1st winner 2009-1

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MM2100 Industrial Estate

Block NN8-1, West Cikarang,

Bekasi 17520, Indonesia

Total Associate : 650 persons

Cycle Time Down in Door Mirror Line By

Process Balancing.

PT. ABC

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We are produce and delivered above

products to PT. HPM

Product Introduction

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ThemeCycle Time Down in Door Mirror Line By

Process Balancing.

Circle NamePT. ABC

Company

Name

Introductionof members

MEMBER :

Dewi AnggrainiKartika .AY

Siti Maria

Oden RudiyanaRiana Melasari

Introduction of Circle

Section : Assy 4R Members 4 persons Age Avg 23 years With high professionalism,good performance would have

created a high productivity

Circle Introduction

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step

.

.

.

.

.

.

.

.

5 8 7

STANDARDIZATION

NEXT THEME

A C T I V I T Y

CURRENT CONDITION

ANALYZE & SET A

TARGET

ANALYSIS OF KEY

FACTORS

IMPROVEMENT PLAN

IMPROVEMENT

ACTION

DECIDE A THEME

2 3 4

IMPROVEMENTEVALUATION

2009 QCC Activity Schedule

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Step 1 : Decide the Theme

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ONE YEAR POLICY

To Be No. 1 QCD in All Honda Lock Group Area in 2010.

To Build High Income Institution by Reduce Inefficient Process.

CIRCLE THEME

Cycle Time Down in Door Mirror

Line By Process Balancing

DEPARTMENT ACTIVITY PLAN Development & Reduce Inefficient Process

- Target Value : 15 % Up


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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

Total Cycle Time :

339.94 sec

Nut

Insert

Packing

& Stopper

Assy

Visual

Check

& Setting

Handle

Pin &

Spring

Insrting

Pin

Caulking

Weight

Counter

Caulking

Final

Inspect

Total Cycle Time :

105.76 sec

Flow Process Assembly Door Mirror

Flow Process Assembly Out Handle

RAW

MATERIAL

PAINTING

PROCESS

ASSEMBLY

PROCESS

WARE HOUSE

FINISH GOODS


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Our Team Product are Door Mirror and Out Handle and

Cycle Time Performance for Both Products is Shown below:

Product

Cycle Time

Current StandardCurrent vs

Standard%

DOOR MIRROR

339.34 273.65 + 65.69 24.01%

OUT HANDLE

105.76 96.5 + 9.26 9.6%

Note: Cycle Time is time needs to make one Finished Goods


THE VARIANCE OF DOOR MIRROR CYCLE TIME

STANDARD IS HIGHER THAN OUT HANDLE

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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

DOOR MIRROR Line Graphic CYCLE TIME

0

10

20

30

40

50

60

CycleTime(Second

)

Current 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97

Standard 22.9 25.4 24.9 24.0 23.9 21.6 24.9 30.0 25.5 25.9 24.6

Bracket

Tightening

Turn Light

Tightening

Inner Base

Ass y

Base Comp

Ass y

Seat Base

Comp Assy

Mirror

Group Ass y

Function

Check

Mirror

Perform

Check

Tapping &

Cord Dim

Scull Cap

Assy

FI &

Packing


From Graphic above Shown That Cycle Time Process are not Balance yet

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Step 2 : Current ConditionAnalyze & Set a Target

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Door Mirror Line Graphic Cycle Time

56.6

0

10

20

30

40

50

60

C/T 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97

Bracket

Tightening

Turn Light

Tightening

Inner Base

Assy

Base

Comp

Assy

Seat Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Perform

Check

Tapping &

Cord Dim

Scull Cap

Assy

FI &

Packing

Man Power (MP) 11

Capacity/Man (Cap/Man) 5.78

Production/day 457 pcs/Day

Effective Time 7.2 Hours

Rate Operation (RO) 90 %

Sec

Month : Februari 2009

Tact

Time

Inefficient Cycle Time

Step 2 : Current Condition Analyze &Set a Target

Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Bracket

Tighten

Bracket

Tighten

Turn

Light

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Inner

Base

Assy

Base

Comp

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Mirror

Group

Assy

Function

Check

Function

Check

Mirror

Check

Preform

Mirror

Check

Preform

Tapping

& Cord

Dimention

Tapping

& Cord

Dimention

Skull

Cap

Assy

Skull

Cap

Assy

Final

Inspect

& Packing

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.9731.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Cycle Time Analyze

