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.