Line 5 Optimization

1. Wiji, Antonius (Prod. Supervisor/leader) 1. CP Tan - manufacturing Director Engineering

2. Sutejo, Dolly, Jonner (Engineer) 2. Hasril - Engineering Manager Production

3. Franky (Maintenance SPV) 3. Manorgang Purba - Production Manager Facility

4. Henry Manihuruk (Facility SPV) 4.

Problem statement: 1 Manpower balancing not optimized 1. Productivity Increased from 132% to 152%

1 Layout setup not follow process flow 2. UPPH Increased from 15pcs to 18 pcs/hr

2 Some operator are free, waiting order from

Line Leader3 Line is still follow traditional concept, clock

wise flow4 Layout setup not follow process flow

5 Productivity and UPPH not stable

no standard manpower allocation

6 High WIP in each process

7 Quality issue/skip process

2 Layout of the production line not follow process flow

3 Operator allocated based on the Highest WIP

4 Traditional/Batch Production

1 Inconsistent Productivity and UPPH

Productivity Average: 132% UPPH Average: 15pcs/hr Countermeasure Impact on target

1 Implement Production line U-Shape with Reduce material flow from 43 meters to 24 meters

counter clock wise process flow

2 Create 2 Main line and 1 Sub Assy Line Stable Productivity and UPPH/Reduce WIP

3 Line Balancing based on process cycle time Increase Productivity and UPPH

1 U Shape line with Counter clock wise flow reduce material flow from 43 to 24 M

2

2 Waste: Distance of the Material too high 3. Waste: Transportation time in the process

2 Line Balancing Reduce Manpower from 77 to 60 Operators for 2 shifts

1

1

2 2

3

4

U-Shape Line with counter clock wise flow

Improve Productivity with baseline 181% and Target 201 %

Set manpower allocation to 30 Operator per shift

Reduce Transportation time to 0%

Lean is a different way of looking at things.

Focus on the process, and WASTE in the

process, not the individual carrying out the

process

Need to Standardize all tables for

ergonomics position

2. Breakdown the problem

5. Develop Countermeasures

6. Implement Countermeasure

Transportation of Stripping jacket,Crimping

Bridge, & Crimping Ring con. Eliminated

from 0.9s to 0s

8. Standardise & Share Success

3. Set the Target

Team Leader (name & 'phone ext) Start date & planned duration

Roni 30 Nov 2016 - 30 Dec 2016

1. Clarify the problem 4. Analyse the Root Cause 7. Monitor Results & Process

A3 No. and Name Team members (name & role) Stakeholders (name & role) Department Organisation objective