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