ASSESSING THE ROLE OF THE D63D SUN-VISOR JIG IN IMPROVING PRODUCT QUALITY AND REDUCING DEFECTS

Abstract

In automotive manufacturing, precision in component assembly is vital for overall product quality. The existing quality control process for the D63D sun-visor faced inefficiencies, accuracy limitations and safety concerns. This study evaluates a newly developed jig designed to improve inspection efficiency, accuracy and ergonomics. Using time-based comparisons, surveys and production output analysis the jig was found to reduce inspection time by about 20.4%, standardize operator performance, and enhance safety. The survey results indicate a highly positive reception of the new jig used in sun-visor manufacturing among Quality Control (QC) personnel. The data reveals that the jig has significantly enhanced quality control operations which 85.7% reported a substantial improvement in accuracy, 92.9% observed a significant increase in task efficiency, and 71.4% noted a marked reduction in defects and errors. Furthermore, the ergonomic evaluation was overwhelmingly favourable with 92.9% of respondents stating the jig is very comfortable and easy to use. Following implementation, production output increased while rejection and rework rates declined significantly. These results demonstrate that the jig contributes to higher productivity, improved quality control and a safer working environment.