CS

AGC GROUP

Eliminate Stain Glass

Problem
By : Denny Prasetyaningrum
Promotor : Soeparto

Internal Use
 Theme Selection CS

AGC GROUP

KPI Department Japan has the

biggest share 59%
E-ARG Sales Target Amount: 34.7BRp
Quantity: 130,300 pcs
4,680
4%
8,520
GENUINE
7%

12,870
Japan has problem stain glass
CHINA
10% since 2010 and has not been
73,715
ASEAN MARKET solved.
59% 25,515
20% EUROPE

JAPAN Stain glass problem has to be

Solved to achieved the budget.

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 Schedule Activity CS

AGC GROUP
Innovation

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 Collecting Data CS

AGC GROUP
• First encounter : Stain Glass of NR931M-FHGX
Date : 29 June 2010 Glass
Problem : NR931M-FHGX ( sample sent from Autoglass )
Prod date : March 2010
Claim : Dry glass looks clean
Water poured on the glass and cleaned -----> Mark visible in glass

Fact :
Packing Material : - Plastic wrapping thickness 0.06 mm
- Plastic cover with hole
- Desiccant 2 pcs (200 gr)

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 Record Data Analysis CS

AGC GROUP
Evaluation Result of Part Center

Level of dirt to manufacturer

Score Remark
5 Polishing Material
Bad
4 Cleaner
3 Wipe of Water
2 Wipe with Dry Cloth
1 No need Good
Compared with other suppliers, AMG’s
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evaluation result is the worst
 Target Setting and CS
Customer Satisfaction
AGC GROUP

Level of Dirt According  Customer Need

to Manufacturer
Bad No need removal
5: Polishing Material for our glass which
4: Cleaner is there is no stain
3: Wipe of Water glass.
2: Wipe with Dry Cloth
1: No need Good  Customer
Expectation
TARGET Level on dirt on
level 1.

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 Organize Team and CS

AGC GROUP
Allocate Man Power

CUSTOMER
Synergic coordination
between Sales, QA,
Production and Logistic.
LOGISTIC SALES QA
Mr. Sales acted as:
Mauliater Ms. Denny Mr. Haryoto
•Initiator
•Coordinator
•Manage trial to customer
PRODUCTION •Give feedback to customer
Mr. Mujiyo
and internal Asahimas

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 Observe Problem CS

AGC GROUP
1. Internal Observation
Level Stain (SL) Level Eraserable (EL)
Conclusion:
4 Many 4 Can not After we keep the glass in 2
3 Moderate 3 Difficult months, in a one week the
2 Little 2 Easy stain beginning to arise even it
1 No 1 No need easy to wipe off. SL-EL = 4-2

Week Stain Eraserable

1 1 2

2 2 2
3 3 2
4 3 2
5 4 2
6 4 2

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 CS

AGC GROUP
2. External Observation

Level Stain (SL) Level Eraserable (EL)

4 Many 4 Can not
3 Moderate 3 Difficult
2 Little 2 Easy
1 No 1 No need

Glass No Stain Eraserable

1 4 3

2 4 4

Conclusion: There are stain glass on AMG The receiving goods there is stain on it.
product and difficult to be wiped off which There are many stain and difficult to wipe
received by Autoglass Japan. SL-EL = 4-3 off.

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 Seek Cause of Problem CS
using WWA
AGC GROUP

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 Verification CS

N AGC GROUP Caused

Possibility Check Verify Countermeassure Result
o Result
1 Plastic has remain Send 1 pallet to Yes Change plastic material.
particle as production JAPAN using AATH 1. Petlin plastic (Local) NG
process plastic 2. NTG plastic (Japan) NG
Result: using AATH 3. PE foam plastic (Local) NG
plastic has better 4. LDPE (Local and Japan) NG
than Asahimas . 5. HDPE (Local and Japan) OK

2 No air circulation in At the drying room Yes 1. Add exhaust fan OK (Stain
drying room there was no air 2. Add upper blower and air reduce)
circulation system curtain

3 Washing process The washing process Yes Turned off washing water and NG (stain
using high using high heater blower reduce but
temperature water temperature can’t be
(40⁰-50⁰C) implemented)
4 For non-MB model Send sample for Yes All Japan model either MB or OK (stain
there is no spacer non-MB using non-MB using spacer reduce)
spacer Internal Use
 Comparison of AMG Plastic CS
and AATH Plastic
AGC GROUP
AMG plastic has many stain come
An AATH article has few wrinkles of
from wrinkles which transferring
vinyl and there is little stain of glass.
the pattern on glass.

