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Monday, January 6, 2014
Production Management
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Sunday, December 29, 2013
Jishuken
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Thursday, December 26, 2013
9 Wastes
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Waste is the use of resources over and above what is actually required to produce the product as defined by the customer. If the customer does not need it or will not pay for it then it is waste, this includes material, machines and labour. The Japanese word for waste is “muda” and is often used in books, training courses and by lean consultants to mean waste.
The 9 wastes are:
- Overproduction and early production producing over customer orders, producing unordered materials/goods.
- Material Transportation handling more than once, delays in moving materials, unnecessary moving or handling.
- Inventory - unnecessary raw materials in stores, work in process (WIP), & finished stocks.
- Talent – not using all the skills of your employees
- People Motion - movement of equipment or people that add no value to the product .
- Rework or Defects. Producing or reworking scrap.
- Inappropriate processes - unnecessary processing or procedures (work carried out on the product which adds no value).
- Delays. Waiting hanging around, idle time (time when no value is added to the product).
- Energy.
Others have included additional categories which include; Talent and energy are the additions to Ohno’s original 7.
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Overproduction
Often caused by quality problems, a company know that it will lose a number of units along the production process so produces extra to make sure that the customer order is satisfied. These kind of issue can be tackled using mistake proofing methods (Pokayoke) and by understanding the machine process capabilities of the production equipment. Statistical process control (SPC) will also help monitor production outputs and give warning of problems before they occur.
If the reason a company is overproducing is because of small orders and economic batch sizes then Setup reduction techniques such as SMED can help. If a company can reduce its changeover time then it is then able to produce smaller batches economically. Overproduction has been said by some to be the worst of the 7 wastes as it encompasses the rest of the wastes, often the main driving force for JIT (Just in time) systems.
Material Transportation
Factory layouts can often be the fundamental cause of excess transportation. When appropriate, relaying out the machines within a factory from a functional to a cellular layout has been found by many companies to help not just reduce transportation waste but also reduce WIP and waiting. Excess inventory levels can also lead to wasted handling.
Inventory
Many companies order over and above what is required to fulfil the order, this may be due to quality problems along the production process or the often mistaken belief that is saves money by ordering larger quantities. The true cost of excess inventory levels should be carefully analysed before ordering excess raw materials simply because the purchase price is less. Tackling the root cause of the quality problems should also be a priority.
Talent
The people in the process work with the day to day frustrations and issues. Understanding and resolving these frustrations can have significant & easy results. Involve all your operators in the solutions and the results and be impressive and must be noticed that you should staff "the right man in the right position".
People Movement
Simple “Good Housekeeping” is a very effective way of reducing wasted movement by men and materials. 6S is a technique used by many companies to focus effort on keeping the workplace tidy with unused materials and machines disposed off so as not to create unnecessary clutter and therefore searching. Re-laying out the factory can also help reduce “motion” waste.
Rework & Defective units
If you don’t do it already record and analyse everything that’s Not Right First Time, for at least a month. A simple Pareto will help you priorities your efforts.
Inappropriate Processes
Rework is a typical example of over processing as discussed earlier reducing the root cause of the quality problem is solution eliminating rework. Techniques such as 5 whys, SPC and mistake proofing (Pokayoke) are available to help identify and eliminate causes of quality defects as we've known in 6S article.
Delays & Waiting
Products waiting around in factories either as finished goods or work in progress (WIP) another major cause of waste. WIP is commonly caused by producing large batch sizes where again SMED techniques can help. Delays are also prevalent in information systems, production of schedules & clarity of the next priority.
Concentrating on keeping bottle neck processes going are also a good way of reducing WIP, the book “The Goal” by Eliyahu M. Goldratt has a lot to say on this and has been found to be very useful by many manufacturing managers.
Energy
Poor use of all types of energy is a waste & can be expensive. Compressed air or water leaks often get ignores but are expensive. How long is your equipment switched on for?
Overview
If you were to record all of the non-value added activities (wastes) carried out in a typical manufacturing company do not be surprised to find out that 99% of all your activities carried out are non-value adding, even the best manufacturers manage 95%. The elimination of waste not just reducing it is a vital component of increasing competitiveness of your organisation. The antidot of 9 wastes is using 6S technique. The next step after you know 9 wastes so you can make jishuken project on your factory.
