PDCA Method Application to Mitigate No Hole Drilling Defects in Housing Large RCL Products in the Automotive Sector

Abstract

This study investigates the application of the PDCA (Plan-Do-Check-Act) method to mitigate drilling defects, specifically No Hole defects, in Housing Large RCL products at HMG, Ltd. The research aims to enhance product quality and reduce customer complaints by systematically identifying root causes and implementing targeted improvements. Analysis using fishbone diagrams identified suboptimal layout design and insufficient operator training as primary contributors to defects. During the Do stage, corrective actions included layout redesign of the inspection area, creation of detailed Work Instructions, and introduction of a Warning Sheet highlighting past quality issues. Evaluation post-implementation showed a measurable reduction in No Hole defects from 21 units (56.8%) to 12 units (42.9%), confirming the effectiveness of changes. The Act stage focused on standardizing improvements through training, updated documentation, and monitoring, ensuring integration into daily operations. This study demonstrates PDCA's efficacy in reducing specific defects and enhancing manufacturing quality, emphasizing continuous improvement toward defect-free production and enhanced customer satisfaction.