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

• Update the part drawing with the most recent dimensions.

• Develop a standard input data for the machine used to manufacture the product
• Inspect the machine's efficiency to remove any probable faults
• Designate a leader among the machine operators to oversee the input data fed into the machine for this
part's manufacture.

6. Implement corrective actions

• Assist the design department with accurate dimensioning for the new design.
• Ensure that technicians participating in the manufacturing process receive sufficient training.
• The input data is standardised and sent to all operators and the production department.
• Make sure the cooling period is long enough and gradual enough to prevent the part from developing
residual stresses.
• To minimise excessive stress during hose contraction, provide an ideal set value for pressure and
temperature.
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

GROUP 2