Jishuken

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Jishuken Purpose & Outputs Data (Mar 16, 2009)

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Purpose: Outputs Data :
STEP – 0 TRAINING (Approx. 1 week)
• To Improve members* that will be participating in Jishuken activity, on TPS understanding * Member that understand basic understanding of TPS/experienced in Jishuken (Mid. Level) • Theoretical understanding (before & after Training) & skill level (skill mapping before Jishuken)
• To set up level up target for each member • Level-up target of each member
• Jishuken organization structure
STEP – 1 SAFETY ASSURANCE
• To assure safety issue during Jishuken activity==> Zero Accident • STOP 6 Risk Mapping
• As an basic education to increase safety awareness • Safety kaizen activity schedule
• To kick safety activity as a culture introducing STOP 6 • Summary of risk finding (total & by area)
• As a problem solving practice before continuing next jishuken step (JIT,S/W,QAC) • New company safety standard
• Revised of related standard work sheet (if any)
• New control item & control point
STEP – 2 THEME SELECTION
• To get one representative part number as a model part for jishuken activity from the most JIT problem production line or process for cost reduction purpose • One part number as part theme * High contribution for C/R possibility
• Company Mondai / Komatteru Koto as NEEDS to run jishuken
STEP – 3 MAKE PART FLOW CHART (PFC) “BEFORE”
• To get complete image of part flow and its complexity through Genba Genchi Genbutsu • Part flow chart : * Grouping part * Stagnation point & type * Information of machine / process (T.T., C.T., M.C.T., Loading average, etc.) * Priority jishuken kaizen area * Higlighted the problem (part flow issue)
• To identify the stagnation point & type in production process which known as problem • PQ chart each machine / process
• To decide priority kaizen area
STEP – 4 ARRANGE SMOOTH FLOW (SEIRYUKA)
• To set the condition where the part flow is smooth, fix to each machine. ==> Easier for implement JIT • Part Flow Chart Seiryuka target (image) *Loading capacity *Decide stagnation point type
• To know the needed of store to each line or process • PQ Chart for new part flow
STEP – 5 MAKE PART & INFORMATION FLOW CHART (PIFC) “BEFORE”
• To get the complete image of part & information flow and its current synchronize JIT level • PIFC before * Show the synchronize level for “before” condition * Highlighted the problem.
• To identify the stagnation point (timing & volume) in production process (from warehouse to shipping area) • Lead time number (LT information, LT conveyance, LT process, LT stagnation)
STEP – 6 MAKE PART & INFORMATION FLOW CHART (PIFC) “IDEAL”
• To imagine the condition where part & information is flowing without stagnation, and as a direction for kaizen target • PIFC Ideal *Define the standard each area by 5W2H *Show the synchronize level for “ideal” condition
• Lead time number (LT information, LT conveyance, LT process, LT stagnation)
STEP – 7 GAP / PROBLEM ANALYSIS
• To get the problem (the difference / gap between “before” and “ideal” condition) • Gap Analysis A3 Form *All 4M *Measurable
• Kaizen direction
STEP – 8 SET TEMPORARY STANDARD
• To determine settle condition (Part & Information) for Material, Machine, Man, Method, including timing & volume, and aimed to Pull System with high JIT level at each process • Design of Temporary standard (5W2H) for target condition, including timing & volume of each process
• List up all confirmation item & confirmation point
STEP – 9 CONFIRMATION TRIAL
• To confirm the possibility of temporary standard implementation (if needed) that already set up in STEP 8 to current condition • Final temporary standard (possible to implement) for target condition
STEP – 10 MAKE PART & INFORMATION FLOW CHART (PIFC) “TARGET”
• To clarify the part and information flow as a target based on jishuken target set on Step 7, including the new system, tools, or methods • PIFC target *Summary of all standard each area by 5W2H *Show the synchronized level for “target” condition
• Lead time number (LT information, LT conveyance, LT process, LT stagnation)
STEP – 11 SET UP JISHUKEN TARGET
• Grasp the final jishuken target as a milestone to ideal condition during jishuken period • Jishuken kaizen area
• To get the commitment and same vision toward the jishuken target from top management • Commitment from host management
STEP – 12 SET JISHUKEN GROUP & SCHEDULE
• To establish fix & clear PIC as a jishuken team member and being committed by top management (approved by signature) • Jishuken structure organization (for STEP 13~17)
• To get clear activity plan to achieve the jishuken target • Jishuken kaizen activity plan
STEP – 13 KAIZEN ACTIVITY (1’st Trial)
• To implement & 1’st trial of kaizen ideas to actual worksite (making temporary/permanent tools) • Temporary/permanent tools
• To develop Control Item/Point for daily management operation • Self simulation result – Fluctuation Condition -Visualization control for daily management (control item/point)
STEP – 14 TRAINING & STABILIZATION
• To conduct training of implemented Kaizen ideas (Self simulation) to related operator & leaders • Training schedule
• To Stabilizing implemented Kaizen ideas to make work site more comfortable through created Control Item & Point • Trial result (actual vs target) ==>Confirmation Sheet (A3) -Fluctuation Data -Monitoring tools -Stabilization Condition
STEP – 15 STABILIZATIONCONDITION EVALUATION
• To evaluate trial/stabilization activity result at worksite • Evaluation result (actual vs target)  5W2H
(actual vs target)  refer STEP 12 • Kaizen ideas implementation result (stabilization condition) -Image of stabilized kaizen idea – 7 STEP Kaizen S/W usage
• Lead time calculation
STEP – 16 MAKE STANDARDIZED OPERATION
• To make develop standardized production based on stabilization activity result (previous STEP) formal standards & standardized work for operation management • Standardized Operations of : -Standardized work -Visualization control (Item/Point) -management item/point
• To make visualization & Management of Control Item & Point (per shift, daily, weekly, monthly) • Kaizen summary
• Daily management schedule
STEP – 17 SET NEXT STEP KAIZEN TARGET
• To make activity planning for un-implemented kaizen idea & next STEP Kaizen • Member skill level assessment result
• To Maintain visualization control to established daily operation management • Activity Planning of Remaining Kaizen activity
• Next STEP Kaizen Target

Written by jishuken

April 1, 2009 pada 6:36 am

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