Jishuken

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

Jishuken Purpose & Outputs Data (Mar 2, 2009)

leave a comment »

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
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. • Summary of risk finding (total & by area)
• To kick safety activity as a culture introducing STOP 6. • Safety Kaizen Activity Schedule
• As a problem solving practice before continuing next jishuken step (JIT,S/W,QAC) • New Company Safety Standard
STEP – 2 THEME SELECTION
• To get one representative part number as a model part for jishukenactivity 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 GenbaGenchiGenbutsu. • Part flow chart. : * Grouping part.; *Decide stagnation point.; * Information of machine / process (T.T., C.T., M.C.T., Loading ave., etc.).; * Priority jishuken kaizen area.; * Higlightedthe problem (part flow issue)
• To identify the stagnation point in production process which known as problem.
• 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; – PQ Chart for new part flow
• To know the needed of store to each line or process
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 (Maximum 1 week 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 jishukentarget 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 jishukentarget as a milestone to ideal condition during jishukenperiod • 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 jishukenteam 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 vstarget) Confirmation Sheet (A3) : – Fluctuation Data; – Monitoring tools; – Stabilization Condition
STEP – 15 STABILIZATION CONDITION EVALUATION
• To evaluate trial/stabilization activity result at worksite (actual vs target) • Evaluation result (actual vs target) : 5W2H; • Kaizen ideas implementation : – 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 • Activity Planning of Remaining Kaizen activity
• To Maintain visualization control to established daily operation management • Next STEP Kaizen Target

Written by jishuken

Maret 13, 2009 pada 9:18 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: