Abstract
The challenge of frequent Non-Conformity Reports (NCRs) raised against the manufacturer of electrical harness and cubicle products is compromising the quality of the products. NCRs, including cabling defects, electrical functional failures, and assembly inconsistencies. These issues delay production and affect the operational costs. This case study investigates influencing factors and proposes a strategic solution to optimize the testing system of a train component manufacturing company.
A mixed-method case study was employed, integrating quantitative and qualitative analysis of non-conformity reports (NCRs) with root-cause assessment of two years data. The defect details is described in the NCR and the Problem-solving report product the possible root cause and corrective actions.
Results indicate the highest numbers of NCRs TC1 counts of 125 and TC2 counts 100. While the LV1 Cubicle (66), Static Converter (59), and Traction Converter (49) are reported as the highest defective products, accounting for a total of 40,8% NCRs. Cabling defects are the most common types of NCRs reported accounting for 53%, followed by electrical functional issues (22%) and assembly defects (14%). However, these top three types of family defects accounted for 89% of the total.
Furthermore, the root-cause analysis revealed manpower factors as dominant (55%), followed by machine (20%) and material (13%) factors. It is also discovered that multiple factors can cause a single defect. In addition, a strategic solution to integrating automated testing systems, manpower competency development, and standardized processes control. The application of these strategic recommendations will benefit the manufacturers and their customers. The agility culture is about continuous improvement to optimise innovative solutions in a complex environment.