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MM2100 Industrial Estate
Block NN8-1, West Cikarang,
Bekasi 17520, Indonesia
Total Associate : 650 persons
Cycle Time Down in Door Mirror Line By
Process Balancing.
PT. ABC
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We are produce and delivered above
products to PT. HPM
Product Introduction
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ThemeCycle Time Down in Door Mirror Line By
Process Balancing.
Circle NamePT. ABC
Company
Name
Introductionof members
MEMBER :
Dewi AnggrainiKartika .AY
Siti Maria
Oden RudiyanaRiana Melasari
Introduction of Circle
Section : Assy 4R Members 4 persons Age Avg 23 years With high professionalism,good performance would have
created a high productivity
Circle Introduction
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step
.
.
.
.
.
.
.
.
5 8 7
STANDARDIZATION
NEXT THEME
A C T I V I T Y
CURRENT CONDITION
ANALYZE & SET A
TARGET
ANALYSIS OF KEY
FACTORS
IMPROVEMENT PLAN
IMPROVEMENT
ACTION
DECIDE A THEME
2 3 4
IMPROVEMENTEVALUATION
2009 QCC Activity Schedule
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Step 1 : Decide the Theme
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ONE YEAR POLICY
To Be No. 1 QCD in All Honda Lock Group Area in 2010.
To Build High Income Institution by Reduce Inefficient Process.
CIRCLE THEME
Cycle Time Down in Door Mirror
Line By Process Balancing
DEPARTMENT ACTIVITY PLAN Development & Reduce Inefficient Process
- Target Value : 15 % Up
Step 1 : Decide the Theme
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
Total Cycle Time :
339.94 sec
Nut
Insert
Packing
& Stopper
Assy
Visual
Check
& Setting
Handle
Pin &
Spring
Insrting
Pin
Caulking
Weight
Counter
Caulking
Final
Inspect
Total Cycle Time :
105.76 sec
Flow Process Assembly Door Mirror
Flow Process Assembly Out Handle
RAW
MATERIAL
PAINTING
PROCESS
ASSEMBLY
PROCESS
WARE HOUSE
FINISH GOODS
Step 1 : Decide the Theme
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Our Team Product are Door Mirror and Out Handle and
Cycle Time Performance for Both Products is Shown below:
Product
Cycle Time
Current StandardCurrent vs
Standard%
DOOR MIRROR
339.34 273.65 + 65.69 24.01%
OUT HANDLE
105.76 96.5 + 9.26 9.6%
Note: Cycle Time is time needs to make one Finished Goods
Step 1 : Decide the Theme
THE VARIANCE OF DOOR MIRROR CYCLE TIME
STANDARD IS HIGHER THAN OUT HANDLE
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
DOOR MIRROR Line Graphic CYCLE TIME
0
10
20
30
40
50
60
CycleTime(Second
)
Current 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97
Standard 22.9 25.4 24.9 24.0 23.9 21.6 24.9 30.0 25.5 25.9 24.6
Bracket
Tightening
Turn Light
Tightening
Inner Base
Ass y
Base Comp
Ass y
Seat Base
Comp Assy
Mirror
Group Ass y
Function
Check
Mirror
Perform
Check
Tapping &
Cord Dim
Scull Cap
Assy
FI &
Packing
Step 1 : Decide the Theme
From Graphic above Shown That Cycle Time Process are not Balance yet
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Step 2 : Current ConditionAnalyze & Set a Target
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Door Mirror Line Graphic Cycle Time
56.6
0
10
20
30
40
50
60
C/T 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97
Bracket
Tightening
Turn Light
Tightening
Inner Base
Assy
Base
Comp
Assy
Seat Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Perform
Check
Tapping &
Cord Dim
Scull Cap
Assy
FI &
Packing
Man Power (MP) 11
Capacity/Man (Cap/Man) 5.78
Production/day 457 pcs/Day
Effective Time 7.2 Hours
Rate Operation (RO) 90 %
Sec
Month : Februari 2009
Tact
Time
Inefficient Cycle Time
Step 2 : Current Condition Analyze &Set a Target
Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Bracket
Tighten
Bracket
Tighten
Turn
Light
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Inner
Base
Assy
Base
Comp
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Mirror
Group
Assy
Function
Check
Function
Check
Mirror
Check
Preform
Mirror
Check
Preform
Tapping
& Cord
Dimention
Tapping
& Cord
Dimention
Skull
Cap
Assy
Skull
Cap
Assy
Final
Inspect
& Packing
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.9731.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Cycle Time Analyze
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Man Power Understanding AnalyzeItem Review Analyze Evaluation
Evaluator: Mr Andi (Section Head)
1. Production Quality
Control (PQC)
Understanding
2. NG Part Sample Limit
Understanding
3. Process Flow of Part
to Finished Good
Understanding 0
1
2
3
4
Dewi
Mela
Icha
Kartika
Oden
TrisnoTri
Vivih
Ema
Ani
Sri
STANDARD
ACTUAL
Analyze Skill Map Poin:
1. Understood Process
2. Identify Abnormal Process Ability
3. Able to Teach New Operator
4. Able to Make Improvement
1
23
4
There are no man power factor which can affected to
inefficient cycle time.
