REDUCING THE MAJOR DEFECT RATE IN INJECTION MOULDING FOR COVER DOOR OUTSIDE RH, (KEYLESS) (D63D)

Abstract

In Sipro Plastic Industries Sdn. Bhd., their main production is to produce product cover door outside handle, Rh (Keyless).  The company had reported poor quality of particular products, by using direct injection moulding machine. This is because the quality always one of importance issue in manufacturing industry. This study was conducted to analyse various factors of defects in injection moulding process of the production line of manufacturing organization. Based on some reading material such as journal, book and some study state that some factors such as machine, human, mould, method, technology and material caused defects in injection moulding process. This research focusing on production line which includes the machine, mould, operator, identify the defect rate and causes that lead to the defect occur.  The main objective of this research is to identify the major defect, investigate the causes of major types of defect and recommend the improvement plan to reduce defect rate for product cover door outside handle, Rh (Keyless) using injection moulding operation. 7 tools of quality will be used to identify the major types of defect. Cause and Effect Diagram also will be used to investigate the cause of defect. An interview will be conducted with production line and several departments manager to have some discussion and observation about the study. From the result of this paper machine and manufacturing process selection is very important to produce product cover door outside handle, Rh (Keyless). The best method and technique to produce cover door outside handle is by using injection moulding which control the screw and barrel cleaning, purging of screw and barrel, dry temperature and time, control barrel temperature and high barrel temperature. The result of data analysis and comparison between past rejection data report result and research result show that all three major defects can be reduce by controlled the screw and barrel cleaning, purging of screw and barrel, dry temperature time, control barrel temperature and high barrel temperature.