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