Wednesday, December 25, 2013
6S Concept
1 . What 's 6S
3 .
Zero Waste , which means reduced costs and increased efficiency :
What
we call " 6S " is derived from the company's 5S and visual control
method popularized by Hiroyuki Hirano (1990 ) - Japanese managers are rooted in
the works of two American pioneers who meticulously learned that Frederick W.
Taylor ' s ( 1911) and Henry Ford ( 1922 ) . 6S is a method of structuring and
maintenance intensive work areas originating from Japan that is used by
management in an effort to maintain order , efficiency , and discipline at the
work site at the same time improve overall company performance .
6s is
a culture about how people treat their workplace properly and maintain order
and keep the workplace neat , clean and orderly so that the work can be created
easily . Basically the same with the 5S, 6S but there are additional 1S said the
" safety " , with the goal of working efficiency , work productivity
, quality of work , safety , increasing capital and labor discipline , and work
comfort . So overall , 6S is :
Sort
( seiri )
Set
in Order ( seiton )
Shine
( Seiso )
Standardize
( Seiketsu )
Sustain
( Shitsuke )
Safety
6S can increase work productivity with the
work ethic rooted in the formation to create a comfortable and safe work
environment that has the feeling that would encourage workers to carry out
environmental improvement works and train them to reduce waste , unplanned
downtime and in-process inventory .
Once
implemented in an integrated manner , 6S will increase employee morale , create
positive impressions of the customers and improve the efficiency of the company
. Not only workers who are comfortable with the work environment , the effects
of which continue to make sustained improvement will encourage waste reduction
, better quality and shorter lead times . All of this will make the company
become more profitable and competitive in the world market .
2 . The purpose of 6S
1 .
Zero Breakdown , means better maintenance :
a.
Scrap , dust , furious - furious and pieces - pieces on the floor and on the
engine is reduced
b. By
cleaning the machine carefully and regularly , the condition of the machine is
known at all times ;
c.
Inspection and maintenance of each day to avoid engine damage becomes severe in
the future .
2 .
Zero Defect , which means better quality :
a. If
everything is in place , you avoid taking the wrong item ;
b .
Clean workplace morale would give to anyone ;
c .
Gauges and indicators work well then the quality will be good .
a.
Inventory and work in process becomes less
b. The
rooms were used for items that are not required to be reduced
c. The movements are not necessary as
avoiding and seeking to diminish
d. Reduce movement - a movement that is not
required such as production , lifting , putting , counting and moving .
4 .
Zero Set Up Time , which means no time is wasted :
a.
Because everything laid out regularly , the time wasted searching for tools to be
suppressed
b. Clean
workplace can improve the efficiency and easier for people to find out how the operation
, although trainees can easily operate it .
5 .
Zero Late Delivery , meaning it can meet customer demand on time :
a.
Since no production damaged the subscription request can be fulfilled on
time
b. Good
working environment plant production speed, nothing is wasted and efficiency
is increased
6 .
Zero Injury , which means better safety :
a. The
equipment is clean and shiny easily observe the damage and hazards ;
b. If you
know where the equipment is stored , you can retrieve it if needed sooner
c. If you
put something then you can safely avoid the equipment to fall upon you
d. If there
is a fire ( fire ) and an earthquake or other natural disaster, you know where
the location of emergency exits and fire extinguishers ( mitigation )
7. Zero Customer Claim , means that customers put a high
level of confidence :
a.
Clean factory does not produce goods damaged
b .
Clean factory can produce goods that ensure user safety .
8 .
Zero Deficit , meaning your company forward added :
a. If 6S
has been executed well , definitely a place to be comfortable and interesting
work , no
waste , no accidents , no engine damage and no defective product ,
you can meet the desires and expectations of customers as well as investors ,
Return on Investment ( ROI ) you also will be increased after the
implementation of 6S .
3 . Techniques 6S
1. SEIRI means SHORT or SORTING
Objective : CHOOSING or summarize GOODS . This is done
considering the working space is limited and should be streamlined .