Step 2 : Current Condition Analyze &Set a Target
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Part NameDrawing
Number
Qty/
Bucket
Plastic
Cover
Weight
> 7 kgLoss Time Effect
TF0-000 SCREW TAPPING INSIDE HANDLE (2AP TF0-E0003-0000 500 NO NO
TF0-000 SEAT R,BASE TF0-E0401-0000 200 NO NO
SNB-000 SCREW TAPPING TRUSS 4X14 (2AP) SNB-E0509-0000-D 500 NO NO
TF0-020 COVER R,BASE TF0-E042F-0200 250 NO NO
TF0-000 SEAL B TF0-E040A-0000 1000 NO NO
TF0-000 BASE R,INNER TF0-E0421-0000 30 NO NO
SFA-000 SCREW WASH M5X12 (2AP) SFA-E0503-0000 30 NO NO
TF0-020 HOUSING R TF0-E0311-0200 10 YES NOLoss Time 3.55 Sec to
Remove Plastic
TF0-000 BOLT STUD M6 TF0-E0109-0000 1000 NO NO
TF0-000 MIRROR GROUP R,R1400 (D/M) TF0-E0100-0000 80 YES YESLoss Time 2,58 Sec to
Remove Plastic
SFA-000 SEAL A (2AP) SFA-E0408-0000 1000 NO NO
90106-003 SCREW TAPPING TRUSS 4X12 (2AP) 90106-S70-0030 500 NO NO
TF0-020 BASE R,OUTER TF0-E0423-0200 40 YES NOLoss Time 3.48 Sec to
Remove Plastic
TF0-000 BRACKET SUB ASSY RH-R,A/T S/T TF0-E2300-0000 10 NO NO
90109-003 SCREW TAPPING TRUSS 4X16 (2AP) 90109-S70-0030 500 NO NO
There are 3 Materials that affect to cycle time Directly.
Material AnalyzeStep 2 : Current Condition Analyze &Set a Target
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All Parts are Received
by Warehouse
QC check 100% Parts
withremove plastic
cover one by one
After Checked the Part re-
cover again and put in to
bucket.
