The ICC project successfully achieved its target of 30 percent reduction in twin relay customer claims and improved process spoilage on wire defect reject. After the ICC project, the twin relay customer claim reduced to 0.702 ppm as compared to 2.755 ppm previously. The wire defect quantity also has reduced from 12,002 pieces to 1,916 pieces which amounting to a saving of RM5,864 per month.

The modification of single tray holder, double cylinder and unfit carrier have resulted an increase in productive time rate from 55.9 percent to 78.2 percent, amounting to a 39 percent improvement in productive time. Not only that, this improvement has also increased the total output production. Previously, it was recorded that the total output was 336,000 pieces, and has simultaneously increased to 459,000 pieces per week.

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An ICC team at Amkor aimed to reduce 70 percent of high defect rate at DD2B production line which usually achieved a performance of 97.8 percent. By incorporating TRIZ invention solutions into the existing processes, the team has managed to reduce the defects by 70 percent improvement. Not only that, this has brought a positive impact to the marking defect rate as it has reduced to 0.35 percent from 1.16 percent previously.

Kulim (M) Berhad managed to resolve the problem of faulty Sterilised Fresh Fruit Bunches (FFB) Conveyor (SFC). SFC which appeared to play a crucial role in the daily operations benefitted from the approaches implemented through Innovative and Creative Circle. Overall, three improvements were done accordingly. To start of with, the installation of inverter took place, a newer position of SFC gear box were installed and finally application of bypass system. Now, there aren’t any cases of SFC break downs and this indeed brought a boost to efficiency in processes.

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Petronas Penapisan (Terengganu) Sdn Bhd has based approaches through Innovative and Creative Circle to design and develop the Desorbent Sight Glass (DSG). DSG is made of carbon steel metal and is known for its durability towards high pressure and corrosion. This ground-breaking solution managed to overcome inefficiency during the sampling process of the desorbent. Prior to this, an average of 25 minutes was needed for the entire process from valve opening to draining oil contamination (DOC). However, only 2 minutes was recorded for the desorbent sampling process upon the installation of DSG into Desorbent Sump Tank Sample Box.

Extra rework activities were required and thus this increased operation cost to RM41,250 per month. After incorporating ICC initiatives, Proton has managed to obtain zero – defect performance and only 12 workers are needed as compared to 13 employees before. With no cases in unclean cylinder block, Proton manages to save cost of zero – defect performance by RM346,500 every year.

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The capability of Delloyd in eliminating defects has increased customer satisfaction rate from 16 percent to 75 percent after implementing the e-Robotic’s system of blue ocean strategy. The issue of uninstalled parts does not occur and Delloyd has managed to achieve a zero defect rate as compared to having 595 cases previously. This has brought to a cost saving of RM25,593.

Sapura Brake Technologies Sdn. Bhd. (SBT) is a subsidiary of Sapura Industrial Berhad which specializes in the production of brake technologies. In the year 2014, Sapura Brake Technologies had won the National OSH Award 2014 under the category of Small and Medium Enterprise Award from Ministry of Human Resources (MOHR) for their excellence in implementing occupational safety and health at the workplace.

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ICC project is beneficial to PROTON in defeating the quality issues of the new model. With the implementation of the ICC Project, PROTON has successfully reduced the defect cases to 9 units monthly, indicating a reduction of 97 percent in reject rate. This achievement has reduced the DPH level to 20 and for the first time true performance has increased to 96 percent.