Menampilkan postingan dari 2016


In Japan quality control (quality control = QC) or quality assurance (QA = quality assurance) is defined as the development, design, fabrication, and servicing of products that will satisfy the needs of consumers at the Lowest possible cost. Quality control starts with an independent examiner and methods of statistical demonstration soon turned to the method of “self-examination on all units” based on autonomous control against defects in fabrication process itself. Now in Japan, the number of surveillance is less than five percent of the employees of the factory and almost ten percent of all employees of the factory was the supervisor. In Japan, oversight by a special watchdog has been reduced to as little as possible for Several reasons: Trustees Whose activities are outside the fabrication process of conducting operations without value added. In addition, feedback from supervisors on the fabrication process usually takes a lot of time so that parts or defective products continue to

Things to Look For in a reduction of Labor.

In improvements reduce the number of workers on the line, Toyota eliminate wasted operations, reallocate operations, and reduce labor. Disappearance operation completely useless will result in the reallocation operation among workers in the workplace and a partial reduction of labor. Steps to consider reducing the number of workers with Define time for each worker and revise standard operating routine to get rid of it (reduction). To generate the operating manual repair or compensate for changes in production levels, there are three seal the document that must be considered : 1. The removal operations were futile. When the waiting time for each job being measured, he must stand without doing anything after completing terakhit operations assigned to it. With this, everyone will be able to see that he had time to spare, and there would be fewer obstacles if he is given one or two jobs anymore. 2. Reallocation operation. Reallocation conducted on workers A to E, then the waiting time for

The Statistical Quality Control ( SQC )

Statistical Quality Control derived from America in the 1930s as the industrial application of control chart designed by Dr. W.A. Shewhart . This chart was introduced in the Japanese industry after World War II , mostly as a result of roving lecture Dr. W.E. Deming in 1950 . Although statistical quality control is still an important technique in Japanese quality control system , this system also has some disadvantages : • In SQC , acceptable quality level ( AQL ) which determine the products that pass but with a minimum acceptable quality , set 0.5 % , or 1.0 % . The rate was not satisfactory from the standpoint of companies that try to achieve very high quality manufacturers , for example : the number of defects by one in a million . For example : the factory Toyota , quality control purposes is reached one hundred percent or units either zero defect numbers . The reason is simple : even Toyota can produce and sell millions of cars , individually , a customer will only buy one . If t


Itself form of a round-U is that the entrance and exit lines are in the same position. Spatial rotation U have some variation of ‘concave shapes and circles. The advantage of using this layout is its flexibility to increase or decrease the number of workers needed if you have to adjust to changes in the reduction of number of employees or the number of production. Timely production pull system can also be achieved in each process, a round shape U allows multiple regions or areas specifically developed for operation workers Spatial Improper Spatial was not right that avoided Toyota divided into three main categories: 1. Spatial birdhouse, spatial form is the simplest requires that the workers assigned on one type of machine. This spatial type is called spatial birdhouse because usually rhombic, rectangular and triangular 2. Spatial remote island, room layout is considered that there is a dual-function workers, and enable product flow continuously and smoothly between the various types o


Car manufacturing plant in Japan to deploy an industrial robot that is massive , with reasons such as : enhanced security , improved product quality and increased productivity at lower costs . At present , wages continue to rise and the cost of the most simple robot. In addition , the robot can be adapted to the increasing diversity of products than human labor because the robot requires fewer changes in the layout of the process when the design changes. As our technologies advance every year and decade, more students have been drawn to pursuing robotics as a career. If you have interest or have skills and wants to improve it further, check out Torcs’ robotics jobs site Robot and the Toyota Production System The impact of robotics at work relationship does not mean escape from the Toyota production system , but a logical development of that system . The main purpose of robotics , namely cost reduction , quality assurance , flexible production , and respect for humanity . Contributio


Quality control is a small group of workers who learn the concepts and techniques of quality control constantly and spontaneously to provide problem-solving in the workplace. In the Toyota plant, the main purpose of quality control activities is to promote a sense of responsibility of each worker / employee. Structure of quality control Quality control in the factory Toyota has a direct relationship with official organizations in the workplace, therefore all employees must participate in a number of quality control quality control there squad leader and subordinates. Supervisor or foreman section chief and each acts as an advisor. Each plant or division has a committee to promote its own quality control. In the Toyota plant, quality control activities supported by the person most responsible for each factory. There are numerous other benefits to a water softener that might appeal to a home or business. Namely, whole house water softeners can improve the longevity of your water-based ki


As defined in the regulations at Toyota’s plant, the Quality Assurance should be a quality product that it promotes satisfaction, reliability, and economy for consumers. These regulations outline describes the activities of each department of quality assurance at all stages from product planning to sales and service. Furthermore, the regulations say when and what should be guaranteed by whom and where.That rule is defined as when the eight steps that can be used in a series of business activities from planning to sales. Such steps, among others: 1. Planning products. 2. The design of the product. 3. Preparation of fabrication. 4. Purchase. 5. The designation for sale. 6. Examination. 7. Sales and service. 8. The quality audit. Terms whom and where a special dapartemen managers and department name. What, consisting of the goods are secured and operations for assurance and operations to guarantee it.