WHP QC INCOMING WHP AF
PLASTIC HOUSING
30 x 25 CMPLASTIC MIROR
20 x 25 CM
PLASTIC OUTER BASE
12 x 25 CM
Plastic after used in assembly:
waste
Lost time occured while after checked QC Covering the part again
Door Mirror Parts Flow (Housing, Outer Base, Mirror) AnalyzeStep 2 : Current Condition Analyze &Set a Target
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
SeatBase
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Bracket Tigtening Process 31.87
1. Take a Housing 1.47
2. Open Housing Cover 3.55
3. Put into Jig 1.25
4. Assy Bracket to Housing 6.45
5. Hand Togle Down 1.39
6. Bottom screw tightening 6.21
7. Re-set hand togle position 1.10
8. Inside screw tightening 8.52
9. Take and transfer 1.93
Base Inner Tightening 24.33
1. Put into Jig 1.74
2. Take a Base Outer 1.49
3. Open Base Outer Cover 2.58
4. Put Base Outer to Jig 3.97
5. Base Inner Assy 3.25
6. Screw Tightening 8.36
7. Take and Transfer 2.94
Mirror Group Assy 19.09
1. Put into Jig 1.60
2. Date Stamp 4.84
3. Take a Mirror 1.32
4. Open Mirror Cover 3.48
5. Setting a Mirror 2.97
6. Curve Check 1.91
7. Take and Transfer 2.97
Process of removing plastic cover are in process no: 1, 3 and 6
Line Process which affected by plastic cover AnalyzeStep 2 : Current Condition Analyze &Set a Target
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4M+1E
ANALYZEITEM VERIFICATION GEMBA JUDGE
MAN
Understanding of
Production Quality Control
( PQC ) is Weak
Operator understood PQC
Step1 April 2009
Understanding of Part NG
Sample Limit is Weak
Operator understood about
Part NG Sample Limit1 April 2009
Understanding of process
flow part to goods is weak
Operator understood about
Part Process Flow to Goods1 April 2009
MACHINE Line Lay out is long There are 11 Process 2 April 2009 X
MATERIALPacking standart is not
good2 April 2009 X
METHODEThere are idle time in some
process
Cycle Time Graphic is not
Balance Yet2 April 2009 X
ENVIRONTMENT - - -
Part Covered by plastic andStandar Packing is heavy
= OK (is Not Problem Factor) X = Problem Factor
4M + 1E AnalyzeStep 2 : Current Condition Analyze &Set a Target
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DOOR MIRROR Line Graphic CYCLE TIME
0
10
20
30
40
50
60
CycleTime(Seco
nd)
Current 31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.6 37.58 27.4 33.97
Standard & Target 22.9 25.4 24.9 24.0 23.9 21.6 24.9 30.0 25.5 25.9 24.6
Bracket
Tightening
Turn Light
Tightening
Inner Base
Assy
Base
Comp
Assy
Seat Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Perform
Check
Tapping &
Cord Dim
Scull Cap
Assy
FI &
Packing
Current
C/T :339.34
Standard &
Target
C/T :
273.65
CYCLE TIME DOWN TARGET
339.34273.65
0
50
100
150
200
250
300
350400
Before Target
Second
Step 2 : Current Condition Analyze &Set a Target
TargetDown 19.35%
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POINT OF REVIEW PARAMETER BEFORE TARGET
Q Keep Zero Claim ZERO CLAIM Zero Claim Zero Claim
C Reduce Loss Cost ProcessReduce Cycle
Time339,34 second 273,65 Second
D Level up in Support Deliveryto Customer.
Production
Capacity is
Stabil
10.075Pcs/Month
10.075Pcs/Month
SReduce risk of accident by
reducing packing standard.
Reduce Weight
of Packing
Standard
Weight =
19,26Kg
63.6% of
Weight Down
=> 7 Kg*)
M Optimize Job DescriptionOperator
Reduce quantityMP
11 Man 7 Man
EReduce Waste of Production
Process
Re-Use of
Plastic Cover
Material
Become Waste
Re-Use in
Another
Process
*) Female Operator Canno t Lift Up Buc ket Over Than 7 Kg
Step 2 : Current Condition Analyze &Set a Target
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Step 3 : Analysis of Key Factors
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Need 11
manpower
Unbalance
d
Process
MACHINE MATERIAL
ENVIRONMENT METHODE MAN
D/M Line is
Not yet
Efficient.
