demerit value, however FAI is only used in 52 percent of the total products. The objective of this research is to decrease the demerit value in torso assembly by using integrated first article inspection. The research also analyzes the cause of low inspection rate and the types of defects in torso assembly process. The proposed improvements in this research include training, integrated scheduling, documented inspection, and improving product development process flow. After the improvements torso assembly process has 73.33 percent less demerit value; there are also saving in development time by 2.32 days/product and cost of quality by 50.7 US dollars/products.