<![CDATA[Automotive component industry that manufactures steel and aluminum wheels for both OEM and aftermarket markets, serving global brands such as Toyota, Honda, and Perodua. One of the critical stages in the production process is the Helium Leak Test 3 (HeLT3), which is conducted to detect any leakage in the wheels. This test requires wheel cleanliness and proper valve hole sealing, done either manually or automatically. However, frequent downtime occurs due to valve shortages at the in-plug unit, caused by the failure of used valves to return automatically. This study aims to reduce downtime caused by Plug System Error in the Helium Leak Test 3 process using the Eight Steps methodology. The method was employed to identify the current condition, determine the root causes of the problem, and formulate appropriate corrective actions. Based on the analysis results, an improvement was implemented through the design and installation of a valve transfer conveyor system to automate the transfer of valves from the un-plug unit to the in-plug unit. The results indicate that the implemented improvement successfully eliminated the need for manual valve transfer and reduced downtime caused by Plug System Error by 100%.]]>
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