Ineficient
Process
There are
Some idle
time
packingStandard are
not good
Packing
heavy
Part
Covered by
plastic
No packing
standartLine Setting
Not Good
No Problem
Factor
No Problem
Factor
Cycle
Time
is
High
Step 3 : Analysis of Key Factors
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Step 4 : Improvement Plan
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FACTOR PROBLEMIMPROVEMENT
PLANHOW PIC SCHEDULE
MATERIAL
PART COVERED
WITH PLASTIC
PLASTIC COVER
CHANGE TO
PARTITION CHANGESTANDARD
PACKING
DM ASSY-
QC-PE
MEI JUN
2009
STANDART
PACKING
HEAVY
REDUCE WEIGHT
STANDARD
DM ASSY-
QC-PC
MEI JUN
2009
METHODUNBALANCED
PROCESS
REDUCE LOSS TIME
PROCESS PROCESS
BALANCING
DM ASSY-
PE
JUN AUG
2009
MACHINE
DOOR MIRROR
LINE PROCESSNEED 11 MAN
POWER
MODIFICATION LINELAYOUT
DM ASSY-PE
JUN AUG2009
Step 4 : Improvement Plan
St 4 I t Pl (St d d P ki Ch )
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PART
NAMEBEFORE
PACKING CHANGE
PLANDIMENTION Reason
HOUSING
(4,24 Kg)
10 Pcs
Partision Size :
= 200 mm X 110 mm X 300mmPartision Material : Sponge
Bucket Capacity : 10 Pcs
Weight: 4,8 Kg
Construction : 1 Level (5 Row 2 Column) 1. Partition is
Strong and
easy to
Construct
2. More
Effective to
Prevent
Scratch
3. Caneliminate loss
time of plastic
removal
BASE
OUTER
(6,56 Kg)
40 Pcs
Partision Size := 200 mm X 55 mm x 150 mm
Partision Material : Sponge
Bucket Capacity : 20 Pcs
Weight: 3,28 Kg
Construction : 1 Level (10 Row 2
Column)
MIRROR
(19,26 Kg)
80 Pcs
Partision Size :
= 15 mm X 225 mm x 150mm
Partision Material : Sponge
Bucket Capacity : 30 Pcs
Weight: 6,76 Kg
Construction : 1 Level (15 Row 2Column)
580
mm
400 mm
580
mm
400 mm
300
mm
450 mm
Step 4 : Improvement Plan (Standard Packing Change)
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0
10
20
30
40
50
60
Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
1 2 3 4
Process Merger Plan is Based on Low cycle time process
Step 4 : Improvement Plan (Process Balancing)
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Step 5 : Improvement Action
St 5 I t A ti (P ki Ch )
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PART NAME BEFORE AFTER STANDARD PACKINGIMPROVEMENT
REVIEW
HOUSING
Before:
Cover PlastickQuantity 10 pcs (4.24 Kg)
After :
Cover PartitionQuantity 10 pcs (4.8 Kg)
QC JUDGE:Packing can
prevent scratch
NG
Cost:
Rp 7,600,000.-
BASE
OUTER
Before :Cover Plastic
Quantity 40 pcs (6.56 Kg)
After :
Cover PartitionQuantity 20 pcs (3.28Kg)
MIRROR
Before :
Cover Plastic
Quantity 80 pcs (19.26 Kg)
After :
Cover PartitionQuantity 30 pcs (6.76Kg)
Step 5 : Improvement Action (Packing Change)
St 5 I t A ti (P ki Ch Eff t)
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Bracket Tigtening Process Before After
1. Take a Housing 1.47 1.47
2. Open Housing Cover 3.55 -
3. Put into Jig 1.25 1.25
4. Assy Bracket to Housing 6.45 6.45
5. Hand Togle Down 1.39 1.39
6. Bottom screw tightening 6.21 6.21
7. Re-set hand togle position 1.10 1.10
8. Inside screw tightening 8.52 8.52
9. Take and transfer 1.93 1.93
TOTAL 31.87 28.32
Base Inner Tightening Before After
1. Put into Jig 1.74 1.74
2. Take a Base Outer 1.49 1.49
3. Open Base Outer Cover 2.58 -
4. Put Base Outer to Jig 3.97 3.97
5. Base Inner Assy 3.25 3.25
6. Screw Tightening 8.36 8.36
7. Take and Transfer 2.94 2.94
TOTAL 24.33 21.75
Mirror Group Assy Before After