1 .
Goods are required to work
2 .
Goods are not required to work
3 .
Items that are not needed at all
4 .
Items that do not fit their placement
If
SEIRI not met, then :
• Atmosphere and work activities disrupted
• Difficult to improve productivity , efficiency , and
effectiveness of
Meanwhile,
if SEIRI met, then :
• No waste of space
• Non- utilized efficiently
• Work Environment K3 and increased
• Productivity increased job
• There was no accumulation of goods
Application
of the method Seiri:
A. Criteria
for goods are set aside
• Waste or scrap
• Required elsewhere
• Not required
• Prepare labels
B. Criteria
for machinery / equipment / materials
• When is the item used / certainty of time
• The use is not excluded
• Prepare labels
C. Criteria
for work in process ( half finished )
• Set the certainty of the goods will be used ( time )
• Determine the required amount within the time limit
• When there is excess should be set aside
• Prepare labels
Installation
Label
1 . Specifies the sort order of activities
2 . Observing the items to be sorted
a . Small items together in one box size
b . Items that are not needed are installed LABEL
c . Set shelters were not used goods
d . If there are items missing , repeat the previous steps
e . Create photo documentation before and after SEIRI
Preclude
the existence of Goods Required in Phase SEIRI
• Step seiri or concise tend to precautions that all
materials and goods to be used or to avoid the existence of goods which are not
necessary .
• Prevention is more effective when all personnel
have realized the importance of phase concise , it would be better if the work
culture has become . To measure the implementation stage of this compact as
work culture , it requires attention , awareness and concern for all employees
on unnecessary items .
• If still found items and materials that are not
necessary mean SHORT awareness and concern has not become culture .
2 . Seiton or NEAT or ORGANIZATION.
Objective : spruce or arranging things NECESSARY .
• Goods must be done neatly in place
• Items that do not / have not done should be kept away
from work , but still in the working area
• Waste or Scrap disposed in the space provided for the bin
• Items needed elsewhere have actually been in a designated
place
Method of application Seiton
1 . Prepare labels Seiton
2 . Create guidelines for the preparation of
3 . Identify all items
4 . Goods are not in place label attached Seiton
5 . Do it gradually
6 . Once the label is composed to facilitate the search
Avoid
untidiness in stages Seiton
If the
stage has been run cleanly , but still there is untidiness , there will arise
the question why ?Besides, it
is also the extent to which staff awareness of the importance of neatness
working environment , gradually smoothing the workplace and work environment
should be a " Culture of Work" for each employee and exemplary
leadership or management team , work culture to work neatly should continuously
be imparted to all employees gradual and continuous agenda .
3 . SEISO means RESIK or CLEANING
Objective : workplace and work equipment or clean rehearsal
.
Three rounds of SEISO
1. Operating properties hygiene
• Discover the cause defilement
• Perform the cleaning
2. Object cleanup
• The workplace
• Tools work
3. Prevent damage
• Find the cause of damage to equipment
• Use equipment appropriately according to its function
The
role of employees is an indicator of the success of the work culture in the
stage RESIK Familiarize work to be part of the work culture is not necessarily
easy , because there are elements change a person's behavior , but it can be
pursued gradually , through :
• Commitment coupled with exemplary leadership
• Campaign RESIK program
•The system is able to be done by employees
• Facilities and infrastructure sufficient
Clean the dirty areas is important , but more importantly
how to avoid the reappearance excrement happens .
Method of application SEISO
1. Before and after cleaning
a. collecting the data
b. Analyzing the data
2. Prepare Tape Red , Yellow and Lak / Tipp Ex
a. Red duct tape , paste section of damaged equipment ( can
not be fixed that day )
b. Yellow duct tape , paste section of damaged equipment (
soon to be fixed )
c. Tipp Ex , for the bolt / nut loose ( after dpt marked
Tipp Ex tensioned to easily rectified )
d. Make a list of equipment to be used
3. Prepare Form Forms 1,2 and 3
a. Shape 1 : for recording equipment damaged and can not be
repaired
b. Shape 2 : for recording equipment damaged but can be
repaired
c. Shape 3 : inspect all parts of machinery / equipment
carefully , especially the part that is sensitive .
