Analysis of the causes of Tapper on coils in the winding machine process

Abstract

The winding process is one of the critical stages in coil production because it directly affects the quality of the final product. In this process, mismatches in machine parameters or operational conditions can lead to product defects. One of the defects commonly found is Tapper, which is a surface defect in the form of scratches, abrasion, or peeling on the coil wire that can reduce the visual and functional quality of the product.PT Panasonic Industrial Devices Batam, as a manufacturing company of electronic components with high production volumes, is required to maintain process stability and minimize the occurrence of Not Good (NG) products. However, based on actual conditions in the field, Tapper defects are still found in the winding process, which has the potential to increase the amount of rework, scrap, and reduce production efficiency.This research aims to identify the factors causing Tapper defects in the coil winding process at PT Panasonic Industrial Devices Batam and to determine the most dominant root cause. The methods used include collecting production data, Pareto analysis to determine the main causes of defects, and Root Cause Analysis using the 5 Whys method to explore the fundamental causes of the problems that occur.The results of this study are expected to serve as a basis for formulating effective improvement proposals to reduce the Tapper defect rate, enhance coil product quality, and improve the stability and efficiency of the winding process continuously.