1. Put into Jig 1.60 1.60
2. Date Stamp 4.84 4.84
3. Take a Mirror 1.32 1.32
4. Open Mirror Cover 3.48 -
5. Setting a Mirror 2.97 2.97
6. Curve Check 1.91 1.91
7. Take and Transfer 2.97 2.97
TOTAL 19.09 16.61
Process of removing plastic cover are in process no: 1, 3 and 6
Down 11.14%
Down 10.6% Down 18.23%
Step 5 : Improvement Action (Packing Change Effect)
Step 5 : Improvement Action (Packing Change Effect)
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PLASTIC HOUSING
30 x 25 CM
PLASTIC MIROR
20 x 25 CM
PLASTIC OUTER BASE
12 x 25 CM
Plastic after used :
Re-use Plastic to Cover
J09 Key Set (2R)
Product : Motorcycle Part
Type : J09 Key Set Customer : Honda Thailand Packing Condition : Covered by Plastic
to Prevent Scratch
Plastic Source : Supplier
Step 5 : Improvement Action (Packing Change Effect)
Visibilities Studies to Re-Use Plastic Cover
St 5 I t A ti (B l i P )
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Turn Light Tightening 25.811. Light Assy 10.21
2. Screw & Marking 11.47
3. Take and Transfer 4.13
Base Inner Tightening 24.331. Put into Jig 1.74
2. Take a Base Outer 1.49
3. Open Base Outer Cover 2.58
4. Put Base Outer to Jig 3.97
5. Base Inner Assy 3.25
6. Screw Tightening 8.36
7. Take and Transfer 2.94
Turn
Light
Tighten
Inner
Base
Assy
25.81 24.33
Before merger
Turn Light & Inner Base Tightening 41.69
1. Light Assy 10.21
2. Screw & Marking 11.47
3. Take and Transfer eliminated
4. Put into Jig eliminated
5. Take a Base Outer 1.49
6. Open Base Outer Cover eliminated
7. Put Base Outer to Jig 3.97
8. Base Inner Assy 3.25
9. Screw Tightening 8.36
10. Take and Transfer 2.94
After merger process and
Step 5 : Improvement Action (Balancing Process)
St 5 I t A ti (P M difi ti )
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Step 5 : Improvement Action (Process Modification)
1. Modify Jig Light & Inner Tightening 2. Relay out Working Table
Base Inner Tightening Jig Turn Light Tightening Jig
Light Inner Tightening Jig
There are 2 jigs in Turn Ligh & Base Inner Tightening
(A/T & R/C) Process:
Special for A/T Type
Turn Ligh Tightening Jig added with Base Inner &
Base Outer Tightening Jig
For R/C Type, Base Inner Tigh Jig is not modified
Set Turn Ligh and Bases Inner Driver Move:
Driver(Turn Ligh) Cannt reach ScrewFeeder 4x12 and Base Inner Location
Driver(Base Inner) Cannt Reach Screw
Feeder 4x14 & Turn Ligh Location
St 5 I t A ti (P M difi ti )
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Step 5 : Improvement Action (Process Modification)
Eliminate Idle Working Table
Turn Light
Tightening
Process Table is
disposed,andnext process
move a head.
So
The Linebecome Shortly.
St 5 I t A ti (B l i P )
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Base Comp Assy 58.591. Put into Jig 3.43
2. Base Comp Join 5.84
3. Screw Tightening 16.68
4. Cover Base Assy 5.83
5. Take and Transfer 3.97
Seat Base Comp Assy 12.561. Put into Jig 2.5
2. Seat Base Assy 7.78
3. Take and Transfer 2.28
Before merger
Base Comp & Seat BaseAssy 41.69
1. Put into Jig 3.43
2. Base Comp Join 5.84
3. Screw Tightening 16.68
4. Cover Base Assy 5.83
5. Take a Base Outer -
6. Put into Jig -
7. Seat Base Assy 7.78
8. Take and Transfer 2.28
After merger process and
Base
Comp
Assy
Seat
Base
Comp
Assy
35.75 12.56
Seat Base Assy Process move into Base Comb Tightening Proess
to Stabilize Cycle Time.
