Optimisation of the Partial Runner Set-up Process in Plastic Injection Moulds Using Eight Steps in the Motorcycle Industry
Abstract
Purpose: This study aims to analyse the causes of partial set-up work that is not optimal and provide solutions to the sub-optimal set-up work on family-type moulds in type A.
Methodology/Approach: This study uses an 8-Step improvement approach combined with several methods, including Focus Group Discussion (FGD), Quality Cost Delivery Safety Moral (QCDSM), and Specific Measurable Achievable Relevant Timebase (SMART) method.
Findings: This study found the cause of the partial set-up work being less than optimal due to problems with the Man, Method, and Machine factors. The results of this study show that the set-up time decreased from 240 minutes to 73.4 minutes or 68%. Meanwhile, the process cost for the partial set-up itself decreased from $75 to $3 or decreased by 97%.
Research Limitation/implication: This research has limitations in the partial set-up process, which is less than optimal in plastic injection family-type moulds in the Motorcycle Industry.
Originality/Value of paper: This research has value in optimising the production of plastic injection family-type moulds by reducing set-up time and operational costs for making spare parts in the Motorcycle Industry
References
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Sukma, D.I., Prabowo, H.A., Setiawan, I., Kurnia, H. and Maulana, I. 2022. Implementation of Total Productive Maintenance to Improve Overall Equipment Effectiveness of Linear Accelerator Synergy Platform Cancer Therapy. International Journal of Engineering, 35(7), pp. 1246–1256. https://doi.org/10.5829/ije.2022.35.07a.04.
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Suratno and Ichtiarto, B.P. 2021. Reduce Carbon Emissions of Logistic Transportation Using Eight Steps Approach in Indonesian Automotive Industry Journal Europeen des Systemes Automatises, 54(6), pp. 819–826. https://doi.org/10.18280/jesa.540603.
Wibowo, E.A., Hidayah, M.N.W., Setiawan, R., Wibowo, Y.T. and Krisna, B.L. 2023. Optimisation of plastic injection molding process parameters for cowl B (L/R) sink mark defects by using Taguchi methods and ANOVA. Operations Excellence: Journal of Applied Industrial Engineering, 15(1), p. 21. https://doi.org/ 10.22441/oe.2023.v15.i1.069.
Wiyatno, T.N. and Kurnia, H. 2022. Increasing Overall Equipment Effectiveness in the Computer Numerical Control Lathe Machines Using the Total Productive Maintenance Approach Jurnal Optimasi Sistem Industri, 15(2), pp. 284–292. https://doi.org/10.31315/opsi.v15i1.7284.
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Zhao, N., Lian, J., Wang, P. and Xu, Z. 2022. Recent progress in minimising the warpage and shrinkage deformations by the optimisation of process parameters in plastic injection molding: a review. International Journal of Advanced Manufacturing Technology, 120(1–2), pp. 85–101. https://doi.org/10.1007/s00170-022-08859-0.
Zulkarnaen, I., Kurnia, H., Saing, B. and Nuryono, A. 2023. Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach. Jurnal Sistem dan Manajemen Industri (JSMI), 7(2), pp. 179–192. https://doi.org/10.30656/jsmi.v7i2.7512.
Aprianto, T., Nuryono, A., Setiawan, I., Kurnia, H. and Purba, H.H. 2022. Waste Analysis in the Speaker Box Assy Process to Reduce Lead Time in the Electronic Musical Instrument Industry. Quality Innovation Prosperity 26(3), pp. 53–65. DOI:10.12776/qip.v26i3.1744.
Arman, S.E., Rahman, S. and Deowan, S.A. 2022. COVIDXception-Net: A Bayesian Optimization-Based Deep Learning Approach to Diagnose COVID-19 from X-Ray Images. SN Computer Science, 3(2), pp. 1–22. https://doi.org/10.1007/s42979-021-00980-3.
Asih, H.M., Suhariyanto, T.T. and Ramadhan, M.C. 2022. Designing Standard Operation Procedure to Produce Environmentally Friendly Liquid Detergent. Opsi, 15(2), p. 317. https://doi.org/10.31315/opsi.v15i2.6446.
Bere, P., Neamtu, C. and Udroiu, R. 2020. Novel method for the manufacture of complex cfrp parts using fdm-based molds. Polymers, 12(10), pp. 1–20. https://doi.org/10.3390/polym12102220.
