vii 3.5.1.4 Draft an Improvement Plan
41 3.5.1.5 Data Comparison between Current Condition and
Improvement Plan Using Pareto Chart. 41
3.5.2 Workplace Analysis 43
3.5.2.1 Illuminance Noise Measurement 43
3.5.2.1.1 Selecting the Workplace 45
3.5.2.1.2 Set Up the Equipment 45
3.5.2.1.3 Collecting Data 45
3.5.2.1.4 Analysis Data 45
3.5.2.1.5 Suggestion and Improvement Plan 45
3.5.2.2 Muscle Fatigue Assessment 46
3.5.2.2.1 Preparing the Questionnaire 46
3.5.2.2.2 Select the workplace 46
3.5.2.2.3 Analysis the questionnaire 47
3.5.2.2.4 Suggestion and Improvement Plan 47
3.6 Proposed the New Layout 49
3.7 Summary 49
4. RESULT AND ANALYSIS 50
4.1 Introduction 50
4.2 Problem Identification Using Cause-And Effect Diagram 51
4.3 Cycle time for Dry Sanding Process 52
4.4 Cycle time for Water Break Test Process 55
4.5 Cycle time for Sanding Filler Process 57
4.6 Cycle time for Filler Process 59
4.7 Cycle time for Primer Top Test Process 61
4.8 Cycle time for Primer Bottom Process 63
4.9 Cycle time for GreyAntistatic Process 65
4.10 Cycle time for Touch Up Part Marking Process 67
4.11 Overall Cycle Time for Every Panel 69
4.12 Production Demand and Operator Needed for Every Panel. 71
4.13 Calculation of Productivity in Painting Department 72
viii 4.14 Proposed area of workstation from the re-layout activity
Improvement Plan 75
4.15 Process Analysis Technique Current Condition – Process Flow 1 77
4.16 Process Analysis Technique Current Condition – Process Flow 2 78
4.17 Process Analysis Technique Current Condition – Process Flow 3 79
4.18 Process Analysis Technique Improvement Plan – Process Flow 1 80
4.19 Process Analysis Technique Improvement Plan – Process Flow 2 81
4.20 Process Analysis Technique Improvement Plan – Process Flow 3 82
4.21 Pareto Chart of Process Flow 1 Time – Current Condition 83
4.22 Pareto Chart of Process Flow 1 Time – Improvement Plan 84
4.23 Pareto Chart of Process Flow 1 Distance – Current Condition 85
4.24 Pareto Chart of Process Flow 1 Distance – Improvement Plan 86
4.25 Pareto Chart of Process Flow 2 Time – Current Condition 87
4.26 Pareto Chart of Process Flow 2 Time – Improvement Plan 88
4.27 Pareto Chart of Process Flow 2 Distance – Current Condition 89
4.28 Pareto Chart of Process Flow 2 Distance – Improvement Plan 90
4.29 Pareto Chart of Process Flow 3 Time – Current Condition 91
4.30 Pareto Chart of Process Flow 3 Time – Improvement Plan 92
4.31 Pareto Chart of Process Flow 3 Distance – Current Condition 93
4.32 Pareto Chart of Process Flow 3 Distance – Current Condition 94
4.33 Analysis Data: Product Process Analysis 95
4.34 Calculation of Lead Time Improvement Operating Cost 98
4.35 Summary 101
5. DISCUSSION 102
