COMPARATIVE ANALYSIS BETWEEN MANUAL

METHOD AND COMPACT POINT GUIDE (CPG) TO

OPTIMIZE WIRE HARNESS PRODUCTION AT PT.
SUMITOMO WIRING SYSTEM

Nama : Yanuar Dwi Fitriyanto

Nim : 3222011018

Dosen Pembimbing: Vivin Octowinandi, S. Tr. T., M. Sc.

Electronics Manufacturing Engineering

2022
 Background Problems Objectives Advantages Limitation

1 BACKGROUND

2 The Wire Harness production process does not always

run properly

3 Wire Harness Wire harness production is currently using a manual

method
Production Process
4
The large number of defects produced during the
production of wire harness manually
 Background Problems Objectives Advantages Limitation

1 PROBLEMS

2
How to determine the How to analyze the
optimal process of the resulting defect and
3 resulting defect by
parameters using manuals 1 2
downtime data?

and tools?

4
 Background Problems Objectives Advantages Limitation

1 OBJECTIVES

2 Can determine the optimal process of the resulting defect with

1 parameters using manuals and tools

3
2 Can analyze defect data, downtime and costs generated

4
 Background Problems Objectives Advantages Limitation

1 ADVANTAGES

The production of data on the

2 The production of defect and
downtime analysis data in the Wire
harness production process using a
compact point guide at PT.
3
Sumitomo Wiring System Batam
Indonesia.
causes of defects that occur as well
as recommended solutions for
2 improvement in the production of
subsequent wire harnesses at PT.
1 Sumitomo Wiring System Batam
Indonesia.

4
 Background Problems Objectives Advantages Limitation

1 LIMITATION

2
2
The data analyzed is primary data.

3
1
This study only discusses the analysis of the defect
missing location on the Wire Harness connector using
4 the manual method and compact point guide (CPG)
carried out at PT. Sumitomo Wiring System Batam
Indonesia.
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 WIRE HARNESS

1 Main Harness
2
2 Door Harness
The wire harness is a combination of several

3 cables commonly used in vehicles and has the

3 Roof
function to conduct electric current and signal in Harness
a vehicle
4
4 Rear Harness

5 Front Harness
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 CONNECTOR

2 Housing 1
Place or holder for
contact installation
A connector is one of the electronic components
3 that serve to connect one circuit to another
mechanically.
Contact 2
4 Iron material is used as
an electric or current
boiler installed in the
housing.
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 COMPACT POINT GUIDE (CPG)

3
Compact Point Guide (CPG)

4 Compact Point Guide (CPG) is a tool that functions to check for errors in the installation of wire to
connectors in the wire harness assembly process.
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 PARETO CHART

2
A pareto chart is a graph or bar chart that draws a comparison

3 of data from an event arranged by its size to show the main

problems that must be fixed.

4
 Wire
Connector
Harness
1 FISHBONE DIAGRAM
Man
Operational labor or labor involved in the
production process begins with the
2 delivery of products.
Machine
A machine is a system, part of an
equipment, facility, or part of a machine
3
used in manufacturing.
Method
4 The procedure and terms of service that go
into production are called methods.
Fishbone
CPG Pareto Chart Data Primer Cycle Time
Diagram
Materials
Material is one of the factors affecting
aspects of components, raw materials, and
1 4 other materials used to make finished
products.
Measurement
Measurement is part of the measurement,
2 5
which can be done manually or
automatically (distance, volume,
temperature, pressure, etc.).
Environment
3 6 Environments that include weather,
natural disasters, and workplaces are
elements that cannot be foreseen or
controlled.
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 DATA PRIMER

TablePrimer Data

2
Primary data is fundamental or central
information used in a study. The process of
collecting primary data usually uses methods
3
such as interviews, surveys, experiments, and so
on, primary data is collected directly from

4 primary sources.
 Wire Fishbone
Connector CPG Pareto Chart Data Primer Cycle Time
Harness Diagram

1 CYCLE TIME
Cycle Time Data

2
Cycle time or what is often referred to as
standard time is the time needed in a production
3 process from the initial process to the final
process.

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 IMPLEMENTATION STAGE

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA COLLECTION

2
Data collection in the design of this final project was carried out

3 using the observation method and conducting interviews directly with

PT. Sumitomo Wiring System is related to the types of defects that
occur during the wire harness production process.

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

DATA USING MANUAL METHOD

1

4 Pareto Chart

From the pareto diagram above, it can be seen that the lowest cumulative percentage of defects at
miss location or wire installation errors in the connector holes with a number of defects is 14 pcs.
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA USING MANUAL METHOD

4
Fishbone Diagram
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA USING MANUAL METHOD

Table Root Cause
Factors Hypothesis Verification Root cause?
2 Lack of training Provide retraining NO

Man
The operator does
Create check items
not follow the NO
3 procedure
using a checksheet

There is no
inspection tool Create a tool that
Method detects defects YES
Inspection still missing location
4 manually

Distracted
operation Make changes to
Environment the line design or NO
Limited/Narrow work area layout
work area
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA USING COMPACT POINT GUIDE

In this process, data is obtained using the Compact Point Guide

3 (CPG) method. This method is one solution to detect defects
in the wire harness production process.

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA COMPILATION

Data compilation is a process of compiling data obtained into certain parts and
2 sequences.

Defect Data Grouping Table

Data Record Downtime Table

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA PROCESSING

Data processing is one of the series carried out to process data

3 defects that occur in the wire harness production process in
order to get an analysis and conclusion on the implementation
of this final project.

4
 Implementation Data Data Using Data Using Data Data Data
stage Collection Manual Method CPG Compilation Processing Analysis

1 DATA ANALYSIS

The data analysis process in the implementation of this final

3 project is carried out by comparing wire harness production
data using the manual method and using the Compact point
Guide (CPG) method.

4
 Implementation Schedule

1 IMPLEMENTATION SCHEDULE
Implementation Schedule

4
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