Improvements in the manufacturing processes for reinforcement panels of automotive dashboards
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Abstract
This research aimed to improve the manufacturing process of the reinforcement assembly for automotive dashboards by focusing on reducing working time and production costs through the elimination of non-value-added activities. The study was conducted by analyzing the workflow using flow process charts, fishbone diagrams, and prioritizing problems with Failure Mode and Effects Analysis (FMEA). Process improvements were then implemented based on the ECRS principle and the 7 QC Tools to enhance operational efficiency. The results showed that the number of work steps was reduced from 53 to 49. By moving the workpiece storage position closer to the operator, unnecessary movements were minimized, operational agility was improved, and worker fatigue was reduced. The production time per unit decreased from 290.6 to 274.3 seconds, representing approximately a 5.61% reduction. Additionally, the production cost decreased from 88,531.2 baht per year to 86,420.16 baht per year, a reduction of 2.39%. This leads to decreased error ratios and staff weariness during transportation, hence increasing production line efficiency without necessitating further investment in new resources.
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