TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures xi
CHAPTER 1: INTRODUCTION 1
1.1 Background 1
1.2 Problem Statement 2
1.3 Objectives 3
1.4 Project Scope 3
CHAPTER 2: LITERATURE REVIEW 4
2.1 Introduction 4
2.2 About Glass Run Channel 5
2.2.1 Function of Glass Run Channel 5
2.2.2 Design of Glass Run Channel 6
2.2.3 Material of Glass Run Channel 8
2.2.4 Chemical Additives of Glass Run Channel 8
2.2.5 Manufacturing Process of Glass Run Channel 9
2.3 Extrusion Process 11
2.3.1 Principle of Extrusion 11
2.3.2 Continuous Vulcanisation 12
2.3.3 Extrusion Die 13
2.4 Transfer Moulding Process Defects 14
2.4.1 Introduction to Transfer Moulding 14
2.4.2 Defects on Glass Run Channel 15
2.4.2.1 Factor That Causes Short Moulding Defects 16
2.4.2.2 Factor That Causes Bubble Defects 18
2.4.3 Elimination of Defects 20
2.5 Previous Research 21
CHAPTER 3: METHODOLOGY 24
3.1 Introduction 24
3.1.1 Methodology of Project 26 3.2 Investigation of Root Cause
27 3.2.1 Man Factor Contribution to Defects
28 3.2.2 Method Factor Contribution to Defects
29 3.2.3 Machine Factor Contribution to Defects
30 3.2.4 Material Factor Contribution to Defects
31 3.3 Plan for Data Gathering
32 3.3.1 Observation on Man Factor
32 3.3.2 Observation on Method Factor
33 3.3.3 Observation on Machine Factor
34 3.3.4 Observation on Material Factor
35 3.4 Data Gathering
36 3.4.1 Data Interpretation for the Man Factor
36 3.4.2 Data Interpretation for the Method Factor
37 3.4.3 Data Interpretation for the Machine Factor
39 3.4.4 Data Interpretation for Material Factor
40 3.5 Analysis of Data Identify the Root Cause
41
3.6 Recommend the Solution 41
3.7 Suggest Improvement Made 41
CHAPTER 4: RESULT DISCUSSION 42
4.1 Result for Man Factor 42
4.2 Result for Method Factor 46
4.2.1 Observation on Transfer Moulding Process 46
4.2.1 Observation on Joint Compound Weighing Process 50
4.3 Result for machine Factor 52
4.3.1 Process Capability Ratio for Mould Temperature 54
4.3.2 Process Capability Ratio for Injector Pressure 55
4.4 Result for Material Factor 56
4.4.1 Observation on Specific Gravity test 56
4.4.2 Observation on Joint Compound Weight Sample 58
4.5 Suggestion on Improvement Should Made by the Company 59
4.5.1 Improvement Suggestion to Man Factor 59
4.5.2 Improvement Suggestion to Method Factor 61
CHAPTER 5: CONCLUSION RECOMMENDATION 62
