Master Approach Sdn.

Bhd

LEAN PRODUCTION SYSTEM (LPS)

06TH SEPT 2011

WHAT IS LPS ?
LPS is about doing more with less:

Time Inventory Space Labor Cost

LPS CONCEPT

5S Standard Operation 7 Wastes Control Suggestion System Visual Control Defect Detection Total Preventive Maintenance (TPM)

LPS CONCEPT
2 Pillars of LPS

Method
1) Process Flow Small lot size 1-piece flow Machine layout Streamline of production Setup time improvement Standardized work KANBAN
Stop after completion

JIT
2) Takt time Prodn Reduce Leadtime

3) Pull Production 1) Work segregation (Man/MC) 2) Defect Prevention

Man Utilization

JIDOKA
Stop at abnormality

Quality built-in process

WHAT IS JUST-IN-TIME (JIT) ? Inventory control method which uses Pull Production System to eliminate waste of: Raw Material
Work-In-Progress (WIP) Finished-Goods

Purpose of JIT is to:

Produce product to meet demand, not to surplus or in advance of need.

Humanized Automation or Awareness to : WHAT IS JIDOKA (AUTONOMATION)?

Detect Abnormalities & Product Defect Detect Process Malfunction Alert Operator of Defect STOP if Defect is detected Seek Permanent Action by Checking Root Cause

Purpose of JIDOKA is to:

Detect defect immediately and correct it accordingly.

LPS ROAD MAP

The LPS improvement which jumps over this step is impossible.

SUMMARY OF 5S DEFINITION
Japanese Term
Seiri

English Equivalent Meaning in Japanese Context

Sorting Throw away all rubbish and unrelated materials in the workplace Set everything in proper place for quick retrieval and storage Clean the workplace; everyone should be a janitor Standardize the way of maintaining cleanliness Practice 'Five S' daily - make it a way of life; this also means 'commitment'

Seiton
Seiso Seiketsu Shitsuke

Setting in order
Systematic Cleaning Standardization Self-Discipline

LPS IMPLEMENTATION (STEP I)

Practice of 2S + 1S
Seiton
(Setting in Order)

Seiri
(Sorting)

Seiso
(Systematic cleaning)

Safety Seikets u
(Standardizing)

Shitsuk e
(Self-discipline)

SEIRI (SORTING)

Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and so forth in the plant and work area. Keep only essential items and eliminate what is not required, prioritizing things per requirements and keeping them in easily-accessible places. Everything else is stored or discarded

SEIRI (SORTING)
IDENTIFY CATEGOR Y OF ITEM REQUIRE D? N ISSUE RED TAG Y LABEL ITEM & STORAGE AREA

KEEP IN TEMPORAR Y STORAGE

DISPOSITI ON WITHIN 30 DAYS

RECORD ITEM

SEIRI (SORTING)
SORTING GUIDELINE:Things

used frequently - Keep at the workplace/on the person. Things used infrequently - Keep far away. Things used sometimes - store at workplace. Things not used - Discard. Things used to be kept for just-in-case - keep as contingency items

There should be a place for everything and everything should be in its place. The place for each item should be clearly labeled. Items should be arranged in a manner that promotes efficient work flow, with equipment used most often being the most easily accessible. Workers should not have to bend repetitively to access materials. Each tool, part, supply, or piece of equipment should be kept close to where it will be used in other words, straightening the flow path. Seiton is one of the features that distinguishes 5S from "standardized cleanup".

SEITON (SETTING IN ORDER)

SEIRI (SORTING)
TOOLS ARRANGEMENT

SAFETY
Safety at minimum should ensure all Personal Protective Equipment (PPE) is in place for operators. Evidence of periodic check on PPE condition and usage must be displayed. Briefing operators on importance of using PPE for their own safety must be conducted.

RULES AND REGULATION

GUIDELINE :Entry and Exit Attire Requirement Working Hour Replacement of operator Cleanliness / Housekeeping Facility Maintenance Schedule Parameter Checking Food and Drink Authorized Personnel

VISUAL CONTROL
Visual control are means, devices, or mechanisms that are designed to manage or control the operations (processes) so as to meet the following purposes:
Make

the problems, abnormalities, or deviation from standards visible to everyone and thus corrective action can be taken immediately, Display the operating or progress status in an easy to see format. Provide instruction. Convey information. Provide immediate feedback to people.

VISUAL CONTROL APPLICATION

Color-coded

pipes, wires or marking at gauges to display

control level. Painted floor areas for good stock, scrap, trash, etc. Shadow boards for parts and tools. Indicator lights . Workgroup display boards with charts, metrics, procedures, etc. Production status boards. Direction of flow indicators

EDUCATION AND TRAINING

Establish

Standard Operating Procedure Review Operator Skill Chart Adequacy Establish Operator Training Process Flow Establish Operator Training Record Review manpower requirement

TIMELINE TO EXIT STEP 1

N o 1 2 Activity Implement 2S + 1S Rules and Regulation Leader KN Lee Hanif Tajul Zairol Hanif Tajul Zairol
05/0 9 12/0 9 19/0 9 26/0 9 03/ 10 10/ 10 17/1 0 24/ 10 31/1 0

Visual Control Board

4
5 6

Training Material Setup

Operator Training Exit Step 1

Zambri Zubri
Zambri Zubri -

REQUIREMENT FROM LEADERS

Establish

Team Provide activity detail and timeline Guide and drive Team to achieve result Provide weekly update to committee

COMMITTEE TEAM

TEAM MEMBER

TEAM 1

TEAM 2

TEAM 3

TEAM 4

OPERATION CODE NAME

IMAPS
Improving Master Approach Production System

CRITERIA TO SUCCEED
Team commitment to accomplish goal and timeline High spirit of team work to support each other Good communication and feedback on progress Support from top management Never give-up spirit

PRIORITIZATION OF WORK
Name
KN Lee

Immediate
1. Setup raw part preparation line to 600pcs/day capacity 2. Define jobscope of Executive, Supervisor and leader 3. Transfer quality checking process to production 1. 2. 3. 1. 2. 3. 4. 5. 6. 1. 2. 3. Manage hourly output achievement Change position of Persona-E spoiler Mold #1 Machine and equipment maintenance schedule Oven temperature stabilization Parameter control setup for paint supply Paint mixing room document setup Manage hourly output achievement Manpower issue Establish maintenance plan Color matching activity 2 hourly meeting on quality Spray booth outstanding fabrication issue

Permanent
1. 2. 5S activity plant wide Re-layout Block C to meet LPS concept

Hanif

1. 2. 1. 2.

Initiate rules and regulation for Blk C Visual control implementation at shopfloor Initiate rules and regulation for Blk C Visual control implementation at shopfloor

Tajul

Zainal

1.

Problem solving for top 2 defect

PRIORITIZATION OF WORK
Name
Mike

Immediate
1. Setup flow of supply from Blk C to Blk B

Permanent

Zubri

1.

Transfer assembly and rework line from Blk A to Blk B

1. 2. 3.

Establish SOP Training operator Cycletime improvement