A Comparative Defect Waste Occurrence in Major Processes of Automotive Assembly Line

This paper addresses on identifying a selected waste or ‘muda’ and verifying through comparison between the four major process in automotive assembly line. Amidst eliminating seven wastes verify in lean manufacturing (LM) philosophy, waste of defect is selected in this study due to its higher defects percentage in automotive assembly line. LM is known for its advantages in industry especially in automotive sector. Eliminating waste of defects is important in meeting customer demand. These will not only ensure customer satisfaction, but it is a significant factor in the success of a company. Throughout this study, the data is collected during three months in year 2012 consecutively that lies on four major processes in automotive assembly line. From initial to the final process, the finding gains are also visualized as well as being analyzed before its reach to the end user. Overall, this paper offers a comparative review on waste of defect occurrence in a complete automotive assembly process with collective data demonstrated and can be extended for problem solving application method for future improvement.