PROCESS IMPROVEMENT OF PLASTICS FORMING BY USING FAILURE MODE AND EFFECT ANALYSIS TECHNIQUE CASE STUDY GP COMPANY

Abstract

This article is aims to reduce defects in the blow molding process, In Mold Labeling, to analyze the cause of the problem and formulate measures to prevent recurrence and reduce the production cost of damaged goods to increase the potential of the production process. The methodology starts from collecting data using the Check Sheet and problem priorities to implementing the solution using Pareto 80:20 rule and breaking down the cause of the problem with a cause-and-effect diagram. In addition, the cause was analyzed to determine the cause of the problem using the FMEA tool and assessed by using a risk guided RPN score greater than 100 points. Suggesting guidelines for corrective action and revaluating after improvement to prevent problems. There is a risk of reoccurring problems. The results showed that the blistered label problem was a problem that should be resolved urgently. By correcting all 3 causes 1.) The temperature in the screw barrel and the flow head is too low. Fix it by adjusting screw barrel temperature to 190°c, 195°c. Flow head temperature setting at 215°c, 220°c 2.) Label suction hole at blocked mold preventing ventilation. Fixed by increasing the label suction holes to 13 holes. 3.) The airflow is not enough. Modified by adjusting the blower pressure to 7-8 bar. After the improvement, it was found that the amount of waste can be reduced by up to 2,150 pieces per month, representing a percentage of 91.88%, which can reduce the damage value to the production cost by 36,550 baht per monthly, the percentage was 91.88%, and after the improvement, the RPN decreased by 271 points, representing a percentage of 92.18% As a result, the production process control can increase the efficiency of the production process. It can reduce wasted costs and reduce the amount of waste in the production process.