NUMERICALLY CONTROLLED VINYL ARMREST PRODUCTION: ENHANCING PRODUCTIVITY AND REDUCING COSTS

Abstract

The production of armrests involves creating a substrate and shaping vinyl before assembling the final product. As a key component of the car door, the armrest is one of the most profitable products for XYZ Sdn. Bhd. Previously, the company relied on manual vinyl slab cutting and die-cutting of sheet and rolled materials. These labour-intensive methods are inefficient for mass production due to the numerous processes and significant manpower required. To address these limitations, an automatic knife cutting system using a numerically controlled (NC) cutting machine has been introduced to replace manual cutting. However, no established standards or guidelines currently exist for using the NC cutter specifically for vinyl armrest production. Given the critical nature of this machine in ensuring smooth, safe, and efficient operations, a comprehensive standard operating procedure (SOP) is urgently needed. This project aims to develop a standard document for technical staff to operate the NC cutter for armrest vinyl cutting and evaluate its impact on production and economic performance. Key tasks include software optimization, identification of the maximum cutting layer, and the development of a tailored SOP. The implementation of the NC cutter has demonstrated significant benefits, including reduced raw material waste, improved production rates, and lower overall production costs.