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Man Power Understanding AnalyzeItem Review Analyze Evaluation

Evaluator: Mr Andi (Section Head)

1. Production Quality

Control (PQC)

Understanding

2. NG Part Sample Limit

Understanding

3. Process Flow of Part

to Finished Good

Understanding 0

1

2

3

4

Dewi

Mela

Icha

Kartika

Oden

TrisnoTri

Vivih

Ema

Ani

Sri

STANDARD

ACTUAL

Analyze Skill Map Poin:

1. Understood Process

2. Identify Abnormal Process Ability

3. Able to Teach New Operator

4. Able to Make Improvement

1

23

4

There are no man power factor which can affected to

inefficient cycle time.


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Part NameDrawing

Number

Qty/

Bucket

Plastic

Cover

Weight

> 7 kgLoss Time Effect

TF0-000 SCREW TAPPING INSIDE HANDLE (2AP TF0-E0003-0000 500 NO NO

TF0-000 SEAT R,BASE TF0-E0401-0000 200 NO NO

SNB-000 SCREW TAPPING TRUSS 4X14 (2AP) SNB-E0509-0000-D 500 NO NO

TF0-020 COVER R,BASE TF0-E042F-0200 250 NO NO

TF0-000 SEAL B TF0-E040A-0000 1000 NO NO

TF0-000 BASE R,INNER TF0-E0421-0000 30 NO NO

SFA-000 SCREW WASH M5X12 (2AP) SFA-E0503-0000 30 NO NO

TF0-020 HOUSING R TF0-E0311-0200 10 YES NOLoss Time 3.55 Sec to

Remove Plastic

TF0-000 BOLT STUD M6 TF0-E0109-0000 1000 NO NO

TF0-000 MIRROR GROUP R,R1400 (D/M) TF0-E0100-0000 80 YES YESLoss Time 2,58 Sec to

Remove Plastic

SFA-000 SEAL A (2AP) SFA-E0408-0000 1000 NO NO

90106-003 SCREW TAPPING TRUSS 4X12 (2AP) 90106-S70-0030 500 NO NO

TF0-020 BASE R,OUTER TF0-E0423-0200 40 YES NOLoss Time 3.48 Sec to

Remove Plastic

TF0-000 BRACKET SUB ASSY RH-R,A/T S/T TF0-E2300-0000 10 NO NO

90109-003 SCREW TAPPING TRUSS 4X16 (2AP) 90109-S70-0030 500 NO NO

There are 3 Materials that affect to cycle time Directly.

Material AnalyzeStep 2 : Current Condition Analyze &Set a Target

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All Parts are Received

by Warehouse

QC check 100% Parts

withremove plastic

cover one by one

After Checked the Part re-

cover again and put in to

bucket.

WHP QC INCOMING WHP AF

PLASTIC HOUSING

30 x 25 CMPLASTIC MIROR

20 x 25 CM

PLASTIC OUTER BASE

12 x 25 CM

Plastic after used in assembly:

waste

Lost time occured while after checked QC Covering the part again

Door Mirror Parts Flow (Housing, Outer Base, Mirror) AnalyzeStep 2 : Current Condition Analyze &Set a Target

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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

SeatBase

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Bracket Tigtening Process 31.87

1. Take a Housing 1.47

2. Open Housing Cover 3.55

3. Put into Jig 1.25

4. Assy Bracket to Housing 6.45

5. Hand Togle Down 1.39

6. Bottom screw tightening 6.21

7. Re-set hand togle position 1.10

8. Inside screw tightening 8.52

9. Take and transfer 1.93

Base Inner Tightening 24.33


2. Take a Base Outer 1.49

3. Open Base Outer Cover 2.58

4. Put Base Outer to Jig 3.97

5. Base Inner Assy 3.25

6. Screw Tightening 8.36

7. Take and Transfer 2.94

Mirror Group Assy 19.09


2. Date Stamp 4.84

3. Take a Mirror 1.32

4. Open Mirror Cover 3.48

5. Setting a Mirror 2.97

6. Curve Check 1.91


Process of removing plastic cover are in process no: 1, 3 and 6

Line Process which affected by plastic cover AnalyzeStep 2 : Current Condition Analyze &Set a Target

