Defect reduction in the board front door trim manufacturing process

Through the study of production process for Board Front Door Trim, significant production defects that affect the production cost were found. Therefore, the objective of this study is to reduce defects. By using 7 QC Tools in the analysis of the defect problem within the inefficient production process, the causes of the problems in each step of the plastic injection process were considered, categorized and classified. The problems are solved by improving the production process to decrease the defects. The results from improving production operation indicate that the number of defects in terms of the incomplete piece, the most common type of defects can be brought down from 609 units to 251 units per month. The total production defects of 1,306 units per month can be decreased to 814 units per month. Also, the average defective rate is decreased from 8.52% to 5.37%.