To joining Seat
Base Assy
Process into Base
Comb Tightening
Process needs &
Seat Base Assy
needs to re-lay out
working table anddispose Seat Base
Comp Assy Table.
Step 5 : Improvement Action (Balancing Process)
St 5 I t A ti (P M difi ti )
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Base Comp Tight &
Seat Base Comp
Assy
Step 5 : Improvement Action (Process Modification)
Re-Layout Seat Base Assy Process
1. Seat Base Comp Assy Table is Eliminated
2. Base Comp Tightening Process Move to Seat Base
Position.
3. Buffer Table is Added in Base Comp Tightening Table .
St 5 I t A ti (B l i P )
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Mirror Group Assy 10.771. Put into Jig 1.60
2. Date Stamp -
3. Take a Mirror 1.32
4. Open Mirror Cover -
5. Setting a Mirror 2.97
6. Curve Check 1.91
7. Take and Transfer 2.97
Before merger
Bracket Tightening 40.811. Take a Housing 1.47
2. Open Housing Cover eliminated
3. Put into Jig 1.25
4. Assy Bracket to Housing 6.45
5. Hand Togle Down 1.39
6. Bottom screw tightening 6.21
7. Re-set hand togle position 1.10
8. Inside screw tightening 8.52
9. Date Stamp 7.84
10. Take and Transfer 1.93
11. Stamp & Caulking Check 4.65
After (movement process)
To Stabilize Process, Stamp Date Process is moved toBracket Tightening Process.
Mirror
Group
Assy
19.09
Moved to
Bracket
Tightening
Process
Step 5 : Improvement Action (Balancing Process)
Step 5 : Improvement Action (Balancing Process)
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Mirror Group Assy 10.771. Put into Jig 1.60
2. Date Stamp
3. Take a Mirror 1.32
4. Open Mirror Cover -
5. Setting a Mirror 2.97
6. Curve Check 1.91
7. Take and Transfer 2.97
Function Check 34.381. Put into Jig 3.73
2. Cord Assy 6.11
3. Push Button 19.64
4. Take, Mark & Transfer 4.90
Before merger
Function Check 45.151. Put into Jig 1.60
2. Date Stamp
3. Take a Mirror 1.32
4. Open Mirror Cover eliminated
5. Setting a Mirror 2.97
6. Curve Check 1.91
7. Take and Transfer 2.97
8. Put into Jig 3.73
9. Cord Assy 6.11
10. Push Button 19.64
11. Take, Mark & Transfer 4.90
After merger process andJoin to No1 process
Mirror
Group
Assy
Function
Check
19.09 34.38
Join to No1 process CheckFunction
Process
is Joined
to Mirror
Group
Assy
Process
Step 5 : Improvement Action (Balancing Process)
Step 5 : Improvement Action (Balancing Process)
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Mirror Check Preform 56.601. Put into Jig 3.5
2. Cord Assy 4.15
3. Push Button 3.64
4. Check M/C Preform 39.67
5. Take, Mark & Transfer 5.64
Tapping & Cord Dim 37.581. Put into Jig 2.3
2. Test Cord Length 5.25
3. Seal A Assy 4.65
4. Tapping 13.32
5. Gap Check 4.17
6. Bending Check 4.2
7. Take & Tansfer 3.69
Before merger
Mirror Assy andCheck Preform
54.75
1. Put into Jig 3.5
2. Cord Assy eliminated
3. Push Button 3.64
4. Check M/C Preform 39.67
5. Take, Mark & Transfer 5.64
6. Put into Jig 2.3
7. Test Cord Length eliminated
8. Seal A Assy eliminated
9. Tapping eliminated
10. Gap Check eliminated
11. Bending Check eliminated
12. Take & Tansfer eliminated
After merger process and
Mirror
Check
Preform
Tapping
& Cord
Dimention
56.60 37.58
Move Seal AJig,
Tapping
In This Joining
Process, Checker
Machine iddle Time
is Used to do Next
Process.