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4M+1E

ANALYZEITEM VERIFICATION GEMBA JUDGE

MAN

Understanding of

Production Quality Control

( PQC ) is Weak

Operator understood PQC

Step1 April 2009

Understanding of Part NG

Sample Limit is Weak

Operator understood about

Part NG Sample Limit1 April 2009

Understanding of process

flow part to goods is weak

Operator understood about

Part Process Flow to Goods1 April 2009

MACHINE Line Lay out is long There are 11 Process 2 April 2009 X

MATERIALPacking standart is not

good2 April 2009 X

METHODEThere are idle time in some

process

Cycle Time Graphic is not

Balance Yet2 April 2009 X

ENVIRONTMENT - - -

Part Covered by plastic andStandar Packing is heavy

= OK (is Not Problem Factor) X = Problem Factor

4M + 1E AnalyzeStep 2 : Current Condition Analyze &Set a Target

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DOOR MIRROR Line Graphic CYCLE TIME

0

10

20

30

40

50

60

CycleTime(Seco

nd)

Current 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97

Standard & Target 22.9 25.4 24.9 24.0 23.9 21.6 24.9 30.0 25.5 25.9 24.6

Bracket

Tightening

Turn Light

Tightening

Inner Base

Assy

Base

Comp

Assy

Seat Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Perform

Check

Tapping &

Cord Dim

Scull Cap

Assy

FI &

Packing

Current

C/T :339.34

Standard &

Target

C/T :

273.65

CYCLE TIME DOWN TARGET

339.34273.65

0

50

100

150

200

250

300

350400

Before Target

Second


TargetDown 19.35%

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POINT OF REVIEW PARAMETER BEFORE TARGET

Q Keep Zero Claim ZERO CLAIM Zero Claim Zero Claim

C Reduce Loss Cost ProcessReduce Cycle

Time339,34 second 273,65 Second

D Level up in Support Deliveryto Customer.

Production

Capacity is

Stabil

10.075Pcs/Month

10.075Pcs/Month

SReduce risk of accident by

reducing packing standard.

Reduce Weight

of Packing

Standard

Weight =

19,26Kg

63.6% of

Weight Down

=> 7 Kg*)

M Optimize Job DescriptionOperator

Reduce quantityMP

11 Man 7 Man

EReduce Waste of Production

Process

Re-Use of

Plastic Cover

Material

Become Waste

Re-Use in

Another

Process

*) Female Operator Canno t Lift Up Buc ket Over Than 7 Kg


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Step 3 : Analysis of Key Factors

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Need 11

manpower

Unbalance

d

Process

MACHINE MATERIAL

ENVIRONMENT METHODE MAN

D/M Line is

Not yet

Efficient.

Ineficient

Process

There are

Some idle

time

packingStandard are

not good

Packing

heavy

Part

Covered by

plastic

No packing

standartLine Setting

Not Good

No Problem

Factor

No Problem

Factor

Cycle

Time

is

High

Step 3 : Analysis of Key Factors

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Step 4 : Improvement Plan

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FACTOR PROBLEMIMPROVEMENT

PLANHOW PIC SCHEDULE

MATERIAL

PART COVERED

WITH PLASTIC

PLASTIC COVER

CHANGE TO

PARTITION CHANGESTANDARD

PACKING

DM ASSY-

QC-PE

MEI JUN

2009

STANDART

PACKING

HEAVY

REDUCE WEIGHT

STANDARD

DM ASSY-

QC-PC

MEI JUN

2009

METHODUNBALANCED

PROCESS

REDUCE LOSS TIME

PROCESS PROCESS

BALANCING

DM ASSY-

PE

JUN AUG

2009

MACHINE

DOOR MIRROR

LINE PROCESSNEED 11 MAN

POWER

MODIFICATION LINELAYOUT

DM ASSY-PE

JUN AUG2009

Step 4 : Improvement Plan

St 4 I t Pl (St d d P ki Ch )