*SL-EL = 4-3 *SL-EL = 2-2

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 CS

AGC GROUP
Action 1 Action 2

Petlin Anti Block Plastic NTG plastic

Conclusion:
Conclusion:
1. NTG Plastic is better than AMG Plastic . It
1. Petlin Plastic is better than AMG Plastic .
shown a little stain on the glass and possible
2. Price higher 30% than AMG plastic.
to wipe off lightly
3. SL-EL = 2-2
2. SL-EL = 2-2.
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 Action 3 CS

AGC GROUP

PE Foam Front Position PE Foam Side Position

Advantage: Has pores for air circulation, less wrinkle

Trial Date: May 15th 2012 and almost none. SL-EL = 2-2
Disadvantage: Because of the color was bleak/non-
transparent, if crack/scratch occurred would be
invincible.
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 Action 4 CS

AGC GROUP

Japan LDPE 0.06 mm Japan LDPE 0.03 mm

Conclusion:
1. The result of this
trial shows that
even though
already use LDPE
vinyl, the stain still
occurs.
The condition before open the plastic The condition before open the plastic
2. SL-EL = 4-3

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 Action 5 CS

AGC GROUP

AGJA AMG AMG

HDPE 0.025 mm HDPE 0.03 mm HDPE 0.03 mm+Foam

Conclusion: Conclusion: Conclusion:

Japan’s HDPE plastic the
result is not to good. The
stain lightly seen eventhough
it is easy to wipe off.
SL-EL = 2-2
AMG’s HDPE plastic is the best AMG’s HDPE & foam also good.
result There is a little
For stain glass. There is no stain Stain and easy to wipe off but is
on it. difficult to find the crack
SL-EL = 1-1 Because the plastic not so clear.
SL-EL = 1-1
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 Conclusion CS

AGC GROUP

No Kind of Plastic Material Stain Level (SL) Eraserable Level (EL)

1 Petlin Anti Block 2 2
2 NTG Plastic 2 2
3 PE Foam 2 2
4 Japan LDPE 4 3
5 Japan HDPE 2 2
6 AMG HDPE 1 1

The best result when AMG

using HDPE plastic from our
supplier.

Internal Use
 Stain Glass Simulation CS

AGC GROUP in AMG

Level Stain (SL) Level Eraserable (EL)

4 Many 4 Can not
3 Moderate 3 Difficult
2 Little 2 Easy
1 No 1 No need

Conclusion:
1. Temperature affected the stain glass.
2. Pressure affected the stain glass.

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 Decrease CS

AGC GROUP Temperature

Upper Blower and Air Curtain
Exhaust Fan Installation
Installation

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 Measurement Result CS

AGC GROUP

Conclusion: The best condition is the washing water,

heater blower and exhaust fan TURNED OFF. But It can
not be implemented due to the glass will be dirty after
Autoclave process not directly goes to the Trimming
process.Use
Internal
 CS

AGC GROUP
Result Picture

Hot Condition Cool Condition Glass that

wrapped
in cool
condition
resulted in
much less
stain and
easy to be
wiped

OK
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 Prevent Pressure on CS

AGC GROUP
Glass Surface
No Spacer With Spacer

The thickness of the

cartoon spacer is 3mm

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 CS
Result Picture
AGC GROUP

No Spacer With Spacer

With Spacer is better than "Without

Spacer", even there is a little stain but it
easy to remove.

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 Last Conclusion CS

AGC GROUP

1. From all the trials and improvement by us we

can summarize that the best condition when we use
HDPE plastic. It has been proven that there is no stain
glass.
2. Glass that wrapped in cool condition resulted in
much less stain and easy to be wiped.
3. Spacer is better than “Without Spacer”, even there
is a little stain but it easy to remove.

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 Comparison between AMG, AATH, CS

AGC GROUP
and LSH Supply
N Specification AMG AATH LSH
o
1 Lead time 3 weeks 10 days 4 days
2 Spacer for non Yes Yes Yes
MB model
3 Silica gel Yes Yes No information
4 Plastic material LDPE HDPE No information
5 Wrapping Same Same Same
condition
6 Stain glass Much stain glass shown a little stain shown a little stain
and difficult to on the glass and on the glass and
remove by wiping easy to remove by easy to remove by
off. wiping off . wiping off .

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 Material Comparison CS

AGC GROUP
No HDPE LDPE
1 Density 0.94 – 0.97 grm/cm3. Density 0,88 – 0,91 grm/cm3.
2 Melting point 130⁰ C. Melting point 110⁰ C.
3 Rigidity/stiffness/strain has proven Pull force/Strain is more flexible than
quite good but prone to scratch HDPE
4 Non scratch resistant Scratch resistant

5 Has small pores than LDPE so it Its pore is bigger than HDPE
hasn’t enough room for air
circulation

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 CS
Price Comparison
AGC GROUP

Price (IDR) Cost Reduction

Old: 22.400/Kg Per Sheet 59% 2,703 Rp
New: 24.700/Kg Per month 14,058,175 Rp
Per Year 168,698,100 Rp

Internal Use
 Standarisasi CS

AGC GROUP

• Set the condition max 33°C when packing in

trimming process.
• Using spacer for all models (MB and Non MB)
• Change material plastic using HDPE
• Using plastic with thickness min 30 micron.

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 Next Action CS

AGC GROUP

• Using HDPE Plastic

December delivery using HDPE plastic from
customer.

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 CS

AGC GROUP

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