Step 5 : Improvement Action (Balancing Process)
Step 5 : Improvement Action (Balancing Process)
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Bracket
Tighten
Turn
Light
Tighten
Inner
Base
Assy
Base
Comp
Assy
Seat
Base
Comp
Assy
Mirror
Group
Assy
Function
Check
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
31.87 25.81 24.33 35.75 12.56 19.09 34.38 56.60 37.58 27.40 33.97
Skull Cap Assy 27.401. Put into Jig 3.13
2. Take a Skull & Visual Check 8.98
3. Skull Assy 7.56
4. Gap Check 3.86
5. Take & Transfer 3.87
Tapping & Cord Dim 33.971. Part Completeness Check 5.21
2. Apperance Check 3.56
3. Mirror Check & Wash 4.23
4. Visual Check 9.47
5. Mirror Assy Shake 2.21
6. Take a miramat Bag 2.01
7. Put in 2.94
8. Bag Close 1.38
9. Place to Bucket 2.96
Before merger
Tapping & Cord Dim 48.031. Put into Jig 3.13
2. Take a Skull & Visual Check 8.98
3. Skull Assy 7.56
4. Gap Check 3.86
5. Take & Transfer eliminated
6. Part Completeness Check 5.21
7. Apperance Check 3.56
8. Mirror Check & Wash 4.23
9. Visual Check eliminated
10. Mirror Assy Shake 2.21
11. Take a miramat Bag 2.01
12. Put in 2.94
13. Bag Close 1.38
14. Place to Bucket 2.96
After merger process and
Skull
Cap
Assy
Final
Inspect
& Packing
27.40 33.97
Skull CapAssy is
Joined in to
FI & Packing
Process.
Step 5 : Improvement Action (Balancing Process)
Step 5 : Improvement Action (Merger Process Effect)
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PROCESSBEFOREMERGER
(in second)
AFTERMERGER
(in second)
CYCLE TIME
VARIANCEREMARKS REVIEW
Bracket Tightening 31.87 40.81 Up 8.94 Additional ProcessFrom No
Cost =
Rp 16,073,400Turn Light Tightening 25.81
41.69 Down 8.45
Inner Base Assy 24.33 Base Comp Assy 35.75
43.53 Down 4.78Cycle Time
Before
= 339.34 Second
Seat BaseComp Assy
12.56
Mirror Group Assy 19.0945.15 Down 8.32 Function Check 34.38
Cycle Time After= 273.96 Second
Mirror Check Preform 56.6054.75 Down 39.43 Tapping & Cord
Dimention37.58
Skull Cap Assy 27.448.03 Down 13.34Final Inspect &
Packing33.97
T O T A L 339.34 273.96 Down 65.38 (19.26%)
Step 5 : Improvement Action (Merger Process Effect)
Step 5 : Improvement Action (Visual Check)
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Gomi
Benang
Spit/Gumpalan Cat
Sagging
Orange Peel
Cat Tipis
Fading/Un matching colour pada posisi tertentu
Matching NG/beda warna
Gelombang Scrath
Bari
Gelombang
Weld
Shape/berubah bentuk, tumpul
PAINTING
MATERIAL
Before NG Material, Painting and NG Process Items is re-check inFinal Inspection Assembly (D/M & O/H)
After Final Inspection Check only For Assy Process NG Item ,
ex: Scrath
Step 5 : Improvement Action (Visual Check)
Visual Check Item Determination
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Step 6 : Improvement Evaluation
Step 6 : Improvement Evaluation
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Part after check is Packed
in to Bucket with PartitionAll Parts are Received
by Warehouse
QC check 100% Parts
and Remove Plastic
Cover
Part Processed in
Assembly.
All Parts are Received
by Warehouse
QC check 100% Parts
withremove plastic
cover one by one
After Checked the Part re-
cover again and put in to
bucket.
Operator remove cover
again in line before
process
WHP QC INCOMINGWHP AF
WHP QC INCOMING WHP AF
After
Before
Lost Time of Remove Plastic Cover in Assembly is eliminated.
