ENGINE HOOD DEFECT ANALYSIS OF MAUNG 4X4: MULTI-LINE OPTIMIZATION STRATEGY AND ITS IMPACT ON PRODUCTION COST AND SCHEDULE – A CASE STUDY AT PT XYZ

Abstract

Abstract

This study investigates a case of mass defects in specialized vehicle engine hoods, providing a framework for production optimization while maintaining tight delivery schedules. We analyzed 81 engine hood units with dimensional gaps and surface waviness through time-cost comparisons between normal production and repair scenarios. A multi-line optimization model was developed and root causes were identified using fishbone analysis. A five-line production strategy with two shifts reduced repair time by 89,6% with only a 2.4% cost increase compared to a single-line approach. Defect repairs increased manufacturing costs by 68.1% per unit. Inadequate welding jigs were identified as the primary cause of component deformation. The multi-line optimization strategy effectively balanced quality requirements with schedule constraints, offering manufacturing industries a practical approach to manage mass defects while minimizing delivery delays.

Keywords: defect correction; engine hood; specialized vehicle; multi-line strategy; production efficiency