Moisture Reduction to Enhance Shock Absorber Performance Using a Combination of Eight Steps and VDI 2222 in the Motorcycle Industry

Purpose: This study addresses the issue by developing a machine to reduce moisture levels and improve shock absorber performance within a two-wheeled vehicle manufacturing company to ensure product quality and safety. Methodology/Approach: This study uses an 8-step improvement approach combined with Verein Deutscher Ingenieure (VDI) 2222, then enriched with 5W+1H and Specific Measurable Achievable Relevant Timebase (SMART), and finally evaluated with the Cost-Benefit Ratio (CBR) method. Findings: The study revealed that the product's moisture level exceeded the inspection manual's standard, causing compression instability and potential safety risks. The intervention reduced the moisture level from 538 ppm to 336 ppm, achieving a 38% reduction. The improvement project demonstrated a CBR of 4.2, indicating its potential and profitability. Research Limitation/Implication: This research has implications for management in replicating this result across other production lines to reduce lead time and lower fixed costs on cleaning machines. Originality/Value of paper: This research demonstrates the value of using an external air blow machine to reduce moisture levels to standard quality, thereby decreasing lead time and fixed costs in shock absorber production.