DISCUSSION 102 Lead Time Improvement By Re - Layout At Aerospace Company (Ctrm Aero Composite Sdn Bhd).

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

5.1 Introduction 102 5.2 Wastes in Painting Department 105 5.2.1 Man 105 5.2.2 Management 105 5.2.3 Method 106 5.2.4 Money 106 ix 5.2.5 Machine 106 5.3 Defects in Painting Department 107 5.3.1 Slump at T stands area 107 5.3.2 Broken at chamfering 107 5.3.3 Part Marking dirty and not clear 107 5.3.4 Filler not remove in drill hole. 108 5.3.5 Scratch mark 108 5.3.6 Dented 108 5.3.7 Pin hole 109 5.3.8 Damage 109 5.3.9 Filler not remove at edge. 109 5.3.10 Paint run 110 5.3.11 Paint thin 110 5.3.12. Over spray. 110 5.4 IlluminanceLight Intensity Value 112 5.5 Analysis Suggestion Improvement of Illuminance 114 5.5.1 Illuminance Value for Part Marking QC Inspection Section 114 5.5.2 Illuminance Value for Sorting Section Illuminance Value 115 5.5.3 Illuminance Value for Rework Section 116 5.5.4 Illuminance Value for Filler Section 117 5.5.5 Illuminance Value for Spray Booth 1 118 5.5.6 Illuminance Value for Spray Booth 2 119 5.5.7 Illuminance Value for Spray Booth 3 120 5.5.8 Illuminance Value for Dry Sanding Section 121 5.5.9 Illuminance Value for Water Break Test Section 122 5.5.10 Illuminance Value for Masking Section 123 5.6 Noise Level Measurement 124 5.6.1 Noise Level for Part Marking QC Inspection Section 125 5.6.2 Noise Level for Sorting Section 125 5.6.3 Noise Level for Rework Section ` 126 5.6.4 Noise Level for Filler Section 126 5.6.5 Noise Level for Spray Booth 1, Spray Booth 2, Spray Booth 3 127 x 5.6.6 Noise Level for Dry Sanding Section 128 5.6.7 Noise Level for Water Break Test Section 129 5.6.8 Noise Level for Oven 130 5.7 Muscle Fatigue Assessment 132 5.7.1 Area of Pain Aching for Operator and Improvement Plan Sorting Section. 135 5.7.2 Area of Pain Aching for Operator and Improvement Plan Dry Sanding Section 136 5.7.3 Area of Pain Aching for Operator and Improvement Plan Water Break Test Section 137 5.7.4 Area of Pain Aching for Operator and Improvement Plan Filler Section 138 5.7.5 Area of Pain Aching for Operator and Improvement Plan Spray Booth 139 5.7.6 Area of Pain Aching for Operator and Improvement Plan Oven Section 140 5.7.7 Area of Pain Aching for Operator and Improvement Plan Part Marking QC Inspection Section 141 5.8 Analysis of Muscle Fatigue Assessment 143 5.8.1 Types of Treatment for Muscle Fatigue 143 5.8.2 Major of Muscle Fatigue in Painting Department 144 5.8.3 Causing of Muscle Fatigue in Painting Department 145 5.8.4 Suggestion for avoid the muscle fatigue in Painting Department 146 5.8.4.1 Risk factor: Manipulation of heavy loads 146 5.8.4.2 Risk factor: Work with high force exertion 146 5.8.4.3 Risk factor: Monotonous repetitive tasks 147 5.8.4.4 Risk factor: Long-lasting loadings 147 5.9 Summary 147

6. CONCLUSION 148