Академический Документы
Профессиональный Документы
Культура Документы
CONVENSION
2008
GROUP INTRODUCTION
• Problem Identification.
• Analysis of root cause and
countermeasure.
• Implementation of countermeasure.
• Evaluation of result.
• Continuous improvement.
PROBLEM IDENTIFICATION
Fishbone Diagram
Machine HIGH
Man WIP
Rework activity at
inspection station
Method Material
6
ROOT CAUSE DETERMINATION
Fishbone Diagram
Machine HIGH
Man WIP
Rework activity at
inspection station
Method Material
7
ROOT CAUSE DETERMINATION
Pole bend at
corner area
IMPLEMENTATION OF COUNTERMEASURE
L-Support pole
MONITORING OF RESULT
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
No mechanism to
minimize WIP
Method Material
12
IMPLEMENTATION OF COUNTERMEASURE
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
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
Flow
Take out wire from WIP rack
Insert r / seal
Crimping
Put label
ROOT CAUSE DETERMINATION
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
Hole more
bigger
= 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