Promotion 5s System

Promotion 5s depend on top management decisions . When implementing continuous improvement processes such as 5s surely there will be members of management had any doubt about the success or failure of the process. They will say , ” How much productivity will be increased ? ” Or ” How many 5s will help increase the profitability for real?”. Before carrying out processes such as 5s , workers’ way of thinking and his attitude to work must be changed first . All member companies must have sufficient understanding of the true meaning and purpose , and they should integrate its understanding through seminars throughout the enterprise or workplace . Installation of several banners with slogans may be useful as well . For example : ” clean workplace created by the power of all the people ” , or ” there is no waste in the workplace clean ” , and others . Because 5s activities require long-term effort , the whole company needs to understand its purpose . Some members of management may assume tha


Steps to request materials at suppliers : 1. When looking at the empty box material out, then must press the button beside the line . 2. Turn on the lights just below the metal plate that shows the raw material. 3. At the same time , the red light will be lit warehouse bessar material . 4. Overseeing andon – material caller to see the metal plates that are on. 5. Bearer brought the box to the line and release Kanban supplier prior to the production line . 6. Kanban supplier was brought to the post to be checked and classified 7. Kanban supplier then sent to the supplier . Empty boxes already loaded on trucks . Metal plates for each type of material , is essentially a kind of decision- Kanban and Toyota did not mention these metals Kanban . Each box contains lines in addition to material suppliers Kanabn raw . Put the metal plate when the light is added to the file in order of sliding metal lamp. Then the carrier material will take the metal plate from the bottom berkaas and bring it

Rule Kanban

Kanban setting in need to achieve the target JIT Kanban , The following rules need to be done : Rule 1. Taking the necessary product of the process earlier in the necessary quantities when needed. Implementation of this rule, the company’s top management must be able to convince all workers and membuata critical decision to change the way the flow of production, transport, and delivery available. The following sub-rules will also accompany the regulation: • Every decision without Kanban should be banned. • Every decision that is greater than the number of Kanban should be banned. • Kanban must always be affixed on the physical product. Making the Kanban method, the method used for the transport of a variety of spare parts at a certain time with the travel system-around cargo–mix. Rule 2. Process strove to produce products in accordance with the amount taken by the next process. Implementation of these regulations to two balancing the timing of production among all processes. Therefore,


When the standard operation has been set by the supervisor, the supervisor should really be able to do surgery and then ordered his workers to carry out. Supervisor surgery should only be taught, but also explains the reason why the standards have to be maintained, which is standard operating objectives, it provides a stimulus for workers to be responsible for the quality of the product.. In order to ensure that workers or employees did understand these standards, made of two sheets of the key entry operation and operating instructions note the note distributed to the employees. Note the key operation , explained about the important things in all the operations in the standard operating routine, while the operating instructions note , describing the details of each operation on each line and also a method for checking the quality of the product. Both sheet records also contain data that is provided by the standard operation sheets. The sheets of the note are also installed at each proc


In Japanese , has a double meaning jidoka automation and autonomasi: 1) Automation is changing the manual process into a process engine . With this automation , the machine operates by itself when the switch has been pressed but do not have a feedback mechanism to detect errors and there is no means to stop the process in case of a malfunction. The automation of this type can cause a large number of defective parts if any damage to the engine , is deemed unsatisfactory. Go through for more about the HS automation. 2) Autonomasi or autonomation is disabled automatically control ( meaning taken from Toyota ) . To distinguish the two meanings it , Toyota jidoka often call this second type as jidoka ” Ninben -No- aru ” or literal translation , automation with human reason. Although autonomation often involve some type of automation , this will not limit the engine process . Autonomation can also be used in the operation manual. This is different from det


To decrease the time of preparation, first of all need to recognize the state of preparation work that is currently in the factory. Problems that can be encountered when working long setup / setup time that is very varied, among others: 1. Completion of preparation incoherently 2. The setup procedure is not done 3. The procedure was not adhered to in part properly. 4. Materials, Tools, and the mall is not prepared prior to commencement of operations setup. 5. Work attach and detach old. 6. The amount of height adjustment measures. 7. Work preparation has not been assessed properly. This problem can be remedied through the investigation every day and repeatedly check the state of preparation in the actual workplace. Examples of Daihatsu Industry following describes it (M. Greece 1990, T. Morimatsu 1988, and T. Soukura 1987). First of all, standard operating routine sheet for all processes in the printing section to be inspected. For example, processes and standard operating routine that


