TEAM 2QUICK CHANGEOVERCOMPUTER STITCHING
Project start: : April 07th, 2011Final Update : June 15th, 2011
Team Member :M. TAUFIK Bubuh BRian F ImasEason Zhang Desi
CONTENTSTeam MemberTeam 2 OverviewActivities ScheduleProcess Flow ChartTime Observation and Bar ChartSet Up Change over chartSeparate Internal - External time analysisCurrent Status and Change over time target5Why Analysis worksheetShift Internal to External ActivitiesIdea to Streamline Internal and External ActivitiesImplementation ScheduleImplementation Result
QCO Overview
Team2 : To Reduce Changeover of computer stitching
Current SituationIt was take long time to change the mold every time model change is happen
Current QCO timeBased on data collected on April 07th, 2011 total CO time is 416 Seconds
Target
To reduce change over time to 208 seconds on April 14th, 2011 and 146 seconds on June 7th, 2011
Project Team 2
To reduce computer stitching change over by eliminate wasteObjective
Meeting and implementation on work floor every 3 days from 03.00 to 04.00 pmAttendees : All team member plus PIC of improvement area
Meeting Overview
ScheduleNo Description
April May June
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 311 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
1 Training QCO
2 Computerize
3 Select Changeover process on work floor
4 Prepare Implementation
5 2nd QCO Implementation
6 Analysis and make step improvement
7 Idea Implementation to reduce COT
8 Create new change over procedure
9 Prepare QCO implementation
10Make Improvement step
11Implement 3rd QCO
12Wrap Up and Documentation
13Wrap Up and Documentation
132nd Phase observation
Baseline Analysis Process Flow Chart C/O
2nd Analysis Process Flow Chart C/O
3rd Analysis Process Flow Chart C/O
Team 2
Change Over Time Observation Sheet (Baseline)
Team 2
Change Over Time Observation Sheet (2nd)
Team 2
Change Over Time Observation Sheet (3rd)
Additional facts during CO observation Difficult to call mechanic, Mechanic is not stand by in Workplace
Pemanggilan Mekanik Terlalu lama karena mekanik tidak stand by ditempat
Waiting for mechanic to come
Menunggu Mekanik Datang
No SOP for CO Process
Tidak Ada SOP Untuk CO Proses
Must Install the Program if the program not been saved in Computer
Pergantian program bila data belum tersimpan di komputer
The Last Process can’t run, Mold not available enough in tool box
Proses Sebelumnya terhambat, Mold tidak tersedia
2 size of mold for all footwear size
2 Ukuran Mold Untuk semua Size
Limited skill of mechanic
Mekanik dengan skill terbatas
Mechanic Tools is not complete
Tooling/Alat Mekanik tidak lengkap
Mold Sparepart not complete
Sparepart Mold tidak lengkap
Take a long time to do Pattern Cutting
Cutting Pola Pada Saat COT memakan Waktu Lama
If program available, so you just adjust and set the machine
Jika program sudah ada tinggal set mesin saja
Cutter dull/ no available stock
Pisau Kurang tajam/Stock tidak Ada
Matarial waste when do thread cutting
pemotongan benang yang terlalu panjang
No stock for material testing
Material Untuk Test tidak tersedia
No available Qc to Check mold result and material test
QC Tidak Ada untuk check hasil dari ganti mold dan test bahan
Machanic and Operator not wearing Safety tool while working
Mekanik dan Operator tidak memakai APD (earplug)
Workplace not set in order
Workplace tidak tertata rapi (not Set In Order)
If necessary color thread change must be done if there’s any different color
Pergantian Warna benang perlu dilakukan jika warna beda
Machine maintenance is not well May happen any rework
Perawatan mesin yang kurang baik, memungkinkan terjadinya rework
Takes a long time to set computer program because limited mechanic skill
Untuk set program memekan waktu lama karena skill mekanik terbatas
Takes a long time to change the mold because more rework happen
Pergantian mold Memakan waktu lama karena berkali kali rework
No SOP to set computer program
SOP Untuk Set Mesin/program tidak ada
Take s a long time to cementing because out of glue
Proses lem sangat lama karena lem habis
