NO

Registration date
QC Story Sheet 【Section】
Production Engineering △ ×
date
/ GM
Aproval
Manger QC leader
(Subject)
Theme : Optimalization SVC Reduction Activity 【Name】 △ × /
Finish date Rizqi Fatulloh △ × /
Title : Reman Wiring Harness Injector △ × /
1.Background/Theme selection 5.Analysis 7.Result & Effect
- Management Policy 5.1 Metode
1. High Quality Product Reman of analysis
2. Cost SVC Reduction Activity
2.Current Status & Issue
1. Plan Prod Engine All Model FY2017 2. Clarification base 3. Plan Prod Engine Model 12V140
on Model Associativ
e
Base on Machine Diagram
Model, HD 785-7
is Popular Model

Engine 12V140 is Base on this analysis

Popular Model we need Refference Data of Reman Manual, Drawing and Durability of Wire harness for
reman process
4. Pareto Part HD785-7 6. Improvement
(100% Replace & Highest of Amount Cost) Target Improvement : Verification Data Based on Analysis
Reman Wiring Harness Injector with the Good
Quality and Good Durability of wire harness

About Wiring Harness injector

Note
Can't Reman
(policy KLTD)
Finish
Improvement
Target
Improvement
Introduction of measurement insulation resistance
Location Wiring Harness
Injector in Cyl Head
Engine.
it is 1st sense for reman
electrical part

The Function of wire Harness Injector is connectivity electricity from controller engine to
Injector.
Trial 1. Measure Insulation Trial 2. Measure wire harness <2000
3.Target Resistance Base onMΩdata trial 1, we want to know about root cause
Current Condition, Cost Part Wiring Base on BP FY2017 Decide Target problem for each pcs wiring harness <2000 MΩ. so we are
cutting for each portion to know detail problem (portion a, b
and c like in picture)

8.Standarization
TARGET

$ 37,406
SAVING
$ 29,925

All Part, New and Reuse within Standart, but we Create Working Standard base on
found of Reused characteristic different within New Improvement Activity (SOP & Checkhsset)
characteristic
No Correlation between insulation value with
SMR 9.Yokonirami
$ 7,481
Current Model Engine 12V140 Yokonirami to All Engine
Base on this data, why does in portion C value 16D140 ries
Target to Reduce Replacement Ratio decrease?
10.Challenges for future
Become 20%
Dec '15 Jan'17 Feb'17 Mar'17 Apr'17
Item
W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2
CONTINUE PDCA FOR
6. Plan & Actual (Sche)

Menentukan Tema ACHIVEMENT

Kondisi saat ini & Menentukan Target REPLACEMENT RATIO
Membuat Rencana Perbaikan WIRING HARNESS UNTIL
20%
Analisa Penyebab Masalah
Melaksanakan Rencana Perbaikan
Evaluasi Hasil
Standarisasi
Rencana Berikutnya
 It
Menentukan Tema

6.Plan & Actual

Kondisi saat ini & Menentukan Target
Membuat Rencana Perbaikan
Analisa Penyebab Masalah
Melaksanakan Rencana Perbaikan
Evaluasi Hasil
Standarisasi
Rencana Berikutnya
 Schedule
Dec '15 Jan'17
Item
W3 W4 W1 W2

aat ini & Menentukan Target

Rencana Perbaikan
enyebab Masalah
akan Rencana Perbaikan
 Plan
Jan'17 Feb'17 Mar'17
W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Actual
Apr'17
W1 W2
 Dec Jan
Item
W3 W4 W1 W2 W3
Menentukan Tema

Kondisi saat ini & Menentukan Target

Membuat Rencana Perbaikan
Analisa Penyebab Masalah
Melaksanakan Rencana Perbaikan
Evaluasi Hasil
Standarisasi
Rencana Berikutnya
Jan Feb Mar Apr
W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2
Verification
No
1
2
3
4
No
1
Verification
Counter Measure AnalysisPoint Issue and Action
Reman Manual Visual Check
Drawing Standart Issue Visual Check, and Measurement Insulation Resistance
Decide List Facility Prepare Megger Test and Multitester to measurement
Development Durability Detail Analyze to know durability
of Wire Harness 1. Trial Measurement of Reuse Part and New Part (KBN)
2. Compare data SMR (Hours) unit vs Result Trial
Measurement of Reused Part (KBN)
3. Facilitator Analyze About Material of wire harness (MTC)
 4. Deeply Analyze to know material composition for
reference decide standart of Durability Wire Harness
(Institute Technology Bandung (ITB))

Counter Measure AnalysisPoint Issue and Action

Reman Manual Mention only Visual Check ( Done)