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Manufacturing Waste in Storage Transfer

In certain cases, where in one plant has multiple products, and certainly at the plant have more than one warehouse. If the product is made has some similarities or sometimes almost the same raw material used also has the same characteristics. So frequent exchange of materials between warehouses with one warehouse to another. If one runs out it will be filled by the existing stock in warehouse to another. Transfers between warehouses is the one who will become a serious problem. Stock transfer as in in the principle of lean manufacturing must be minimized if possible eliminated because it would add to the burden of the company. Expenses for the time used for the transport process both labor and fuel used for transportation.

Manufacturing wastage will of Increase of Operating Fund

Expenses are very complex enterprise, ranging from raw material costs, production costs, maintenance costs, labor costs and others. With the manufacturing waste, the company will increase the cost burden. Therefore, all waste must be managed and removed from manufacturing. How big is the burden borne by stocking waste which occurs in the production. This is a variable that is difficult to quantify because it involves the habits, activities conducted daily. Savings derived from lean manufacturing activities and reduce waste may be calculated if the tangible gains and losses can be known.

Wasteful Carrying and Inspection

Stock is buried in the warehouse and in production indirectly slow the production process time and delivery processes. Wasted time include time spent removing, transporting and carrying of material / product from one place to another place and time required to conduct an inspection of the product in a state of over-capacity. Carrying Wasteful No we know the path that is used to transfer material from the initial material and products derived from container to be a finished product ready to be sent at the customer requires a distance of miles. Therefore, if there is accumulation of product in the warehouse or in production will add mileage to the customer’s product. Trimming this route part of lean manufacturing.

Wasteful Use of Space

As outlined in the concept of 5S, stockings wastage is also strongly influenced by conditions 5S inadequate, both in production and in the warehouse. In connection with stockings wastage place and space usage must be considered and resolved as effectively as possible. 5S management role is needed to settle this issue. Existing space must be arranged with due regard to: 1. Line in use, transportation and goods transportation in and out of the warehouse and in production 2. Settlement system that is easy to identify and capture the goods. 3. FIFO system should remain the reference in the queue system and arrangement of goods in the warehouse to facilitate the retrieval of goods. 4. If the production of material placement should not interfere with production activities

Remove All Stocking wastage

Stocking wastage in question is a stock that exceeds the capacity or an abnormal condition that is produced. Of course, not only the existing stock in the warehouse. But also all the stock which is still in process. All stock must strive to normal because if these conditions persist will lead to stability disrupted production. Moreover, to ensure proper management of stocks in the warehouse, NetSuite WMS offers inventory management capabilities and functionality to optimize your warehouse processes. Stocking wastage is not only material or product ready for sale but could be spare parts, tools and others. As described earlier in the warehouse stock issues should refer to the management fully based on the concept of 5S. And all the wastage that has to do with the stock must remove.

Excess Production will Advance Procurement of Materials and Parts

In the previous discussion stated that overproduction will lead to stock products abundant in the area of store that can cause uncontrolled 5S condition. Of course, not only that caused by excess production. Procurement is also affected by the production that is not balanced. Increased procurement would not want to do to replace the materials and parts that had already become a product. This is done to improve production efficiency to avoid waste in other lines. Lean manufacturing is like a pillar of the house. They mutually support one another. If there is one out of balance it must be corrected, or other elements relating will be damaged as well.

Strong commitment to promotion of 5S

Success of 5S promotion depends on top management decisions. 5S will succeed if driven directly from the directors, managers and other top management ranks. When the campaign begins with the spirit of lean manufacturing there is always a voice that doubts the success of this 5S. They’ll say, “How much productivity would be increased” or “How many 5S would help increase the real income” The way of thinking and attitude of workers towards 5S should be changed first. All member companies must have a sufficient understanding of the meaning and real purpose, so has the perception of equality of 5S and its purpose. All member companies must integrate their understanding through seminars, training throughout the company and the workplace. Installation of several banners with slogans can be useful too. For example: “a clean workplace created by the power of all people” or “No waste of workplace clean” and others.

Beware! Note storage Cutting Tools, Measuring and Oil

5S management (Seiton concept) in this business is absolutely necessary. How to store the tools that have a degree of risk both in terms of risk reduction in quality and risk of accidents. If you were hurt or a loved one died because of a crane accident, you will need an expert crane accident lawyer behind you to obtain the compensation you and your family needs to care for the injured. First, storage cutting tools such as drills, taps, grinding etc., shall be determined based on the frequency of the instrument used. If the tool was used on many machines for mass production, the most suitable is the system of production lines. On the other hand, if used greeting workshop situations, tools that must be saved by function. Second, because these devices usually lead to a sharp cutter, it is stored need to be considered carefully. Should be provided sufficient space between the ends pointed to protect and facilitate maintenance.

5S Management

Management is the art of managing, organizing, empowering, and watching gnats everything more efficient for a particular achievement. 5S management focused on setting up and implementation of 5S in a corporate environment, supported by all who are included in the company to achieve the level of organizational stability, productivity, quality and employee performance. 5S itself is the basic manufacturing activities that absolutely must be done by each company to improve productivity and efficiency in all lines of the company. 5S is not really a big job, which requires huge funds and resources, but the activities of individuals or groups regarding environmental management work for convenience in working. 5S has a tremendous impact for the creation of lean manufacturing that seeks to reduce waste in production processes.