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PART

NAMEBEFORE

PACKING CHANGE

PLANDIMENTION Reason

HOUSING

(4,24 Kg)

10 Pcs

Partision Size :

= 200 mm X 110 mm X 300mmPartision Material : Sponge

Bucket Capacity : 10 Pcs

Weight: 4,8 Kg

Construction : 1 Level (5 Row 2 Column) 1. Partition is

Strong and

easy to

Construct

2. More

Effective to

Prevent

Scratch

3. Caneliminate loss

time of plastic

removal

BASE

OUTER

(6,56 Kg)

40 Pcs

Partision Size := 200 mm X 55 mm x 150 mm

Partision Material : Sponge


Weight: 3,28 Kg

Construction : 1 Level (10 Row 2

Column)

MIRROR

(19,26 Kg)

80 Pcs

Partision Size :

= 15 mm X 225 mm x 150mm

Partision Material : Sponge


Weight: 6,76 Kg

Construction : 1 Level (15 Row 2Column)

580

mm

400 mm

580

mm

400 mm

300

mm

450 mm

Step 4 : Improvement Plan (Standard Packing Change)

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0

10

20

30

40

50

60

Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

1 2 3 4

Process Merger Plan is Based on Low cycle time process

Step 4 : Improvement Plan (Process Balancing)

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Step 5 : Improvement Action

St 5 I t A ti (P ki Ch )

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PART NAME BEFORE AFTER STANDARD PACKINGIMPROVEMENT

REVIEW

HOUSING

Before:

Cover PlastickQuantity 10 pcs (4.24 Kg)

After :

Cover PartitionQuantity 10 pcs (4.8 Kg)

QC JUDGE:Packing can

prevent scratch

NG

Cost:

Rp 7,600,000.-

BASE

OUTER

Before :Cover Plastic

Quantity 40 pcs (6.56 Kg)

After :

Cover PartitionQuantity 20 pcs (3.28Kg)

MIRROR

Before :

Cover Plastic

Quantity 80 pcs (19.26 Kg)

After :

Cover PartitionQuantity 30 pcs (6.76Kg)

Step 5 : Improvement Action (Packing Change)

St 5 I t A ti (P ki Ch Eff t)

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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Bracket Tigtening Process Before After

1. Take a Housing 1.47 1.47

2. Open Housing Cover 3.55 -

3. Put into Jig 1.25 1.25

4. Assy Bracket to Housing 6.45 6.45

5. Hand Togle Down 1.39 1.39

6. Bottom screw tightening 6.21 6.21

7. Re-set hand togle position 1.10 1.10

8. Inside screw tightening 8.52 8.52

9. Take and transfer 1.93 1.93

TOTAL 31.87 28.32

Base Inner Tightening Before After


2. Take a Base Outer 1.49 1.49

3. Open Base Outer Cover 2.58 -

4. Put Base Outer to Jig 3.97 3.97

5. Base Inner Assy 3.25 3.25

6. Screw Tightening 8.36 8.36

7. Take and Transfer 2.94 2.94

TOTAL 24.33 21.75

Mirror Group Assy Before After


2. Date Stamp 4.84 4.84

3. Take a Mirror 1.32 1.32

4. Open Mirror Cover 3.48 -

5. Setting a Mirror 2.97 2.97

6. Curve Check 1.91 1.91

7. Take and Transfer 2.97 2.97

TOTAL 19.09 16.61

Process of removing plastic cover are in process no: 1, 3 and 6

Down 11.14%

Down 10.6% Down 18.23%

Step 5 : Improvement Action (Packing Change Effect)


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PLASTIC HOUSING

30 x 25 CM

PLASTIC MIROR

20 x 25 CM

PLASTIC OUTER BASE

12 x 25 CM

Plastic after used :

Re-use Plastic to Cover

J09 Key Set (2R)

Product : Motorcycle Part

Type : J09 Key Set Customer : Honda Thailand Packing Condition : Covered by Plastic

to Prevent Scratch

Plastic Source : Supplier


Visibilities Studies to Re-Use Plastic Cover

St 5 I t A ti (B l i P )

