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Penerapan Mistake Proofing untuk Mencegah Miss Process pada Block 1 TR di Mesin IGR-045 dan IGR-046 Line Cylinder Block

The production process at the Cylinder Block line of PT Toyota Motor Manufacturing Indonesia requires strict compliance with global quality standards. One critical point is the handling of 1 TR blocks, which must be processed in machines IGR-045 and IGR-046. The problem arises because the physical appearance of 1 TR and 2 TR blocks is very similar, leading operators to occasionally misidentify them. This condition may cause a miss process, resulting in defects, reduced quality, unstable KPIs, and increased rework costs. To address this issue, a simple yet effective mistake proofing (poka-yoke) system was designed. The system consists of proximity sensors to detect block type, a stopper cylinder to automatically hold 1 TR blocks before processing, and indicator lamps to provide visual alerts to operators. The design followed the SMART principle, with root cause analysis carried out using fishbone diagrams and the 5 Whys method. Implementation was conducted through the PDCA cycle to ensure sustainability. Results showed a reduction of miss process cases for 1 TR blocks to zero, improved KPI stability in quality and productivity aspects, and cost savings through the elimination of rework and the reuse of refurbished components. Furthermore, operators enhanced their skills in operating, maintaining, and troubleshooting the system, aligning with Toyota's Hoshin Kanri objective to develop individual capability and create a more efficient and enjoyable workplace.

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AL-KK-2026-00004
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No. Panggil
3245201 TA p
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Karawang : Akademi Komunitas Toyota Indonesia.,
Deskripsi Fisik
29 cm, hlm, Ilus; Berwarna
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Indonesia
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