6S BATTERY

NUR FADHILAH BINTI JAAFAR

NURHANNAH BINTI AZNI
CHE ALIM AMIRUL BIN CHE SALMI
 Project title: Defects reduction in pasting plates.
Background and reason for selecting the project:
Pasting plates are rejected in the pasting section. This problem causes several types of losses in the company, such as time, material, capital and also
customer dissatisfaction.

Project goal:
To reduce defects up to six sigma level.

Voice of customer: Measuring Variable / chart:

Quality of product.

Project boundary:
Focusing on DCLA (-ve) plates.

Team members:
Production manager, Operator for pasting phase

Expected beneficial benefits:

A considerable cost saving due to defects reduction.

Expected customer benefits:

Receiving the product with high quality.
Pareto Chart

Pareto chart of pasting defects

10000 100
Pareto Chart for Pasting Defects

8000 80
Type of defect Number of defects

Frequency
Missing pallet 6680 6000 60

Percent
Distortion 3020
Lump 255
Total 9955 4000 40

2000 20

0 0
Type of defect Missing pallet Distortion Lump
Frequency 6680 3020 255
Percent 67.1 30.3 2.6
Cum % 67.1 97.4 100.0
Product Photos of Good Battery and Defect Battery
 Voice of Customer Diagram

REQUIREMENT DRIVER CRITICAL TO QUALITY (CTQ) MEASURABLE VARIABLE TARGET

1 Produce good product to Customer 1 Customer complaint No complaint

Good quality of product Quality assurance
2 No defects 2 Defect percentage 0%
SIPOC Diagram (for pasting process)
FMEA Diagram Process Function Failure Mode Failure Effects Failure Causes S O D R.P.N.
Action to reduce
failure

Pasting of plates • Hopper paddle • Missing of • Hopper paddle 8 • Set hopper

rpm pellet so mostly rpm high or low paddle speed
decreases in 8 5 320 between 25-28
weight of pasted rpm
plate (Improper
pasting
•  Knurling • Knurling not • Change after 3
problem proper after months and
sometime 9 6 432 weekly
inspection

•  Zero setting of • Careless of • Skilled

hopper operator 8 4 256 operator

•  High density • High and low • Set the mixture

and low density temperature of temperature
mixture between 40 to 50
degree Celcius
6 6 288
and use chiller

•  Belt condition • Thickness • Change belt

decreases with after 40000
time 7 4 224 pannel

•  Improper • Mask hole size • Weekly audits

masking over due to wear
and tear 6 6 288

•  Squeeze roller • Not proper • Weekly

maintenance changing of
6 5 240 squeeze roller

•  Squeeze • Improper • For proper

pressure maintenance pressure
5 7 280 maintenance
weekly
Cause and Effect Diagram Related to Missing Pellet Defects
Pasted Manufacturing Process Flowchart
MSA – Attribute Agreement Analysis
 Process Capability for Missing Plate

Date Missing plate Sample size

05/04/2021 344 2000

06/04/2021 340 2000

07/04/2021 336 2000

08/04/2021 345 2000

09/04/2021 321 2000

12/04/2021 343 2000

13/04/2021 354 2000

14/04/2021 345 2000

15/04/2021 324 2000

16/04/2021 365 2000

19/04/2021 344 2000

20/04/2021 346 2000

21/04/2021 347 2000

22/04/2021 325 2000

23/04/2021 365 2000

26/04/2021 345 2000

27/04/2021 344 2000

28/04/2021 354 2000

29/04/2021 352 2000

30/04/2021 341 2000

Hypothesis Testing for Population Proportion