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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Turn Light Tightening 25.811. Light Assy 10.21

2. Screw & Marking 11.47


Base Inner Tightening 24.331. Put into Jig 1.74


3. Open Base Outer Cover 2.58





Turn

Light

Tighten

Inner

Base

Assy

25.81 24.33

Before merger

Turn Light & Inner Base Tightening 41.69

1. Light Assy 10.21

2. Screw & Marking 11.47

3. Take and Transfer eliminated

4. Put into Jig eliminated


6. Open Base Outer Cover eliminated





After merger process and

Step 5 : Improvement Action (Balancing Process)

St 5 I t A ti (P M difi ti )

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Step 5 : Improvement Action (Process Modification)

1. Modify Jig Light & Inner Tightening 2. Relay out Working Table

Base Inner Tightening Jig Turn Light Tightening Jig

Light Inner Tightening Jig

There are 2 jigs in Turn Ligh & Base Inner Tightening

(A/T & R/C) Process:

Special for A/T Type

Turn Ligh Tightening Jig added with Base Inner &

Base Outer Tightening Jig

For R/C Type, Base Inner Tigh Jig is not modified

Set Turn Ligh and Bases Inner Driver Move:

Driver(Turn Ligh) Cannt reach ScrewFeeder 4x12 and Base Inner Location

Driver(Base Inner) Cannt Reach Screw

Feeder 4x14 & Turn Ligh Location


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Eliminate Idle Working Table

Turn Light

Tightening

Process Table is

disposed,andnext process

move a head.

So

The Linebecome Shortly.


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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Base Comp Assy 58.591. Put into Jig 3.43

2. Base Comp Join 5.84


4. Cover Base Assy 5.83


Seat Base Comp Assy 12.561. Put into Jig 2.5

2. Seat Base Assy 7.78


Before merger

Base Comp & Seat BaseAssy 41.69


2. Base Comp Join 5.84


4. Cover Base Assy 5.83

5. Take a Base Outer -

6. Put into Jig -

7. Seat Base Assy 7.78



Base

Comp

Assy

Seat

Base

Comp

Assy

35.75 12.56

Seat Base Assy Process move into Base Comb Tightening Proess

to Stabilize Cycle Time.

To joining Seat

Base Assy

Process into Base

Comb Tightening

Process needs &

Seat Base Assy

needs to re-lay out

working table anddispose Seat Base

Comp Assy Table.



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Base Comp Tight &

Seat Base Comp

Assy


Re-Layout Seat Base Assy Process

1. Seat Base Comp Assy Table is Eliminated

2. Base Comp Tightening Process Move to Seat Base

Position.

3. Buffer Table is Added in Base Comp Tightening Table .


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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Mirror Group Assy 10.771. Put into Jig 1.60

2. Date Stamp -


4. Open Mirror Cover -


6. Curve Check 1.91


Before merger

Bracket Tightening 40.811. Take a Housing 1.47

2. Open Housing Cover eliminated


4. Assy Bracket to Housing 6.45

5. Hand Togle Down 1.39

6. Bottom screw tightening 6.21

7. Re-set hand togle position 1.10

8. Inside screw tightening 8.52

9. Date Stamp 7.84


11. Stamp & Caulking Check 4.65

After (movement process)

To Stabilize Process, Stamp Date Process is moved toBracket Tightening Process.

Mirror

Group

Assy

19.09

Moved to

Bracket

Tightening

Process



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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Mirror Group Assy 10.771. Put into Jig 1.60

2. Date Stamp


4. Open Mirror Cover -


6. Curve Check 1.91


Function Check 34.381. Put into Jig 3.73

2. Cord Assy 6.11

3. Push Button 19.64

4. Take, Mark & Transfer 4.90

Before merger

Function Check 45.151. Put into Jig 1.60

2. Date Stamp


4. Open Mirror Cover eliminated


6. Curve Check 1.91



9. Cord Assy 6.11

10. Push Button 19.64


After merger process andJoin to No1 process

Mirror

Group

Assy

Function

Check

19.09 34.38

Join to No1 process CheckFunction

Process

is Joined

to Mirror

Group

Assy

Process



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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Mirror Check Preform 56.601. Put into Jig 3.5

