Applying Kaizen in Quality for Reducing Dent Defect per Unit

Abstract

Continuous improvement (Kaizen) is considered as a main concern and prerequisite for competitiveness in today's manufacturing. One form of continuous improvement is in the field of product quality. The continuous quality improvement is the key to long-term success and high performance of the organization. A case study was conducted in a manufacturing company. In the year 2019, company has not yet reached the target in particular on cylinder head part. One of the defects that still occur is dent. Research carried out using Toyota Business Practices (TBP) approach. Toyota Business Practices is a method for applying kaizen in daily work. This study aims to reduce the number of defect using Toyota Business Practices. By applying Toyota Business Practices, the results of the improvement made were obtained improving the position of shutter table, installing slipper stand, and improving the design of slipper stopper. With these improvements, the average dent defect per unit reduced by 4.35 %. Furthermore, it will get the new standard to ensure the quality of product in the future.