Simplifying Tool as Simple as Possible

The question that often arises from a manager who handles lean manufacturing to the operation associated with the tool is “Can the tooling variation can be reduced?” The consideration is if possible reduced the time required to search tools, screwdrivers, wrenches can be reduced. The next question is “What is the variation in the screw tightening operations can be combined? So one tool can be used for a screw.

Quick and Easy in the Preparation of Materials

Prepare materials in manufacturing must get serious handling as it takes a long time. If this is not done improving the time in line then prepared materials manufacturing activities will be wasted just for materials handling. While the core of manufacturing activities is a product of the material to assemble into finished goods. The main duties of lean manufacturing is how to reduce the time needed to prepare materials that will be used for production To reduce the time in the handling of this material simply by applying existing 5S concepts , especially concepts Seiton. Even though in a split second in time can reduce, but it must be done.

FIFO PRINCIPLES

First-In First-Out in Seiton very important to load and prepare the correct WIP. The principle of First-In, First Out should be noted that the first goods that can be retrieved and placed first used as well. FIFO rule is preferred over other cargo, namely the Last-In, First-Out (LIFO), where new parts are stacked above the old parts. With LIFO, only new parts are used and which remain under the old and unused. This can potentially cause problems in quality control. When you load the stock with a forklift, the position of each pallet will be determined by the direction of the forklift. Therefore, if the pallets are placed in one direction as in the image palette can not be taken by the FIFO. Trajectory should be made to the carrier as shown in figure 2. Storage shelves should be wide and shallow like a chest of drawers, or has many entrances.

Implementation of the WIP

Seiri and Seiton typically applied to WIP. Toyota production system is specifically emphasized the importance of stock reduction. Improvement activities will run smoothly if everyone in the entire plant to feel the extravagance, interference or problems. These problems include excessive WIP stock, stock units and the defects that were obstructed by the interference machinery manufacturing processed next. Lean manufacturing will run as expected if the 5S management principles , especially the concept Seiton Seiri and applied to WIP management. In order for each operator to know the problems, standardized goods with plate placement instructions. Examples glance will enable anyone to easily know whether a certain item boxes are the proper place or not, or whether the boxes above the maximum.

Stock Control

Stock control in the production must be observed by all parties. Because if any one of the blank material, the production will not work. If production can not run the time wastage will occur. Lean manufacturing certainly will not be achieved. Therefore, various ways have done to keep the remains there is no excess stock or less. 5S management role here is emphasized to ensure adequate supply to remain available. Effectiveness of stock is very helpful to reduce waste time and waste WIP is the basic component for building a lean manufacturing are well preserved

Briefing Every Morning Before Work

Training and training, briefing and briefing. Achieving lean manufacturing through the 5S management will be accomplished if reminded of every time. To remind the concept, management and implementation of 5S done with training. Training is not only meeting in the classroom, but every time there is a job that requires training is always inserted 5s management and implementation. In addition, each morning meeting, each group containing the job briefing must start with the implementation of 5S. Do they fulfill the conditions of the workplace 5S standards that exist or not. Are all the members already understand the procedures of implementing the 5S workplace respectively. Everything should be responsible for maintaining controlled conditions.

Make Seiton as a Habit

To ensure lean manufacturing can be achieved through Seiton activities which include the separation of materials, placement of goods, the use of labels and lines of instructions to limit the maximum and minimum, then the most difficult step is to ensure the activities and conditions remain good. 5S is the foundation of manufacturing activity that is continuously being done by anyone who becomes a member of the company. Therefore the responsibility for maintenance and implementation of 5S activity should also be conducted jointly.

Codes and Amounts Labeling

Once positioned properly regulated, then the next step is to use a label showing the item code and amount. This code is important to facilitate the inventory of material. In a system inventory search process will be easier if there is code like this, because such codes are usually already contain the location, position and type of merchandise. For instructions amount to be determined maximum and minimum. To determine this amount to avoid the use of even numbers will be confusing. Remember that in lean manufacturing and 5s attempted any form of standard management visualized. For example, given a maximum size for a clear demarcation line and can be seen (not to be read). Similarly, the minimum threshold. If such numbers are limited by the minimum 20 pcs, will complicate the operator having to count existing material in the container. Very ineffective. But keep in mind that this code should also be made as simple as possible, so that could be easily understood by all operators.

Outstanding Material Must be Shown Clearly

Lean manufacturing 5S for container All goods must be identified quickly by all the member production. So that the addition, the space has been determined position and address where the goods in one space must be found quickly and accurately. The identity of the goods must be agreed by all member firms of up to service manager level. The room or place used for storing goods, should be managed appropriately, both in terms of the arrangement based on 5S standard. Nothing is considered waste in terms of lean manufacturing . A good placement will launch the service performance.

Minimize the Use of Space with Containers

Lean manufacturing is very concerned with the use of space as efficiently as possible. Any use of one square meter must be accounted for in terms of efficiency, usefulness and economic value. Containers, packaging materials are intended to make it more concise and easier in the arrangement. Containers can be easily stacked vertically and horizontally to fill the space effectively. The use of containers also facilitate the production operators to pick up and put the items accurately and quickly.

Placement of goods refer to the layout and efficiency

Each manufacturer has a different space, and they must arrange the layout of its space with the most efficient manner possible. Because the concept of lean manufacturing layout also affects the production work, especially the movement of goods and service production. The principle underlying the determination of the location of the goods to be stored is 1. Frequently used items placed around the work that is often used, making it easy to grab. 2. Other items that are rarely used is placed farther from the operator. However if space allows more laid dean of the operator. 3. These items should be easily accessible, placed between the shoulder and waist height workers.