If making repair work, respect for humanity can be maintained by observing the following rules: Give workers a valuable job. Workforce reduction is sometimes seen as a way to force the workers to work hard without any humanitarian considerations. But this criticism is based on a misunderstanding of the nature of repair work or in case of using the wrong procedure. Interest improvement program is to increase the amount of net operating added with use values that can be done with the same amount of labor. Interest improvement work program is to eliminate unnecessary work like that and using that time to perform a clean operation with added value, so that the overall standard of operation time and the number of workers is reduced / less. If it is difficult to understand the Toyota production system would be difficult to implement, especially in an environment that the union is strong. In the factory Toyota, respect for humanity is a matter of human energy unification with useful and effec


Manual operation can be classified into three categories, among others: 1. Pure extravagance. unnecessary work that must be removed is the wait time, the buildup of the product, and multiple transfers. 2. Operation Without Added Value. Operations that are basically useless but may be required in the existing operating procedures, such as taking parts, opened the package from the seller, moving tools from one hand to another, etc. To get rid of it needs to be a change in the spatial lines or items of the seller delivered in a state without packaging. 3. Operations Net Increase the Value Added. Conversion or processing operations which increase the value of raw materials or semi-finished by adding a laborer namely subperakitan spare parts, placement of raw materials, materials pengerjakan gears, body painting work, etc. Net operating for value added merupaka small part of the overall operation, mostly only increase costs. By increasing the percentage of net operating to increase the valu


According to the Toyota production system, the engine room layout will be rearranged to smooth production flow. Each worker will hold three types of machines. For example: • one worker would hold a lathe. • one worker will be a grinding machine. • one worker will driller at the same time. This system is called the handling of multiple processes. In other words, workers single function, a concept that is used to apply the factory Toyota, now working as a double function. In a line of double-handling process, one worker to handle multiple machines of various processes one by one, in each work process will take place only when workers were completing the work assigned to it within the specified cycle. As a result, the entry of each unit into line unit offset by the completion of other end products, as ordered by the operation of a time cycle. Such production is called production and transport of one piece. It can provide the following advantages: • Since the product is created one by one,


In any fabrication there are two types of improvements are: Improvements in manual operations and improvements in machinery equipment . The first involves the definition of standard operation , the reallocation operation among workers , rearrangement , storage of spare parts and products , etc . The second improvement involves the use of new equipment for example robots and automated machines . In the factory Toyota repair manual operation is always done before mempebaiki completeness machine . The reason is : • From the point of utility costs , repair the engine may not be profitable . • Perubaan manual operation if necessary can be developed as an initial condition , while no machine equipment repairs . • Repairs to the machine perlangkapan often fail if done manually corrected before surgery . Promoting policies Jidoka Autonomy or ” Jidoka ” substantially improve machine equipment to reduce the number of workers . However , there are two issues to consider when applying Jidoka nam


How Kanban Supplier should have applied to the Supplier Kanban supplier has two steps, namely : 1. At 8 am , the driver of the truck sending Kanban supplier and empty boxes to the supplier. 2. Once kegudang , the driver handed over to the Kanban warehouse worker and immediately moved to the truck which already contains spare parts and Kanban , then diangkkut to Toyota . There are two things that should be noted , namely : a. Kanban supplier and supplier production time of reservation . Kanban number of suppliers who were taken to the warehouse is not always within their number of boxes taken back to Toyota . b. How do I use the truck for Kanban System : a three – truck system . One truck is being driven by the driver , other trucks are used to unload parts in Toyota , Other trucks laggi used to load parts in the warehouse . So the three workers involved in the loading and unloading simultaneously. The automotive industry is highly competitive and that’s why it is so important to

Classification of Costs Using ABC Classification

Classification / ABC analysis is the analysis of a group of items in descending order based on the cost of the item per period of time or the total cost.In general, ABC classification used in controlling inventories . Factors that determine the interests of an item : 1. Cost per unit item 2. The total value of money items 3. Sensitivity item to changes in design 4. The risk of theft of items 5. Difficulty obtaining items 6. Inventories item 7. The space required to store items 8. Availability of manpower , resources and facilities needed to make items 9. Lead time of ordering the first item until its arrival ABC analysis can be used to determine: 1. Cycle counting , that means more frequent item A test of the item B and C. 2. Engineering , meaning that items A and B provide guidance on the engineering section to find items that need to be focused . 3. Priority of purchase , meaning that the purchasing activity is focused on high -quality raw materials and users with a high amount . 4.

