This research focuses on the design and fabrication of a jig and fixture to optimize the assembly process of panel pins for a car side mirror power motor. The current manual assembly method is inefficient, time-consuming, prone to frequent errors, and results in material wastage. To address these challenges, the study aims to develop a jig and fixture that enhances efficiency, reduces cycle time, and improves ergonomics. The methodology encompasses data collection, concept generation, CAD modeling using SolidWorks, and precision machining for prototype fabrication. Key analyses include time study, cost evaluation, and ergonomic assessment. The results reveal a significant 50.82% reduction in cycle time, from 4:04 minutes to 2:00 minutes, resulting in improved productivity and streamlined operations. Ergonomic analysis highlights enhanced operator posture and minimized physical strain, while cost analysis estimates the total fabrication cost at RM 156.26, emphasizing the design’s cost-effectiveness. This project successfully demonstrates the potential of jigs and fixtures to address manual assembly inefficiencies, improve manufacturing outcomes, and serve as a practical model for broader industrial applications.
