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SMIT

CONVENSION
2008
GROUP INTRODUCTION

AHMAD YUSRI HAWARIAH MOHD HADI YUSMIN SOHANA


TO REDUCE WORK IN
PROGRESS AT CONVEYOR 4
INPECTION AREA
IMPROVEMENT STEPS

• Problem Identification.
• Analysis of root cause and
countermeasure.
• Implementation of countermeasure.
• Evaluation of result.
• Continuous improvement.
PROBLEM IDENTIFICATION

- There is a lot of WIP between inspection


process at conveyor 4 ( Body BLM)
FINAL
ASSEMBLY

GROMMET TESTING VISUAL AUDIT


WIP WIP
ROOT CAUSE ANALYSIS

Fishbone Diagram
Machine HIGH
Man WIP
Rework activity at
inspection station

Pole type not


suitable
Pole bend

Branching & clip out


of dimension

Method Material
6
ROOT CAUSE DETERMINATION

Fishbone Diagram
Machine HIGH
Man WIP
Rework activity at
inspection station

Pole type not


suitable
Pole bend

Branching & clip out


of dimension

Method Material
7
ROOT CAUSE DETERMINATION

Pole type used at cornering area on


the final assembly board is not suitable

Pole bend at
corner area
IMPLEMENTATION OF COUNTERMEASURE

ACTION TO PREVENT POLE FROM


BENDING
- To use more strong pole structure at
cornering area

L-Support pole
MONITORING OF RESULT

WIP Monitoring Chart


18

Start using L-support


16
pole
14
QTY (UNIT)

12

10

0 3/11 4/11 5/11 6/11 7/11 8/11 10/11 11/11 12/11 13/11 14/11 15/11 17/11 18/11
WIP 14 4 16 10 8 15 10 4 9 12 8 8 2 10
TARGET 10 10 10 10 10 10 10 10 10 10 10 10 10 10
EVALUATION OF RESULT

18
WIP Monitoring Chart
16
Start using L-support
14
pole
QTY (UNIT)

12

10

0 3/11 4/11 5/11 6/11 7/11 8/11 10/11 11/11 12/11 13/11 14/11 15/11 17/11 18/11
WIP 14 4 16 10 8 15 10 4 9 12 8 8 2 10
TARGET 10 10 10 10 10 10 10 10 10 10 10 10 10 10
CONTINUOUS IMPROVEMENT

Root analysis- continue


Machine
Man HIGH WIP

No mechanism to
minimize WIP

WIP rack too large

Method Material
12
IMPLEMENTATION OF COUNTERMEASURE

Action to continually reduce WIP


- Use single hook to hang WIP harness
instead of WIP rack
EVALUATION OF RESULT

18

16

14 Start using L-
support pole
QTY (UNIT)

12

10

8 Start using
hook to hang
6 harness

0 10/1 11/1 12/1 13/1 14/1 15/1 17/1 18/1 19/1 20/1 21/1 24/1 25/1 26/1 27/1
3/11 4/11 5/11 6/11 7/11 8/11 1/12 2/12 3/12
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
WIP 14 4 16 10 8 15 10 4 9 12 8 8 2 10 2 1 1 2 1 2 1 0 0 0
TARGET 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10
COST SAVING

COST SAVING (REDUCE HOLDING COST)

= No. of WIP reduction X WIP unit prize


= (WIP before – WIP after) X WIP unit prize
= (10 – 2 ) X RM 128.00
= RM 1,024.00
TO IMPROVE PRIMARY PRESS
PROCESS
PROBLEM IDENTIFICATION

- Primary press process is slow and cause


high WIP at all primary press machine.
ROOT CAUSE ANALYSIS

Fishbone Diagram
Machine Primary press
Man process slow

Process insert
rubber seal slow
Not suitable
rubber seal
Hole rubber selection
seal small
Method Material
18
EVALUATION OF EXISTING SITUATION

Primary Press Process Flow

Flow
Take out wire from WIP rack

Insert r / seal

Crimping

Put label
ROOT CAUSE DETERMINATION

Rubber seal used for wire size 1.25 mm2


is not suitable.
Part number : 828904-1X
KANBAN RELATED

No Kanban Side
1 SS8002 Both side
2 SF1342 Single side
3 SF1343 Single side
4 SS8005 Single side
5 SS6008 Single side
6 SS8006 Single side
7 SS6009 Single side
IMPLEMENTATION OF COUNTERMEASURE

ACTION TO PREVENT PRIMARY PRESS


PROCESS SLOW

- To replace another rubber seal at the same


area

Hole more
bigger

Part no: 828905-1X


COMPARISON CYCLE TIME

Average cycle time using rubber seal 828904-1

= 182 sec / bdl


= 9.1 sec / pcs

Average cycle time using rubber seal 828905-1

= 84 sec / bdl
= 4.2 sec / pcs

4.9 second
Cycle time saving

= 98 sec / bdl
save every
= 4.9 sec / pcs pcs
COST SAVING CALCULATION

Cost saving
= Time saving X Unit Cost
= No of r/seal used X (Time/r seal) X Unit cost
= 22 X 160 X 8 X (4.9/3600) X RM4.50
= RM 172.48 / month
= RM 2,069.76 / year

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