The problem is that the width of materials produced by the cutting-to-size (CTS) machine was found to be varying outside the allowed tolerance of ±0.5mm. This was discovered during a quality inspection and could lead to rejected materials. The root cause was determined to be uneven mill edges on the raw materials. To address this, the corrective action was to change the feeding method on the CTS machine to use a back stopper, which would shear off the mill edges. The preventative action would be to create standard operating procedures for the machine and implement a poka-yoke system to prevent similar issues in the future. The benefits would be no customer complaints due to improved quality and accuracy of materials,

1. 5W1H Consider These Questions (“Q”): Answer As Many “Q” As You Can!
1W – What {Apa } What is the Problem? What type is
Problem?
Accepts a nonconforming product less than
0.5 %(IInd type error) or rejects a
conforming product if more than 0.5 % (Ist
type error).
During Cut-To-Size the Width Variation found – Width
is not within specification [Tol. ± 0.5 mm].
It applicable to both errors of type I and type II.
2W – Where
{ Mana }
Where was the problem found?
Where does it impact?
Problem occur in shearing division, on CTS machine.
It impact on delay of dispatch/ Customer end: stoppage
of line, ideal manpower due to no material etc , low
Productivity of machine, and cost of hold material
[COPQ] increases. Rework the material like Segregate
the material [ok, not ok material].
3W – Who
{ Siapa}
Who found the problem? Who lead to the
solution? Who does it affect? Who is the
responsible?
Quality inspector found the problem.
CFT will investigate the problem by using Problem
Solving Method.
All person / dept. / Customer is affected.
The System are responsible in setting the standard such
as SOP.
4W – Why
{ Kenapa }
Why this is problem? Why: - Mill edge not sheared during Cut-To-Size
process.
Why: - Mill edge not uniform throughout it length, it
varies.
Why: - Mill edge is manufacturing defect of Raw
material.
5W – When
{Bila}
When was the problem found?
When in the sequence of inspection? When
will you know you have solved the
problem?
In day shift, in afternoon after 3.00 pm. In randomly
sampling inspection, found last sheet width variation
throughout length.
After received Positivity Feedback from Customer.
1H – How {
Bagaimana }
How big / Sever this problem? It might lose royalty of Customer or dissatisfaction and
also lose market share.
Problem
Description
Width Variation, in Cut-To- Size material.
Root Causes Mill edge of Raw material.
Corrective Action Shear the mill edge parts, By Changing Feeding method such as using back stopper.
Preventive Action Prepare SOP/TDC/TPR and Implement Poka-Yoka System on machine.
Prepare Training Schedule to all level i.e Operator by CFT.
Benefit No Customer Complaint.
Inspection time decreases means NVA activity reduced.
Improve Productivity / Cycle time Increases.
Improve Quality and accuracy in dimension within Tol. ±0.5mm
Result of cost saving by minimizing the rework.