Problem Statement

End Date :

Signature :

Starting Date : 30 Juli 2012

1. Problem Statement

Eliminate Pallet Reading Error Alarm

Depalletiser

Name : Chandra Pramana

Job Title : Packaging Technician I In Training

Function : Team Leader

Name : Pratondho Hany Prakoso

Job Title : Packaging Technician I In Training

Function : Team Member

Role : Execute & Update Action List

Update Team Performance Indicator

Update Minutes of Meeting & Attendance list

Standardize counter measure ( OPL, WI, SOP )

Execute 5 WHY

Role : To lead & coordinate weekly meeting

Monitor and improve team result

Update Communication Board

Update Team Master Plan

Support data collection and deployment

Execute job planned

Monitoring result & reported

3. Loss Type

Down time Waste

Breakdown Defect

Minor stop Starup

Setup Process

Rework

Safety Environment

4. Loss DeploymentAlarm Pallet Reading Error Data P1 Data Collect ( Week 29 )Tuesday, 17 July 2012 ( PL-24 Production )

Thursday, 19 July 2012 ( PL-16 Production )

Pallet Reading

Error P1 Alarm

Shift Shift 1 Shift 2 Shift 3 Shift 1 Shift 2

Intensitas 5 7 6 7 13

Pint PL-24 ( 17 July 2012 ) Bremer PL-16 ( 19 July 2012 )

0

2

4

6

8

10

12

14

Shift 1 Shift 2 Shift 3 Shift 1 Shift 2

Pint PL-24 ( 17 July 2012 ) Bremer PL-16 ( 19 July 2012 )

Pallet Reading Error P1 Alarm Data Collect Per Shift

Shift 3

13

Bremer PL-16 ( 19 July 2012 )

Shift 2 Shift 3

Bremer PL-16 ( 19 July 2012 )

Alarm Data Collect Per Shift

5. Failure Mode

Brake

ELMOT

Roller + Sproket

Conveyor

Chain Conveyor

Unit

Proximity +

Roller Proximity

Pallet Conv. Unit

OK OK NOK OK

Photocell

Crate Presence

Photocell

Pallet Presence

Reflector

Crate Presence

Reflector

Pallet Presence

Photocell

DEPALLETISER

Reflector

OK NOK NOK OK

6. TargetTarget Alarm Pallet Reading Error After Week 30

ELIMINATE PALLET READING ERROR ALARM

7. Master Plan

29

1 State problem √

2 Team selection √

3 Define loss type √

4 Loss deployment

5 Describe the failure mode

6 Set target

7 Master Plan

8 Analyze the problem rootcause

9 Define countermeasure and action plan

10 Start monitor result

11 Create and train standard

12 Define future actions

Note:

No Team ActivityWeek

30 31 32 33 34 35 36 37

√

√

√

√

√

√

√

√

√

= Plan

√ or √ = Actual

* Centang √ dengan menggunakan ballpoint setelah suatu step dari aktivitas selesai

Week

8. 5-Why Sheet

Why (1)

Ch

eck

Pallet di P1 sering

"bablas" menyebabkan

Alarm Pallet Reading

Error

Internal CausePallet berhenti tidak pada

posisinya OK

FIVE WHY ANALYSIS

Problem Description

Potential Causes

Why (2)

Ch

eck

Why (3)

Ch

eck

Why (4)

Ch

eck

Pallet masih berjalan ketika

motor berhenti OK

Ada jarak chain masih

bergerak akibat moment

dari pallet

OK Chain kendor OK

Sensor photocell tidak

membaca dengan benar OK

Sensor photocell pallet

presence masih menyala

"ON" ketika pallet sudah

berhenti

OK

Posisi reflector photocell

pallet presence terlalu

melebar dari pallet

OK

FIVE WHY ANALYSIS

Potential Causes

Why (5)

Ch

eck

PREVENTIVE ACTION CORRECTIVE ACTION

Machine,

MethodeCILT AM-3-Depall-005 Adjust chain elongation

MachineOPL Position Reflector

Pallet Presence

Reposition reflector,

adjust posisi photocell dan

reflector dapat membaca

semua jenis pallet

FIVE WHY ANALYSIS

Potential Causes

4M

Actions

9. Corrective Action5 Why Action # Countermeasure Owner

Chain Roller Pallet

Conveyor kendor dan

kurang pelumasan

1

Adjust kekencangan

rantai dan lakukan

pelumasan berkala

sesuai CILT AM-3-

Depall-005

Pratondho

Reposisi support

reflector, adjust posisi

photocell dan reflector

dapat membaca semua

jenis pallet

2

Reposisi reflector

photocell pallet

presence

Chandra

Failure Mode

Yes

Expected

dateActual date

Start Q3

2012Max

31 32 33 34 35

28-Jul-12 28-Jul-12

3-Aug-12 3-Aug-12

Reoccurrencies Weekly

0

36 37

Reoccurrencies Weekly

9. Improvement ResultPallet Reading Error Alarm Week 31 after Trial Setting on PMD week 30

PL 16 - Bremer Production

PL 24 - Pint Production

Pint PL-24 Bremer PL-16 Pint PL-24 Bremer PL-16

Shift 1 5 7 0 0

Shift 2 7 13 0 0

Shift 3 6 13 0 0

Pallet Reading

Error P1 Alarm

Before After

0

2

4

6

8

10

12

14

Pint PL-24 Bremer PL-16 Pint PL-24 Bremer PL-16

Before After

:

31.2. Pemeriksaan ke-

Ausan Rantai

31.3. Pemeriksaan ke-

Ausan Spie & Borek

Sproket

31. Palet Conveyor

31.1. Pemeriksaan ke-

Ausan Sproket

AM - CILT STANDARD

Cleaning, Inspection, Lubrication and TighteningMachine Section Depalletiser 31.Pallet Conveyor

Part : Sproket & Chain

Jarak Bebas

Line : Prepared by : Yoyok

Equipment : Approved by : PKM

D W

NI1

1

1> Adjustment

Borek / Baut

Tanam sproket

> Replace Spie

Sproket

Standard

measurement :

Jarak Bebas /

Kekencangan Rantai

max 30mm

NI I> Adjustment

tension sproket

> Jika

adjustment

sudah maksimal

dan rantai masih

terlalu kendor,

potong rantai

Standard

measurement :

Sproket Tidak kocak

terhadap Shaft

gearbox

NI I

Action if abnormal

Standard

measurement :

Sproket tidak Runcing

& Tidak kocak

terhadap Shaft

gearbox

I

Interval

> Replace

Sproket

AM - CILT STANDARD WeeklyBottling Date : 30 Agustus 2010

Depalletiser Date :

Depalletiser 31.Pallet Conveyor

Standard : Method Tool

M Y

10 mnt

PM Weekend

10 mnt

10 mnt

Time RemarkInterval

Ref. OPL

WeeklyDate : 30 Agustus 2010 CILT-AM-3-

Depall-005Date :

Depalletiser 31.Pallet Conveyor