Improvement of body welding accuracy percentage / Tajul Hasran Tumeran

This project is about the improvement of body welding accuracy percentage of Toyota IMV Hilux. In automotive industry, it is important to get fine and good fitting in assembly part process such as assemble interior trim panel, dashboard, seat, engine and others to follow tolerance and standard require for quality purpose. Therefore, this improvement project is to reach good body welding accuracy percentage in Welding Shop before entering Assembly Shop. Four M elements method: Man, Method, Machine, and Material have applied during the study and observation body welding accuracy percentage problem. Three major problems have been highlighted which are welding process, welding jig accuracy and welding jig total preventive maintenance (TPM). Body measurement by co-ordinate measuring machine (CMM), welding jig measurement by portable measuring machine (Vectoron), welding panel/part color map measurement by scanning machine (Perspectoron), design and drawing by Autocad software, kaizen welding standard operation process (SOP) and setup Total Preventive Maintenance (TPM) Welding Jig Team have been covered to improving body welding accuracy percentage. High body accuracy percentage achievement is important to avoid problem avoid panel assemble in assembly shop or assembly line. The benefit from this project is to eliminate problem regarding jig and body fitting that means to achieve or reduce complete vehicle defect production unit (CV DPU). The most important things of this project are to give better services to increase quality, manufacturer productivity and also to decrease production cost.