Reduction of Defective Products Caused by Wire Winding in the Packaging Process

A case study company manufacturing electrical wires had a wire winding problem in the packaging process. This adversely affects the number of defective products and production costs. To diminish this problem as well as the need for reworking, this research aims to determine an optimum condition for the wire winding in the packaging process through statistical analyses. Three factors were considered in this study, i.e., the speed of the Accumulator, screw speed of the coil winding machine, and the Form Coil height. The experiments were performed under different winding conditions where the number of defective products was the process response. The results revealed that the change in the three factors significantly affected the number of defective products. When using the speed of the Accumulator of 120 m/min together with the screw speed of 14.30 RPM and the Form Coil height of 52.60 mm can reduce the number of defective products caused by the wire winding problem from 22% to 0.87%.