Bjerke, M.B. and Renger, R. 2017. Being smart about writing SMART objectives. Evaluation and Program Planning, 61(1), pp. 125–127. https://doi.org/10.1016/j.evalprogplan.2016.12.009.
Darmawan, H., Hasibuan, S. and Hardi Purba, H. 2018. Application of Kaizen Concept with 8 Steps PDCA to Reduce in Line Defect at Pasting Process: A Case Study in Automotive Battery. International Journal of Advances in Scientific Research and Engineering, 4(8), pp. 97–107. https://doi.org/10.31695/ijasre.2018.32800.
Filho, G.M.S. and Simão, L.E. 2022. A3 methodology: going beyond process improvement. Revista de Gestao, 15(4), pp. 1–15. https://doi.org/10.1108/REGE-03-2021-0047.
Jaqin, C., Kurnia, H., Purba, H.H., Molle, T.D. and Aisyah, S. 2023. Lean Concept to Reduce Waste of Process Time in the Plastic Injection Industry in Indonesia. Nigerian Journal of Technological Development, 20(2), pp. 73–82. https://doi.org/10.4314/njtd.v18i4.1396.
Jebb, A.T., Ng, V. and Tay, L. 2021. A Review of Key Likert Scale Development Advances: 1995–2019. Frontiers in Psychology, 12(May), pp. 1–14. https://doi.org/10.3389/fpsyg.2021.637547.
Kale, P.D., Darade, P.D. and Sahu, A.R. 2021. A literature review on injection moulding process based on runner system and process variables. IOP Conference Series: Materials Science and Engineering, 1017(1), pp. 1–8. https://doi.org/10.1088/1757-899X/1017/1/012031.
Khan, R.M. and Mushtaq, A. 2022. Material Selection and Manufacturing of Halogen-Based Headlamp for Two-Wheeler Vehicle Technologies’, Iranian Journal of Chemistry and Chemical Engineering, 41(1), pp. 88–108. https://doi.org/10.30492/IJCCE.2021.121678.3976.
Kosasih, W., Doaly, C.O. and Shabara 2020. Reducing Waste in Manufacturing Industry using Cost Integrated Value Stream Mapping Approach. IOP Conference Series: Materials Science and Engineering, 847(1). https://doi.org/10.1088/1757-899X/847/1/012061.
Kurnia, H., Manurung, H., Suhendra and Juliantoro, K.B. 2023. Implementation of Lean Service Approaches to Improve Customer Satisfaction and Sustainability of Health Equipment Procurement Process at Hospitals. Quality Innovation Prosperity, 15(3), pp. 1–17. https://doi.org/10.12776/QIP.V27I3.1875.
Lo, C.H., Chen, C.C., Siek, P.H.L and Yoandara, C.M. 2022. Design of Injection Molding of Side Mirror Cover. Sensors and Materials, 34(6), pp. 2243–2252. https://doi.org/10.18494/SAM3828.
Martowibowo, S.Y. and Khloeun, R. 2019. Minimum warpage prediction in Plastic Injection Process using Taguchi method and simulation. Manufacturing Technology, 19(3), pp. 469–476. https://doi.org/10.21062/ujep/314.2019/a/1213-2489/MT/19/3/469.
Mawardi, I., Jannifar, A. and Lubis, H. 2019. Effect of Injection Temperature on Defect Plastic Products. IOP Conference Series: Materials Science and Engineering, 536(1), pp. 1–6. https://doi.org/10.1088/1757-899X/536/1/012102.
Rahmawati, D., Puryani, P. and Nursubiyantoro, E. 2019. Optimalisasi Kapasitas Stasiun Kerja Dengan Penerapan Theory of Constraints (Toc). Opsi, 12(1), p. 12. https://doi.org/10.31315/opsi.v12i1.2828.
Setiawan, Setiawan, I., Jaqin, C., Prabowo, H.A. and Purba, H.H. 2021. Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry. Quality Innovation Prosperity, 25(3), pp. 48–64. https://doi.org//10.12776/qip.v25i3.1613.
