Application of QC Story to Solve Problem in the Process of the Lumber Production

Abstract

This participatory action research applied the QC Story technique to solve problems in lumber production at Sutraland Company Ltd. A factory manager and foremen were involved in introductory interviews and observations. The analysis revealed that cracked lumber in the final production stage significantly impacted productivity. Data regarding defects and errors was collected over three months. The root cause was then analyzed using Why-Why analysis and brainstorming. Three main causes were found: (1) the lack of a work instruction manual for the wood drying process, (2) the lack of standards for wood grading and defect identification, and (3) inadequate training for employees. A solution plan was established using the 5W1H technique, which included creating work instructions for the wood drying process and specifying procedures, responsibilities, and performance standards for all eight process steps. Two work standards were proposed for defect identification and wood grading. Employees were trained, and the documentation was made available at the workplace. After implementing the plan, data showed that the number of cracked lumber decreased from an average of 11 pieces per month to 3 pieces per month, a reduction of 72.72%