Defect Reduction in the Assembly Process of Front Bumper

The main objective of this project is to reduce the defects and costs that do not add value to the products within the Front Bumper assembly line. The costs that do not add value to the products withih the Front Bumper assembly line before improvement are 9,244.8 Baht. In the study of such an assembling process in order to specify the problems, the Pareto diagram principle was used. Additionally, the 5Whys theory and the Cause and Effect diagram were also applied to analyze and find the root causes of the problems for improving the process. As a result of the study, 3 damaged types of parts can be identified by deformed parts there are 15 pieces, incompleted parts there are 5 pieces and missing nuts parts there are 4 pieces. After improving the process, the number of damaged parts can be reduced i.e., parts deformed from 15 to 0 pieces, and parts incomplete assembled from 5 to 0 pieces. Consequently, the costs that do not add value to the products within the Front Bumper assembly line turn to 1,926 Baht. So, the costs that do not add value to the products are decreased by 79%.