Step 6 : Improvement Evaluation
New Flow Material Receiving
Step 6 : Improvement Evaluation
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PLASTIC HOUSING
30 x 25 CM
PLASTIC MIROR
20 x 25 CM
PLASTIC OUTER BASE
12 x 25 CM
Plastic after used :
waste
After
Before
PLASTIC HOUSING
30 x 25 CM
PLASTIC MIROR
20 x 25 CM
PLASTIC OUTER BASE
12 x 25 CM
Plastic after used :
J09 Key Set
Step 6 : Improvement Evaluation
Step 6 : Improvement Evaluation
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Step 6 : Improvement Evaluation
Item Before After Before vs After
MP Quantity 11 persons 6 persons 5 personsLabour Cost Rp. 13.200.000 Rp. 7.200.000 Rp. 6.000.000
Invest
ment
Partion - Rp. 7.600.000Rp. 23.673.400
Re-Layout - Rp. 16.073.400BEP
= 4 month
C/T (sec)TactTime
(sec)MP RO
Cap/Man
(hr)
Cap/Day
(7.2hrs)
Cap/
Month
Before 339.34 56.60 11 90% 5.78 458 10.075
After 273.96 54.75 6 90% 10.78 473 10.415
Before vs
After
Down
19.2%
Down
3.26%
Down 5
persons-
Up
86.6%Up 3.2% Up 3.2%
Break Event Point Analyze
Production Capacity Analyze
Total Investment for This Improvement is Rp. 23.673.400. And It Will
Reach BEP for 4 Months with Cost Down/Month is Rp. 6.000.000.
Step 6 : Improvement Evaluation
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POINT OF REVIEW PARAMETER BEFORE TARGET RESULTEVALUA
TION
Q Keep Zero Claim NGPROCESS
Zero Claim Zero Claim Zero Claim C
Reduce Loss Cost
Process Cycle Time
339,34
second
273,65
Second
273,96
Second D Level up inSupport Delivery
to Customer.
ProductionCapacity is
Stabil
10.075Pcs/Month
10.075Pcs/Month
10.415Pcs/Month
(Up 3.37%)
S
Reduce risk of
accident by
reducing packing
standard.
Weight of
Packing
Standard
Weight =
19,26Kg
63.6% of
Weight
Down => 7
Kg
30 Pcs =
6,76 Kg M
Optimize Job
Description
Operator
MP 11 Man 7 Man 6 Man E
Reduce Waste of
Production
Process
Re-Use of
Plastic Cover
Material
Become
Waste
Re-Use in
Another
Process
J09 Key
Set
Packing
Step 6 : Improvement Evaluation
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Step 7 : Standardization
Step 7 : Standardization
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Step 7 : Standardization
MP TACT TIME CAP/MAN CAP/DAY RO
6 54.75 10.95 pcs 473 pcs 90%
Bracket
Tighten
Turn
Light
& BaseTighten
Base
Comp &
Seat BaseAssy
Mirror
Assy &
FunctionCheck
Mirror
Check
Preform
Tapping
& Cord
Dimention
Skull
Cap
Assy
Final
Inspect
& Packing
1. New Line Door Mirror Process is Set for 6 Man Power
Part after check is Packed
in to Bucket with Partition
All Parts are Received
by Warehouse
QC check 100% Parts and
Remove Plastic Cover
Part Processed in
Assembly.
WHP QC INCOMING WHP AF
2. Part Plastic Cover removed at QC Incoming.
Re-use Plastic to
Export Packing J09 Key
Set (2R)
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Step 8 : Next Theme
Step 8 : Next Theme
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Cycle Time Down in Out Handle Line.
Our Team Next Theme is:
PRODUCTCYCLE TIME (Second)
CURRENT STANDARD VARIANCE %
Door Mirror
273.96 273.65 0.31 0.11%
Outer Handle105.76 96.5 9.26 9.6%
Step 8 : Next Theme
Note : Door Mirror Cycle Time Process is Successfully Down in This Year QCC
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Thank youfor your attention
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