Title Issue Date

INCONSISTENT VACUUM HOSE LENGTH 8D KAIZEN REPORT 2/11/2021

1. Team 2. Problem Description

Name Department Inconsistent Length of Vacuum Hose.

MUHAMMAD FAKHRUL AZIM BIN AIZAN Manager

AR HUSIEN JULASRIN Design
MUHAMMAD AZMAN BIN RAMLI Quality
AMIRUL BADIUZZAMAN BIN SININ Production
WALFERD CORNELL R&D
3. Containment Actions

• Immediately stop the production and sales.

• Undergo inspection on the current stocks.
• Track the buyer record for replacement in that particular of time..

4. Root Causes and Verification

The underlying reason was inconsistent data input into the machine during production. For the production of this part,
a few machine operators are using the same machine. For the production of this component, each machine operator
entered a separate set of data into the machine. As a result, the length of the portion is inconsistent.

During the production of this part, the machine operators were seen entering data into the machine, which allowed the
fault to be verified. The machine operators were also requested for the input data they had entered in order to verify
the problem.
5. Identify Corrective Actions

• Production visibility
• Improve quality through continuous monitoring
• Increase machine utilization
• Designate a leader among the machine operators to oversee the input data fed into the machine for this
part's manufacture.
• Improve facility management

6. Implement corrective actions

• IR4.0 can connect machines, tools, and sensors on the shop floor to give process engineers and managers
much-needed visibility into production. For example, organizations can automatically track parts as they
move through assemblies using sensors such as RFID and break beams.
• Environmental sensors can continuously monitor conditions critical to quality and alert management when
quality thresholds are crossed.
• IR4.0 Industrial IoT enables organizations to connect their machines to the internet. This capability lets
organizations not only monitor their machines but also measure important KPIs such as overall equipment
effectiveness (OEE) and overall process effectiveness (OPE) in real-time.
• Leveraging sensors in manufacturing facilities can improve their management and therefore reduce the
operational costs of a factory.

7. Define and plan preventive action

• Before putting pellets into the hopper, inspect and remove any contaminants.
• Double-check the alignment of the hose die's top and bottom moulds.
• Raise the mold's holding pressure and duration.
• Use a less viscous plastic (raw material) that allows air to escape quickly from the mould, preventing
shrinking.
• Create a mould with homogeneous wall thickness and a single direction of flow to prevent hose warping.

8. Recognise the team

Fakhrul
MUHAMMAD FAKHRUL AZIM BIN AIZAN
MANAGER