Understand The Basic Concepts Of The Continuous Cost Reduction Program

The Basic Concepts Of The Continuous Cost Reduction Program Continuous cost reduction program (CCRP) is a program that is structured systematically to improve the quality and productivity of the industry through the reduction or elimination of waste continuously for all activities involved in industrial systems. Chance or opportunity to develop continuous cost reduction program (CCRP) will vary from one company to another, depending on the specifics of the industry. However CCRP conceptually the same for all organizations , which largely depends on the commitment and innovative efforts of Management to reduce or eliminate waste components: Labor costs, material costs , energy costs , and other expenses ( expense costs , space requirements costs , etc). For our energy costs, we rely on electricity club to maintain our low energy costs. I and anyone who partnered up with electricity club recommend homeowners or buildings who uses amounts of electricity to try electricity club as they

The Concept Of The Golden Triangle

The Concept Of The Golden Triangle Golden triangle principle in dividing remedial efforts into three main areas , namely : 1. Wasteland is a foot or bottom of the triangle . 70 % investment of time ( or attempts ) only provides improvements (yield ) of 10 % . Unfortunately , this area is often gained major attention from managers industry as a consequence of the unplanned efforts. 2. Low yield is the center of the triangle . 20 % investment of time ( or effort ) to provide improvements (yield ) of 20 % . The third area of the triangle , this area is a work area that is most frustrating for industry managers , because managers want results a great improvement , but little that can be done . 3. Golden triangle is the top of the triangle , a 10 % investment of time ( or effort ) to provide improvements (yield ) of 70 % . Managers who have the knowledge and commitment to continuous improvement will focus attention on the work area ‘s golden triangle . In connection with the cost reduction


PROCEDURE FOR IMPROVED PREPARATION Four procedures to improve the preparation, among others: 1. Separating the internal setup of an external setup. To change the setup becomes eeksternal internal and external to reduce setup time, pehatikan the following things: a. Develop first mall, tooling, molding, and material. b. Maintaining the mold that is in good condition. c. Make a table to set up operations outside. d. Maintaining neatness storage area malls and prints that have been detached. 2. Repair Operations. The main points to the continuous improvement: a. Keeping the tool and mold storage area neat and organized. b. Monitoring the effects of changing a routine operation. c. Monitor the purposes of labor for each operation. d. Monitor the purposes of each operation. 3. Repair Tools Here’s how to do: a. Organize external setup and change the equipment so that various kinds of setup can be selected by pressing the zero key. b. Change the structure of equipment / utensils created so th

Categories Of Quality Costs

Categories of quality costs Basically, the cost of quality can be categorized into four types , namely : 1. Internal failure costs Represents costs associated with errors and non- conformance is found before handing it to the customer’s product. These costs will not appear if they are not found error or non- conformance in the product prior to shipment. Examples of internal failure costs are: • Scrap : the costs for labor , material , and usually the defective product that is economically irreparable . • Rework : Costs incurred to correct the error ( redo ) the product to meet the specifications defined. • Failure analysis : Costs incurred to analyze the failure of the product to determine the causes of failure. • Reinspection and retesting : costs incurred for re-inspection and re-testing products that have undergone rework or repair back . • Downgrading : the difference between the normal selling price and the reduced price for quality reasons. • Process avoidable losses : the costs


Toyota production system is a powerful method for making production since the system is an effective tool to generate the ultimate goal – profit . The main purpose : 1. Earnings Through Cost Reduction Cost reduction and productivity improvements achieved by removing waste. Types of waste in the fabrication operations : 1. Resource production too much 2. Excessive production 3. preparations too much 4. The capital investment unnecessary Costs in the Toyota production system not only cost fabrication , but also the cost of sales , administrative costs , and capital costs . Therefore, the expenditure of funds to make a profit in the past , present and future , which will be deducted from sales . 2. Removal Product Overload Four types of waste will also increase the cost admiistrasi , direct material costs , direct labor costs and indirect and overhead costs , for example depreciation etc . Workforce too much will cause the waste berikkutnya , the first action is very important that red

Understanding About Kanban System.

SYSTEM KANBAN Kanban is a card that is circulating in the plant of Toyota and has two types that can be used is Kanbab refund and ordering Kanban – production . Kanban returns detailing the amount that must be taken by the next process ,while the production Kanban – bookings indicate the amount to be produced by the process. Kanban system is an information system which harmoniously control the amount of production in each process . As a result , many processes in the plant will be interconnected so as to allow better control. Kanban system is supported by the following : 1. Launching production 2. Freezing jobs 3. Reduction of setup time 4. Activities repairs 5. The design layout engine 6. Autonomasi Function Kanban Kanban has two main functions , namely as production control and as a means of increasing production .Its function as a production control gained by bringing together the process and develop a system that is timely so that the raw materials , components or products