2. Cord Assy 4.15

3. Push Button 3.64

4. Check M/C Preform 39.67


Tapping & Cord Dim 37.581. Put into Jig 2.3

2. Test Cord Length 5.25

3. Seal A Assy 4.65

4. Tapping 13.32

5. Gap Check 4.17

6. Bending Check 4.2

7. Take & Tansfer 3.69

Before merger

Mirror Assy andCheck Preform

54.75

1. Put into Jig 3.5

2. Cord Assy eliminated

3. Push Button 3.64

4. Check M/C Preform 39.67


6. Put into Jig 2.3

7. Test Cord Length eliminated

8. Seal A Assy eliminated

9. Tapping eliminated

10. Gap Check eliminated

11. Bending Check eliminated

12. Take & Tansfer eliminated


Mirror

Check

Preform

Tapping

& Cord

Dimention

56.60 37.58

Move Seal AJig,

Tapping

In This Joining

Process, Checker

Machine iddle Time

is Used to do Next

Process.



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Bracket

Tighten

Turn

Light

Tighten

Inner

Base

Assy

Base

Comp

Assy

Seat

Base

Comp

Assy

Mirror

Group

Assy

Function

Check

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97

Skull Cap Assy 27.401. Put into Jig 3.13

2. Take a Skull & Visual Check 8.98

3. Skull Assy 7.56

4. Gap Check 3.86

5. Take & Transfer 3.87

Tapping & Cord Dim 33.971. Part Completeness Check 5.21

2. Apperance Check 3.56

3. Mirror Check & Wash 4.23

4. Visual Check 9.47

5. Mirror Assy Shake 2.21

6. Take a miramat Bag 2.01

7. Put in 2.94

8. Bag Close 1.38

9. Place to Bucket 2.96

Before merger

Tapping & Cord Dim 48.031. Put into Jig 3.13

2. Take a Skull & Visual Check 8.98

3. Skull Assy 7.56

4. Gap Check 3.86

5. Take & Transfer eliminated

6. Part Completeness Check 5.21

7. Apperance Check 3.56

8. Mirror Check & Wash 4.23

9. Visual Check eliminated

10. Mirror Assy Shake 2.21

11. Take a miramat Bag 2.01

12. Put in 2.94

13. Bag Close 1.38

14. Place to Bucket 2.96


Skull

Cap

Assy

Final

Inspect

& Packing

27.40 33.97

Skull CapAssy is

Joined in to

FI & Packing

Process.


Step 5 : Improvement Action (Merger Process Effect)

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PROCESSBEFOREMERGER

(in second)

AFTERMERGER

(in second)

CYCLE TIME

VARIANCEREMARKS REVIEW

Bracket Tightening 31.87 40.81 Up 8.94 Additional ProcessFrom No

Cost =

Rp 16,073,400Turn Light Tightening 25.81

41.69 Down 8.45

Inner Base Assy 24.33 Base Comp Assy 35.75

43.53 Down 4.78Cycle Time

Before

= 339.34 Second

Seat BaseComp Assy

12.56

Mirror Group Assy 19.0945.15 Down 8.32 Function Check 34.38

Cycle Time After= 273.96 Second

Mirror Check Preform 56.6054.75 Down 39.43 Tapping & Cord

Dimention37.58

Skull Cap Assy 27.448.03 Down 13.34Final Inspect &

Packing33.97

T O T A L 339.34 273.96 Down 65.38 (19.26%)

Step 5 : Improvement Action (Merger Process Effect)

Step 5 : Improvement Action (Visual Check)

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Gomi

Benang

Spit/Gumpalan Cat

Sagging

Orange Peel

Cat Tipis

Fading/Un matching colour pada posisi tertentu

Matching NG/beda warna

Gelombang Scrath

Bari

Gelombang

Weld

Shape/berubah bentuk, tumpul

PAINTING

MATERIAL

Before NG Material, Painting and NG Process Items is re-check inFinal Inspection Assembly (D/M & O/H)

After Final Inspection Check only For Assy Process NG Item ,

ex: Scrath

Step 5 : Improvement Action (Visual Check)

Visual Check Item Determination

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Step 6 : Improvement Evaluation


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Part after check is Packed

in to Bucket with PartitionAll Parts are Received

by Warehouse

QC check 100% Parts

and Remove Plastic

Cover

Part Processed in

Assembly.


by Warehouse

QC check 100% Parts

withremove plastic

cover one by one

After Checked the Part re-

cover again and put in to

bucket.