Setiawan, I., Kurnia, H., Setiawan, Purba, H.H. and Hernadewita, H. 2022. Reduce Transportation Costs Using the Milk-Run System and Dynamo Stages in the Vehicle Manufacturing Industry. Operational Research in Engineering Sciences: Theory and Applications, 5(2), pp. 17–27. https://doi.org/10.31181/oresta240622030s.
Siregar, K., Ariani, F. and Tambunan, M.M. 2019. Reducing Waste in Spare Part Production Process with Lean Manufacturing Approach. IOP Conference Series: Materials Science and Engineering, pp. 1–8. https://doi.org/10.1088/1757-899X/648/1/012016.
Sjarifudin, D., Kurnia, H., Purba, H.H. and Jaqin, C. 2022. Implementation of the six sigma approach for increasing the quality of formal men’s jackets in the garment industry. Jurnal Sistem dan Manajemen Industri, 6(1), pp. 33–44. https://doi.org/10.30656/jsmi.v6i1.4359.
Sousa Silva, R., Barbosa de Alencar, D., Tregue Costa, A.P. and Estanislau Sanches, A. 2019. Kaizen Philosophy Application as Production Standardization and Process Optimization. International Journal for Innovation Education and Research, 7(11), pp. 808–816. doi.org/10.31686/ijier.vol7.iss11.1936.
Sukma, D.I., Prabowo, H.A., Setiawan, I., Kurnia, H. and Maulana, I. 2022. Implementation of Total Productive Maintenance to Improve Overall Equipment Effectiveness of Linear Accelerator Synergy Platform Cancer Therapy. International Journal of Engineering, 35(7), pp. 1246–1256. https://doi.org/10.5829/ije.2022.35.07a.04.
Sundararajan, N. and Terkar, R. 2022. Improving Productivity in Fastener Manufacturing Through the Application of Lean-Kaizen Principles. Materials Today: Proceedings, 62(2), pp. 1169–1178. https://doi.org/10.1016/j.matpr.2022.04.350.
Suratno and Ichtiarto, B.P. 2021. Reduce Carbon Emissions of Logistic Transportation Using Eight Steps Approach in Indonesian Automotive Industry Journal Europeen des Systemes Automatises, 54(6), pp. 819–826. https://doi.org/10.18280/jesa.540603.
Wibowo, E.A., Hidayah, M.N.W., Setiawan, R., Wibowo, Y.T. and Krisna, B.L. 2023. Optimisation of plastic injection molding process parameters for cowl B (L/R) sink mark defects by using Taguchi methods and ANOVA. Operations Excellence: Journal of Applied Industrial Engineering, 15(1), p. 21. https://doi.org/ 10.22441/oe.2023.v15.i1.069.
Wiyatno, T.N. and Kurnia, H. 2022. Increasing Overall Equipment Effectiveness in the Computer Numerical Control Lathe Machines Using the Total Productive Maintenance Approach Jurnal Optimasi Sistem Industri, 15(2), pp. 284–292. https://doi.org/10.31315/opsi.v15i1.7284.
Yani, M., Lubis, R.W., Arfis, A., Putra, B.W. and Hardiansyah, W. 2022. Design and manufacturing processes of half face motorcycle palm fiber reinforced composite polymer. Journal of Physics: Conference Series, 2193(1). https://doi.org/10.1088/1742-6596/2193/1/012011.
Zhao, N., Lian, J., Wang, P. and Xu, Z. 2022. Recent progress in minimising the warpage and shrinkage deformations by the optimisation of process parameters in plastic injection molding: a review. International Journal of Advanced Manufacturing Technology, 120(1–2), pp. 85–101. https://doi.org/10.1007/s00170-022-08859-0.
Zulkarnaen, I., Kurnia, H., Saing, B. and Nuryono, A. 2023. Reduced painting defects in the 4-wheeled vehicle industry on product type H-1 using the lean six sigma-DMAIC approach. Jurnal Sistem dan Manajemen Industri (JSMI), 7(2), pp. 179–192. https://doi.org/10.30656/jsmi.v7i2.7512.
Authors
Setiawan, I., Perdana, B. C., & Aisa, N. N. (2024). Optimisation of the Partial Runner Set-up Process in Plastic Injection Moulds Using Eight Steps in the Motorcycle Industry. Quality Innovation Prosperity, 28(1), 223–240. https://doi.org/10.12776/qip.v28i1.1980
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