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Jishuken Activities (Nov 3, 2008)

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JISHUKEN ACTIVITIES ( Nov 3, 2008 )
STEP – 0 TRAINING (Approx. 1 week)
• STOP 6 Introduction
• TPS Introduction
• TPS – JIT
• QAC
• TPS – SW
STEP – 1 SAFETY ASSURANCE
1. Patrol Check base on “STOP 6” by Jishuken team
2. Making rank criteria by company management
3. Confirm Actual Patrol Check by Company Management
4. Company Decision (Ranking category)
5. 4M analysis
6. Countermeasure for Safety Assurance (Permanent & temporary base on 4M)
7. Company Standardization (Discuss with Management linked to productivity & quality)
STEP – 2 THEME SELECTION
8. Data Searching / Researching & Analysis (past and planning data): – sales order & fluctuation; – stock & defect ratio
9. Clarify the Problems
10. Discuss with Supplier
11. Theme Selection and Decision
STEP – 3 MAKE PART FLOW CHART (PFC) “BEFORE”
12. Make Process Flow Table (and confirm to actual genba)
13. Draw PFC : – Check initial CT&MCT for each process.; – Reveal each problems and decide the priority & area Kaizen
STEP – 4 ARRANGE SMOOTH FLOW (SEIRYUKA)
14. Check Machine Loading Capacity
15. Set Up Fix Part on Each Machine (Temporary Standard for Material & Machine)
16. Set Up PFC Target Image
17. Arrange Smooth Flow (Think time & volume to synchronize before/after process )
STEP – 5 SET TEMPORARY STANDARD
18. Make and Decide Store Location
19. Make TemporaryStandard Job (Material, Man, & Method)
20. Trial Temporary Standard & Simulation (Self confirmation)
21. Keep Temporary Standard Running
STEP – 6 CONFIRMATION TRIAL (Maximum 1 week trial)
22. Confirm Temporary Standard Set Up & Implementation “Pull” System for Several Days : – Issue Information Method to “Pulling“ ( time/volume ); – Use “temporary internal kanban”; – Confirm Current stagnation condition
STEP – 7 MAKE PART & INFORMATION FLOW CHART (PIFC) “BEFORE”
23. Add Information Flow on PFC by setting Temporary STD (Time & Volume)
24. Grasp Current Condition/Information (5W 2H) ==>Clear to reason “why”
25. Lead Time Calculation PART & INFORMATION FLOW CHART (PIFC) (“Before” means that the condition was after setting temporary standard )
STEP – 8 MAKE PART & INFORMATION FLOW CHART (PIFC) “IDEAL”
26. Draw PIFC without any Stagnation on Part & Information : – Set Ideal time & volume; – Set Ideal time & volume; – Set the 4M (5W 2H investigation one by one ) ==>Clear to reason “why” to know the problems & set Milestone Priority
27. Lead Time Calculation of Ideal Condition
STEP – 9 GAP / PROBLEM ANALYSIS
28. To Compare “Before” and “Ideal” Condition 29. List Up Gap/Problem 30. Setting Priority of Problem to be Improved 31. Problem Analysis by 4M
STEP – 10 SET UP JISHUKEN TARGET
32. Decide Kaizen Direction Base on Priority for Each Process 33. Set Up Target Condition ==>Decide Control Point for : – Process Performance Target; – Result Performance Target
STEP – 11 MAKE PART & INFORMATION FLOW CHART (PIFC) “TARGET”
34. Draw PIFC Target : – Set the 4M (5W 2H Investigation) (Clear to reason “why”; Set time & volume for Milestone Target; Gap Analysis)
35. Decide What Supporting Tools Should be Made 36. Lead Time Calculation Base on Target
37. Get Supplier’s Top Management Commitment
STEP – 12 SET JISHUKEN GROUP & SCHEDULE
38. Decide Group Base on Necessity Kaizen To Be Done (Set Role & Responsibility of Each Member)
39. Decide Daily Schedule Activity & Follow Up System (Periodic Discussion with Supplier’s Top Management)
STEP – 13 KAIZEN ACTIVITY
40. Explanation & Nemawasi to Related Shop Floor to Get Request & Support (Self Introduction, explain the purpose & ask for request)
41. Data Processing & Temporary Tools Making
42. Self Simulation
43. Formal Tool Making
44. Make S/W, Supervisory Role & Abnormality Rule
STEP – 14 TRAINING & TRIAL
45. Conduct Training to Related Operator /Leader
46. Trial New System
47. Monitoring & Follow Up (Using Check Sheet)
STEP – 15 TRIAL RESULT EVALUATION
48. Analyze Actual Result vs Target / Standard * Grasp the 4M (5W 2H investigation)
49. Lead Time Calculation for achieved condition * Including reason & analysis : – Check fluctuation of Actual with Standard for Each Control Point; – Run This Step for Several Times; – Run This Step for Several Times; – Check Operator Walking, Motion and Feeling (eyesight, hearing, touch, smell, etc )
STEP – 16 MAKE STANDARDIZED WORK
50. Make Visualization Control for 4M
51. Set Supervisory Role
52. Daily Maintenance by Management Refer to Decided Control Item & Control Point
53. Stabilize the Daily Operation Management
STEP – 17 SET NEXT STEP KAIZEN TARGET
54. Yokoten the Success Story to others
55. Suggest Kaizen Recommendation to Supplier for Level Up Activity
56. Continue Remaining Kaizen

Written by jishuken

Januari 23, 2009 pada 8:34 am

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