Operator remove cover

again in line before

process

WHP QC INCOMINGWHP AF


After

Before

Lost Time of Remove Plastic Cover in Assembly is eliminated.


New Flow Material Receiving


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PLASTIC HOUSING

30 x 25 CM

PLASTIC MIROR

20 x 25 CM

PLASTIC OUTER BASE

12 x 25 CM


waste

After

Before

PLASTIC HOUSING

30 x 25 CM

PLASTIC MIROR

20 x 25 CM

PLASTIC OUTER BASE

12 x 25 CM


J09 Key Set



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Item Before After Before vs After

MP Quantity 11 persons 6 persons 5 personsLabour Cost Rp. 13.200.000 Rp. 7.200.000 Rp. 6.000.000

Invest

ment

Partion - Rp. 7.600.000Rp. 23.673.400

Re-Layout - Rp. 16.073.400BEP

= 4 month

C/T (sec)TactTime

(sec)MP RO

Cap/Man

(hr)

Cap/Day

(7.2hrs)

Cap/

Month

Before 339.34 56.60 11 90% 5.78 458 10.075

After 273.96 54.75 6 90% 10.78 473 10.415

Before vs

After

Down

19.2%

Down

3.26%

Down 5

persons-

Up

86.6%Up 3.2% Up 3.2%

Break Event Point Analyze

Production Capacity Analyze

Total Investment for This Improvement is Rp. 23.673.400. And It Will

Reach BEP for 4 Months with Cost Down/Month is Rp. 6.000.000.


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POINT OF REVIEW PARAMETER BEFORE TARGET RESULTEVALUA

TION

Q Keep Zero Claim NGPROCESS

Zero Claim Zero Claim Zero Claim C

Reduce Loss Cost

Process Cycle Time

339,34

second

273,65

Second

273,96

Second D Level up inSupport Delivery

to Customer.

ProductionCapacity is

Stabil

10.075Pcs/Month

10.075Pcs/Month

10.415Pcs/Month

(Up 3.37%)

S

Reduce risk of

accident by

reducing packing

standard.

Weight of

Packing

Standard

Weight =

19,26Kg

63.6% of

Weight

Down => 7

Kg

30 Pcs =

6,76 Kg M

Optimize Job

Description

Operator

MP 11 Man 7 Man 6 Man E

Reduce Waste of

Production

Process

Re-Use of

Plastic Cover

Material

Become

Waste

Re-Use in

Another

Process

J09 Key

Set

Packing


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Step 7 : Standardization


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MP TACT TIME CAP/MAN CAP/DAY RO

6 54.75 10.95 pcs 473 pcs 90%

Bracket

Tighten

Turn

Light

& BaseTighten

Base

Comp &

Seat BaseAssy

Mirror

Assy &

FunctionCheck

Mirror

Check

Preform

Tapping

& Cord

Dimention

Skull

Cap

Assy

Final

Inspect

& Packing

1. New Line Door Mirror Process is Set for 6 Man Power

Part after check is Packed

in to Bucket with Partition


by Warehouse

QC check 100% Parts and

Remove Plastic Cover

Part Processed in

Assembly.


2. Part Plastic Cover removed at QC Incoming.

Re-use Plastic to

Export Packing J09 Key

Set (2R)

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Step 8 : Next Theme

Step 8 : Next Theme

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Cycle Time Down in Out Handle Line.

Our Team Next Theme is:

PRODUCTCYCLE TIME (Second)

CURRENT STANDARD VARIANCE %

Door Mirror

273.96 273.65 0.31 0.11%

Outer Handle105.76 96.5 9.26 9.6%

Step 8 : Next Theme

Note : Door Mirror Cycle Time Process is Successfully Down in This Year QCC

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Thank youfor your attention

1st winner 2009-1

Documents