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Three 5s Activities Should be Mutually Supportive

5S last three terms are closely related. Seiso is the maintenance of cleanliness is always maintained at its plant. Seiso activity is highly dependent on the standardize Seiketsu cleaning and maintenance activities in the form of work instructions are easily followed by all employees. Shitsuke as the methods used to motivate employees to consistently carry out and participate in Seiketsu and Seiso activities. The three activities above should be supporting each other. Cleaning at a time are well preserved because there is an audit or inspection of the president. Every part of the company maintained in a clean condition. But these conditions only lasted a few days. After the echoes of the campaign was not heard from again, everything returns to normal.

Standardization Lines

Giving the line very effectively used to set limits because it would easily known by everyone just by looking at a glance. The line here will provide security to areas that are safe and dangerous. several examples can be described as below: The dividing line is drawn with white paint or vinyl tape path and the path divides the workplace, so the plant can be maintained high level of security. The lines were also used to indicate the location of the storage cart, product in process, malls, equipment and utensil cleaning.

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.

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.

Remove unused facilities

A lot of facilities in the production area and in the office, such as tables, chairs, computers, fan, hand machines, grinding machines, vacuum cleaners, Air conditioners, lamps and other lighting. Although the treatment is done regularly and properly scheduled, but the longer the treatment performance deteriorated and many were damaged. The problem that often happens is that the facilities are damaged and neglected due; – The extent of plant area so that the daily schedule for repairs are not possible. – Procurement of goods that require long time because it had to go through the procedure, starting from the approval of supervisors until the approval of the manager, and selecting suppliers of goods ordered in accordance

LIST OF UNNECESSARY STOCK

To give a complete report concerning the goods will be removed, it is necessary to recap the stocks of goods. Recapitulation aims to facilitate the reading of the overall stock which is not required and easy to pick what to do. The columns are made in unnecessary stock list includes: Department of Seiri activity, date created unnecessary stock list, the name of the items to be discarded / removed, the item code, quantity, unit costs, overall costs, which will be planned disposal areas, disposal whether the provisions are in accordance with the procedure or not, and references, then coupled with the total number of goods that are not needed and the value of disposal, as well as improvement actions and results.

RED TAGS STANDARD

The red tags are made in accordance with the information needs to be provided. This standard must be agreed by all members of the production, management and everything associated with the production process. Basic information that should be written is the product name, product type, quantity, lot size and the reason is removed. Making Red Tags for marking unused, the model can be varied and modified according to need. But most important are:

STEPS of RED TAGS PROJECT

Determination of the object to be on the label The object will be labeled must be known by all employees with the training and practice in advance directly at their respective working places. Goods / material that needs to be set and the labels are the stocks which includes materials, WIP, parts, semi-finished products and finished products. Machinery equipment include machinery, pallet, trains, malls, tooling, trolley, cutting tools, furniture, prints etc. Include floor space, aisle, shelf and warehouse.

RED TAGS PROJECT

Unused material will hamper production if allowed to accumulate in the production area. This buildup can lead to further waste, decreased productivity, decreased quality, delivery on time, workers’ mess around with piles of garbage and so forth. Therefore, the management must promptly take measures to anticipate the wastage in the company. Red Tags in the company often used to mark the wastage and show items that do not use during production and then throw it away. Labeling steps known as the Red Tags project

Seiri Visual Control

Gradually lean 5S of manufacturing should be indicated both visually and standard operational activities. Shown with the working procedures Activities to get rid of goods that are not needed should be indicated in writing in the work procedures to ensure employees follow these rules. Working procedures which are intended operation instruction, work operation and so on. Work instructions are installed in place that is easy to read. Can be installed above the work table, suspended above the machine so far does not interfere with engine operation

CONTINOUS REDUCTION OF COST USING LEAN-SIGMA TOOLS

1. Cost Reduction Through 5S or 6s The companies lean -sigma start a continuous improvement program is fundamentally through improved houses keeping Using the principles of 5S or 6 S to create and maintain a workplace that becomes a regular clean safe and has a high performance. 5S, allows anyone to separate conditions of normal and abnormal is the foundation for continuous improvement, zero defects , Reduction of costs and to create a safe working area and comfortable. 5S is also a systematic approach to improving the working environment, Processes and products by involving employees on the plant floor or (production line).