Machine test necessary when CO is done
Test Kinerja mesin ketika CO sudah selesai
Changeover improvement wall chart
Team2
Improvement Steps Separate Internal - External time analysis
Current Status and Change over time target
5Why Analysis worksheet
Shift Internal to External Activities
Idea to Streamline Internal and External Activities
Implementation Schedule
Implementation Result
QCO Analysis Internal – External time
Project Elements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TotalTotal COT
Improvement (%)
Baseline 04/07/201
1 (1st QCO)
Internal Time
60 4 10 10 53 31 6
64 27
265
416 Baseline
External ime
45 3 42 31 12 13
5 151
04/14/201
1 (2nd QCO)
Internal Time
4
3 20 17 2
10 2
10 68
211 49%External ime 54
57 12
10
10
143
06/10/2011 (3rd QCO)
Internal Time
2 3 15 17 2 7 2 7 55
173 58%External ime 24 49 13 13 19 118
Team1
Current Status and Change Over Target
Baseline : 416 “Target 2 : 211”Achievement : 173”
Actual Graph
QCO Analysis 5W1H
Improvement (Brain Storming)
Kaizen Idea for Streamline Internal Time
Provide Schedule before CO, Make Sure all team ready for COSiapkan Schedule QCO, agar semua pihak terlibat bisa siap
(Eason Zhang 04/07/2011)QCO/0407/I/1
Do Intensive Maintenance for machine.Lakukan perawatan mesin lebih intensif sehingga tidak mengganggu proses kerja
(Rian F 04/07/2011)QCO/0407/I/2
Provide Mold, Pattern, and tooling before COMempersiapkan Mold, pattern dan Tooling terlebih dahulu sebelum CO
(Rian F 04/07/2011)QCO/0407/I/3
QC must stand by to check the Quality of COQC harus ada untuk memastikan kualitas ganti mold
(taufik 04/07/2011)
Do Programmable Training To mechanic Lakukan Training program pada mekanik
(Imas 04/07/2011)
Improvement (Brain Storming) Kaizen Idea for Streamline Internal Time
QCO/0407/E/6
QCO/0407/E/8
Provide SOP for COT procedure Sediakan SOP untuk prosedure COT Mesin
(Desi 04/07/2011)QCO/0407/E/1
Provide SOP for COT procedure Sediakan SOP untuk prosedure COT Mesin
(Desi 04/07/2011)QCO/0407/E/2
Use the right tools to attach the mold Pakailah tooling yang tepat untuk memasang mold
(Rian F 07/04/2011)QCO/0407/E/3
Provide Mold box based on style / model Sediakan tempat penyimpanan mold sesuai dengan style / model
(Bubuh 04/07/2011)QCO/0407/E/4
Do 6S TrainingLakukan training 6S
(Taufik 04/07/2011)QCO/0407/E/5
Save program setting on the disk, No reset program if there is a model changeSave settingan program pada disk sehingga tidak perlu setting ulang ketika ada pergantian model
(Eason 04/07/2011)QCO/0407/E/7
Provide Material for Stitching TestMaterial buat test harus disiapkan lebih dahulu
(Bubuh 04/07/2011)QCO/0407/E/9
4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011
Team2
Idea Implementation Schedule
Select & Record Element of CO
Shift Internal to External Activities
All crew that responsible for QCO gathering before COT (CI, QC,Operator, mechanic)
Prepare tools with much stock and make sure tools is compatible
Prepare mold and Pattern before COT
Make Improvement Step
2nd Element & time record
3rd Element & time record
Team2
Idea Implementation Schedule
Team2
Idea Implementation GalleryPropose : Provide Mold, Pattern, and tooling before COAttendance : Team 2 and MechanicIdea Linked : QCO/0407/I/3Idea Owner : Rian FLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Provide the right tools and mold for the next CO
04/21/2011
Propose : Use the right tools to attach the mold Attendance : Team 2 and MechanicIdea Linked : QCO/0407/E/3Idea Owner : RianLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Preparation for next CO
04/21/2011
Propose : Provide Mold box based on style / model Attendance : Team 2 and MechanicIdea Linked : QCO/0407/E/4Idea Owner : BubuhLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Mold box is already but still mix with tooling04/21/2011
Team2
Idea Implementation GalleryPropose : Save program setting on the disk, No reset program if
there is a model changeAttendance : Team 2 and MechanicIdea Linked : QCO/0407/E/7Idea Owner : Rian FLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : they provide 2 different disk for different machine04/21/2011
