<![CDATA[Efficient maintenance processes are essential for improving productivity and reducing service lead time in heavy-duty vehicle workshops. During brake overhaul maintenance of Isuzu Giga F Series Air Over Hydraulic (AOH) vehicles, anchor pin removal was identified as a time-consuming operation because the conventional method relied on repeated hammering and a driving iron and required additional mechanic assistance. This study aimed to develop and evaluate a Special Service Tool (SST) to improve the efficiency of anchor pin removal. A Quality Control Cycle (QCC)-based continuous improvement framework was integrated with an engineering design approach involving root cause analysis, 2D and 3D design, material selection, structural analysis, prototype fabrication, and field evaluation. The SST incorporated a threaded sliding-hammer mechanism to generate pulling force for anchor pin removal. Structural analysis using Autodesk Inventor was conducted under an applied load of 400 N. Field evaluation showed that the average processing time per wheel decreased from 162 min using the conventional method to 138 min using the developed SST, representing a 14.82% reduction. The resulting processing time was below the established flat-rate standard of 145.5 min per wheel. The SST also eliminated the need for additional mechanic assistance and reduced activities associated with backplate removal and installation. These findings demonstrate that integrating QCC-based improvement with engineering tool design can reduce maintenance lead time and improve work efficiency in heavy-duty vehicle brake servicing.]]>
