Productivity and Quality Improvement in the Wire Taping Process

Abstract

The wire taping process is a critical step in the production of automotive wire harnesses because it affects product quality and process performance. This study examines a dimensional defect involving wire length deviations from the company standard of 130 ± 5 mm. The study aims to identify the root cause of dimensional defects and determine the optimal jig size to improve quality and productivity performance in the wire taping process. A root cause analysis was conducted using a Fishbone Diagram, while the PDCA method was applied to implement improvements through testing different jig sizes. The analysis results indicate that the primary cause of the defect stems from the Machine factor, specifically the mismatch in jig size. Testing was conducted on four jig variations: US05, US06, US7.5, and US10. The evaluation results showed that the US7.5 jig produced a wire length of 134 mm, which met the company’s dimensional standard, and provided the best performance among the tested jig variations with a cycle time of 704 seconds and an efficiency of 39.35%. Although the productivity target has not yet been achieved, the US7.5 jig is recommended as the standard jig to reduce dimensional defects and improve wire positioning consistency in the wire taping process.