Propose : DO 6S trainingAttendance : B5 CL and WSIdea Linked : QCO/0407/E/5Idea Owner : TaufikLocation : PYI 2nd Floor Meeting room Date/Time : April 14th , 2011 (10:00 – 11:30) Description : Introduce 6S
04/12/2011
Propose : Provide Material For Stitching TestAttendance : Team 2 and MechanicIdea Linked : QCO/0407/E/9Idea Owner : BubuhLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Provide material for stitching test for next CO04/21/2011
Team2
Idea Implementation GalleryPropose : Implement 2nd QCOAttendance : Team 2, Mechanic , QIP and local supervisorDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Implement 2nd QCO
Propose : Attach and Socialize QCO SOP for Current ProjectAttendance : Team 2 , Mechanic, QIP, Local SupervisorIdea Owner : Team 2Location : Production lineDate/Time : June 1st , 2011 (09.00– 09.37) Description : Socialize and Attach SOP for QCO
Propose : Socialize QCO Preparation ChecklistAttendance : Team 2 and Local SupervisorIdea Owner : Team 2Location : Production lineDate/Time : June 1st , 2011 (13.12– 13.23) Description : Socialize and Attach SOP for QCO
04/21/2011
06/01/2011
06/01/2011
Team2
Idea Implementation GalleryPropose : Implement 3rd QCOAttendance : Team 2, Mechanic , QIP and local supervisorDate/Time : June 11th , 2011 (13:08 – 13:26) Description : Implement 3rd QCO
06/11/2011
Team2
Idea Implementation GalleryPropose : Make Process SOPMaker : Team 2Description : Make Qco SOP Process Remark : Version 2 (Standardize)
Team2
Idea Implementation Gallery
Propose : Make Setting Machine SOPMaker : Team 2Description : Make Setting Machine SOPRemark : Version 1
QCO Preparation Checklist
Date :
QCO Process :
line :
QCO Team
No Item Person Check Remark
1 TPM Mechanic 2
2 QIP 1
3 line Supervisor 1
4 CI&IE Team 1
1
Tools
No Item QTY Check Remark
1 Mechanic Tools 1
2 Mold (same as CO model) 1
3 Pattern (insole board) 3
4 Scissor 1
5 Double tape 1
6 Test Material 3
7 Stopwatch 1
8 Camera 1
9 Observation Sheet 1
10 Ballpoint 2
11 QCO SOP 1
Approved by, Checked by,
name name
Propose : Make Preparation Check ListMaker : Team 2Description : Make Preparation Check ListRemark : Version
Team2
Idea Implementation Gallery
Team 2
SOP Before – AfterSeq.
NumberChangeover Element
1Calling Mechanic Memanggil Mekanik
2Take Tooling Ambil Tooling
3Pattern Measurement Mengukur Pola
4Cutting Pattern Memotong Pola
5Cementing Pattern Lem Pola
6Cementing again (rework) Rework Lem
7Attaching Pattern Memasang Pola
8Open Mold Buka Mold
9Saving Mold Simpan Mold
10Attaching New mold Pasang mold baru
11Setting the Program Setting Program
12Pattern test Test Pola
13Stitching test Test Jahit
14Cutting Pattern Memotong Pola
15Attaching Thread Pasang Benang
16Material Test Test Bahan
Seq. Number Changeover Element
1Open Mold Buka Mold
2Saving Mold Simpan Mold
3Attaching New mold Pasang mold baru
4Setting the Program Setting Program
5Cutting Thread Memotong Benang
6Attaching New Thread Memasang Benang Baru
7Attaching Bobbin Memasang Sekoci
8Take Test Material Ambil Material Test
9Stitching Test Test Jahit
10QC Check Periksa Kualitas
11Saving Tested Material Simpan bahan hasil test
12Stitching Material Test Jahit
13QC Check Periksa Kualitas
Total CO TimeBaseline : 416”2nd QCO : 211”Final : 173”
Team 2
Process Change Over Time Recorded & Analysis
Se
con
d
April 7th April 14th June 11th
Baseline : 416 “Target 2 : 211”Final : 173”
Team 2
Streamline External Time Implementation Schedule
4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011
Select & Record Element of CO
Shift Internal to External Activities
All crew that responsible for QCO gathering before COT (CI, QC,Operator, mechanic)
Prepare tools with much stock and make sure tools is compatible
Prepare mold and Pattern before COT
Make Improvement Step
2nd Element & time record
3rd Element & time record
Done Not Done
4/7/2011 4/13/2011 4/14/2011 4/23/2011 4/24/2011
Select & Record Element of CO
Shift Internal to External Activities