4 . SEIKETSU means treating or maintaining a work
environment that is already good.
Goal
and objectives include:
• Maintaining a work environment that is already well
• There should be a uniform standard , the labeling
instructions at all operating conditions
• Check the state of the dean workplace equipment used
• Available trash
In this stage of care is more difficult than maintaining
the reach , because maintaining consistency requires continuous work .
Maintaining workplace conditions have been good this required the participation
of all employees to participate. All employees should have the same
determination to defend it is by three principles:
• No unnecessary items
• Do not scattered
• Not Dirty
Rule Free SEIKETSU:
• All employees involved and responsible for the
implementation of the 5 - S
• Sense of charge must be cultivated
• Clean it expensive, but much more expensive dirty
• Officer in charge of the area is in charge of hygiene,
cleaning service but as a supporter of hygiene
Method of application SEIKETSU
1 . In the individual the burden of care , both at work and
equipment .
2 . Garbage / dirt dumped in the space provided , because
not only cleaning service who should be responsible .
3 . Cultivated .
CARE is a continuation of Phase RESIK stage therefore
monitoring and evaluation activities necessary RESIK stage :
1 . Are there any items that are not needed are still being
around you ?
2 . Do not use equipment that can be taken ?
3 . Do RESIK do every morning ?
4 . Do RESIK done every day after work ?
5 . The extent to which the role of the employee to work
neatly ?
5 . Shitsuke means diligently or habituation
Objective
: Accustomed to foster self-discipline . This means that :
• Employees must be willing , able and daring to change the
behavior of a controlled direction Changes in attitude must be in accordance
with the cultural values
• Strive continuously to improve achievements
Do what you
must do and do not do what should not be done
• Willing to remind and be reminded each other everything
should be done consistently and continuously
Benefits
Shitsuke
1 .
There is no wastage
2 .
Work environment and K3 supported
3 .
Maintenance of the machine can be done better
4 .
Possible defects inevitable product
5 .
Timely service
6 .
There is no grievance / complaint from customers
7 .
Welfare of employees increased
Visual
control in the workplace as part of the stage or diligent Shitsuke
• The first step in controlling the phase that is
visually diligent at work .
• Is the 5 - s program has been implemented and has
been the work culture at the same time?
Anyone
can judge objectively without being influenced by anyone. In order to
control the visual workplace matters that need to be considered are as follows:
1.
Always open to give feedback or criticism of workplace conditions
2.
Accept criticism or input will basically strengthen the implementation of 5S
3. If there is a problem please make particular remedial
action by personnel associated parts
6. Safety
Objective:
Minimize the occurrence of accidents, injuries or other incidents. Thus, each
person should have a role and responsibility in terms of safety as well as
understand how to prevent accidents. Everyone who has a role and
responsibility in terms of both safety manager, asst managers, engineers,
supervisors, foreman, and operators must observe and correct the behavior if
there are colleagues who ignore safety.
The first
thing to do is hazard recognition which includes an analysis of the presence of
hazardous situations caused by workers , equipment , materials , methods of
work , to the environment in a work area . If the hazard is found, then make
use of certain tools that can be used to improve safety. Measurable parameters
of safety success is seen from the Key Performance Indicator (KPI), namely;
1 . Total Recordable Frequency Rate (TRFR)
TRFR =
( ( LTA + RWC + MTC ) x 1,000,000 ) / hours worked
LTA
= Loss Time Accident
RWC
= Restricted Work Case
MTC
= Medical Treatment Case
2 . Safety Behaviour Observation (SBO)
This
observation was made by Manager 1x/week, 2x/week Asst Manager, Engineer and
Supervisor3x/week , 1x/day Foreman , Operator 1x/day . 5S itself is in line
with ergonomics and can be considered as part of the ergonomics. Meanwhile, the
latest S (safety) were added to the 5S or 6S. 5S thus becomes + 1 is one of the
main parts in ergonomics. This causes 6S become an issue very closely with the
ergonomics.
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