Jishuken

Tetap Semangat !!!!! Pasti Bisa !!!!!!!

Jishuken Activities (Mar 16, 2009)

leave a comment »

STEP – 0 TRAINING (Approx. 1 week)
0.1. Evaluate TPS theory understanding & skill level of all Jishuken members (before training)
0.2. All members join training (Stop 6 Introduction, TPS Introduction, JIT, QAC, S/W, 17 STEPS)
0.3. Evaluate theory understanding of all Jishuken members (after training) & skill level (before Jishuken)
0.4. Based on evaluation result, set up target level up for each member (level up target should be step by step, do not jump to the high level)
STEP – 1 SAFETY ASSURANCE
All member must :
1.1 Confirm existing safety standardization. If not available, make temporary standard (adopt from TMMIN)
1.2 Do genba patrol to part theme line member (refer to step 2)
1.3 Check base on “STOP 6” to do risk management
1.4 Set the target (permanent / temporary C/M, rank down)
1.5 4M analysis (priority finding Rank A)
1.6 Making safety kaizen activity plan based on 4M
1.7 Do countermeasure (permanent or temporary) based on kaizen activity plan
1.8 Re-check the kaizen result (effect to QCDMPE)
1.9 Making new company standardization & visualization (discuss with Management linked to productivity & quality)
1.10 Socialization & training to shop floor & safety committee
STEP – 2 THEME SELECTION
2.1. Data searching / researching & analysis (Toyota affiliates Part) : – Search for Planning and Actual Data (monthly, daily) to see std vs actual of : Fluctuation Sales order; Fluctuation Production; Stock Level; (Defect ratio), Over Time, Space, etc. ; – To select Company’s most concern problems
2.2 Clarify the problems : – Breakdown Problem; – Clear to reason “Why” (std vs actual)
2.3 Discuss with Host Company and to related parties (host management, shop floor, & OMCD as consultant)
2.4 Theme selection and decision
STEP – 3 MAKE PART FLOW CHART (PFC) “BEFORE”
3.1. Make process flow table through genba genchi genbutsu
3.2 Grouping the Part which have the same flow
3.3 Make PFC “before” : – Add information for each machine / process : Line T.T, CT & MCT, Loading average, etc.; – Decide stagnation point & type; – Show each problems and decide the priority & area Kaizen, including parts, process, men that related to main line of part theme
STEP – 4 ARRANGE SMOOTH FLOW (SEIRYUKA)
4.1 Set Up Fix Part on Each Machine (temporary standard for material and machine)
4.2 Set Up PFC Target Image (as blueprint for STEP 10) : – Arrange smooth flow; – Decide store / sequence location
STEP – 5 MAKE PART & INFORMATION FLOW CHART (PIFC) “BEFORE”
5.1 Observe current condition / information : – 5W2H investigation one by one; – Timing (When) & Volume (How many) std vs actual (min ~ max) value –>Clear to reason “Why”
5.2 Show synchronize level at each process based on time & volume
5.3 Find out the problem
5.4 Lead time calculation
STEP – 6 MAKE PART & INFORMATION FLOW CHART (PIFC) “IDEAL”
6.1 Draw PIFC without any stagnation on part & information : – Define the standard using 5W2H; – Set ideal time & volume ==> Clear to reason “why”
6.2. Show synchronize level at each process based on time & volume
6.3. Lead time calculation of ideal condition
STEP – 7 GAP / PROBLEM ANALYSIS
7.1. To compare “Before” and “Ideal” condition
7.2. List up gap / problem for each point each process
7.3. Problem analysis of each 4M
7.4. Decide kaizen direction
STEP – 8 SET TEMPORARY STANDARD
8.1. Set temporary standard to synchronize (1st) volume & time (Material as based, Machine, Man, Method) : – From Push to Pull.; – 5W2H ==>clear to reason “Why” ; – Set time & volume for milestone target
8.2. List up confirmation item & confirmation point at each area
STEP – 9 CONFIRMATION TRIAL
9.1. Confirm temporary standard set up of “Pull” system to genba
9.2. Trial temporary standard & simulation (Self confirmation) ==> 3 or 4 times trial
9.3. Keep temporary standard running : – Make information method of “Pull system“ (time / volume). Use “temporary tools / method”
STEP – 10 MAKE PART & INFORMATION FLOW CHART (PIFC) “TARGET”
10.1. Draw PIFC target
10.2. Decide what supporting tools should be made
10.3. Show synchronize level at each process based on time & volume
10.4. Lead time calculation based on target
STEP – 11 SET UP JISHUKEN TARGET
11.1. Discuss with host management due to jishuken target, including resources needed (budget, man power, tools, etc.) plus its benefit
11.2. Decide kaizen direction based on priority for each process * Decide Control Point for : – Process performance target; – Result performance target
11.3. Get the commitment and same vision from top management
STEP – 12 SET JISHUKEN GROUP & SCHEDULE
12.1. Decide group base on necessity kaizen to be done (set role & responsibility of each member)
12.2. Decide daily schedule activity & follow up system (periodic discussion with supplier’s top management)
STEP – 13 KAIZEN ACTIVITY (1’st Trial)
13.1. Explanation & nemawasi to related shop floor to get request & support (self introduction, explain the purpose & ask for request)
13.2. Data processing & temporary tools making : – Always communicate with floor member in making tools
13.3. Self simulation
13.4. Revision / permanent tool making
13.5. Make S/W, supervisory role & abnormality rule
STEP – 14 TRAINING & STABILIZATION
14.1. Conduct training to related operator / leader : – Make sure that they are completely understand to perform as requested
14.2. Stabilizing new system : – Conduct trial for several times (min 3 times PDCA)
14.3. Monitoring & follow up (using check sheet) : – to see worksite member is has clear understanding and standards
STEP – 15 STABILIZATIONCONDITION EVALUATION
15.1. Analyze actual result vs target / standard : – Grasp the 4M (5W2H investigation); – Make sure 3 element of standardized work is available (T/T, work sequence, WIP)
15.2. 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 * Check operator walking, motion an feeling (eyesight, hearing, touch, smell, etc )
STEP – 16 MAKE STANDARDIZED OPERATION
16.1. Make visualization control for 4M. Final confirmation with operator
16.2. Set supervisory role
16.3. Daily maintenance by management refer to decided Control Item & Control Point
16.4. Stabilized the daily operation management : – Observe worksite operations is understand & perform daily operation based on standards
STEP – 17 SET NEXT STEP KAIZEN TARGET
17.1. Assess member skill level after OJD (Jishuken)
17.2. Yokoten the success story to others
17.3. Suggest kaizen recommendation to supplier for level up activity
17.4. Continue remaining kaizen (Safety, Productivity, Quality)

Written by jishuken

April 1, 2009 pada 6:32 am

Tinggalkan Balasan

Please log in using one of these methods to post your comment:

Logo WordPress.com

You are commenting using your WordPress.com account. Logout / Ubah )

Gambar Twitter

You are commenting using your Twitter account. Logout / Ubah )

Foto Facebook

You are commenting using your Facebook account. Logout / Ubah )

Foto Google+

You are commenting using your Google+ account. Logout / Ubah )

Connecting to %s

%d blogger menyukai ini: