Notes- Draft 2 - DAY 3 MODUL_IOI Palm Wood.pptx

Lean Training: Principles, Techniques, and Implementation
Introduction
Lean training is a systematic approach designed to enhance organizational efficiency by minimizing waste while maximizing value. Originating from the Toyota Production System (TPS), lean principles have transcended manufacturing to influence various sectors, including healthcare, construction, and service industries. This essay explores the fundamental principles of lean training, its methodologies, tools, and the impact of its implementation on organizational performance.
Understanding Lean Principles
Lean principles are centered around the concept of value creation for customers. The core idea is that any activity that does not add value to the end product is considered waste and should be eliminated. The five foundational principles of lean management are:
Value: Define value from the customer’s perspective. Understanding what customers perceive as valuable is crucial for effective lean implementation.
Value Stream: Identify all the steps in the value stream for each product or service, eliminating those that do not create value.
Flow: Ensure that the remaining steps flow smoothly without interruptions or delays.
Pull: Implement a pull system where production is based on customer demand rather than forecasts.
Perfection: Strive for continuous improvement through regular evaluation of processes and outcomes.
These principles guide organizations in creating more efficient processes that meet customer needs while minimizing resource expenditure.
Lean Training Techniques
1. Value Stream Mapping (VSM)
Value Stream Mapping is a visual tool used to analyze and design the flow of materials and information required to bring a product or service to a consumer. It helps identify waste and areas for improvement by mapping out each step in the process.
Benefits:
Provides a clear picture of current processes.
Highlights inefficiencies and bottlenecks.
Facilitates communication among team members.
2. Kaizen
Kaizen is a Japanese term meaning "continuous improvement." It involves all employees at all levels working together proactively to achieve regular, incremental improvements to the manufacturing process.
Benefits:
Encourages employee involvement and ownership.
Fosters a culture of continuous improvement.
Leads to sustainable changes over time.
3. Just-In-Time (JIT)
Just-In-Time is an inventory management strategy that aligns raw-material orders with production schedules. The goal is to reduce inventory costs and improve cash flow.
Benefits:
Minimizes waste by reducing excess inventory.
Improves cash flow by decreasing storage costs.
Enhances responsiveness to customer demand.
4. 5S Methodology
The 5S methodology focuses on organizing and managing the workspace efficiently and effectively. The five steps are Sort, Set in order, Shine, Standardize, and Sustain.
Benefits:
Creates a clean and organized work environment.
Reduces time spent searching for tools and materials.
Enhances safety

1. PRESENTED BY Kumar T Balan 1 LEAN MANUFACTURING: DIAGNOSIS & INTERVENTION

2. Reka Peta Proses Kerja MODULE 3 2

3. Objektif Kursus Meningkatkan pemahaman dan mengenali simbol-simbol peta proses dan aliran kerja . Belajar untuk reka atau bentuk ‘ peta proses kerja ’ untuk Work Station masing-masing dalam jangka masa yang ditetapkan . Bincang dan menjana idea untuk memperbaiki Peta Proses Kerja yang sedia ada untuk menjadi lebih efisien . 3

4. Definisi LEAN Lean management is a continuous improvement initiative undertaken by a company that works on small changes in work processes to deliver value to customers. Pengurusan LEAN ialah usaha dari semua lapisan wargakerja secara kecil-kecilan dan berterusan untuk mencipta nilai baru terhadap tugas-tugas yang sedang dilakukan setiap hari . Apakah nilai baru yang anda menyumbang atau boleh lakukan di tempat kerja masing-masing? 1. 2. 3. 4. 4

5. Faedah LEAN By applying Lean, you will be able to challenge yourself to find better work methods or techniques and remain focus on delivering activities/tasks that bring value . Focus & Ownership When employees are focused on delivering value, they will be more productive and efficient, because they won’t be distracted by unclear tasks . Improve Productivity & Efficiency By establishing a pull system, you will be able to deliver work only if there is actual demand . Effective Process (Pull System) When your production is based on actual demand, you will be able to use only as many resources as needed. Better Use of Resources 5

6. 5 Simbol Utama Untuk Reka Peta Proses Kerja 6

7. Definisi PROSES Satu siri langkah-langkah yang melibatkan aktiviti-aktiviti , kekangan dan sumber-sumber yang akan digunakan untuk menghasilkan output yang diingini . Sesuatu proses kerja ada aktiviti permulaan dan aktiviti terakhirnya untuk mencapai sasaran yang telah ditetapkan . 7

8. Peta Proses Kerja Definisi: Suatu gambarajah simbol yang menggambarkan urutan-urutan proses kerja dan pemeriksaan dari mula hingga ‘finish good’ dihasikan . 2. Kegunaan Peta Proses Kerja : Mengetahui kebutuhan akan mesin , penganggaran masa dan sumber . 8

9. Peta Kerja Peta Kerja adalah salah satu alat LEAN yang dapat membantu untuk mengenal pasti dan menghapuskan : Pembaziran - 'waste’ – MUDA Ketidakseimbangan - 'unevenness’- MURA Kerja Yang Tidak Perlu - 'overburden ’ - MURI 9

10. Jenis Peta Kerja Untuk LEAN Peta Kerja untuk Kegiatan Keseluruhan Peta Proses Operasi Kerja Peta Aliran Keseluruhan Proses Kerja Kilang Tumpuan untuk LEAN Untuk tujuan kursus ini , kita akan tumpukan ‘ peta kerja proses di Work Station yang melibatkan wargakerja dan fasilitas di sesuatu proses kerja . 10

11. Performance , Duty & Task Performance Sasaran atau target yang ingin dicapai hasil daripada sesuatu kerja atau tugas . Sasaran tersebut harus dapat diukur . 2. Duty ‘Duty’ bermaksud , mencerminkan kelompak kerja yang utama . Dalam kelompok kerja utama , akan terdapat pecahan tugas-tugas bersiri . 3. Task ‘Task’ adalah tugas-tugas kecil ( unit of work ) 11

12. Performance, Dury & Task 12 Job : Machinist Performance: Duty : Perform Milling Task 1 : Identify, prepare & set up cutting tools Task 2 : Set up milling adjustable cutting tools Task 3 : Select speed and feeds of mill Task 4 : Perform fly cutting & face mill Task 5 : Perform cut-out, angle & open slots Task 6 : Machine pocket or slot Task 7 : Machine a hole Task 8 : Bore holes Task 9 : Control material identification Task 10 : Identify deburr workpiece Task 11 : Perform work inspection Task 12 : Complete all documentation and report

13. Bengkel 1 – Performance, Duty & Task Masa:20 Anda dikehendaki untuk menyedia dan memasak ayam sambal untuk 10 orang. Apakah Performance yang disasarkan ? Senaraikan kesemua duty untuk menyedia dan memasak ayam sambal ? Pilih salah satu ‘Duty’ dan senaraikan kesemua ‘task’ untuk ‘Duty’ tersebut ? 13

14. Pengertian Peta Aliran Kerja Kerja Menganalisa suatu sistem kerja bererti mencatat secara sistematis , meneliti seluruh kegiatan / aktiviti operasi tugas , beserta menyajikan fakta dan spesifikasi kerja yang ada pada sistem kerja semasa Peta kerja umumya adalah alat yang sistematis untuk mengumpulkan semua fakta berkenaan dengan sistem kerja yang diamati sehingga dapat digunakan untuk mengkomunikasikan fakta-fakta tersebut kepada pelanggan atau pihak yang ada kepentingan . 14

15. Kebaikian Peta Kerja Peta kerja adalah suatu alat komunikasi yang sistematis dan jelas , yang dapat digunakan sebagai bahan untuk merancang atau untuk baiki sistem kerja yang sedia ada . Dengan adanya peta kerja , anda dapat melihat semua langkah atau kejadian-kejadian yang dialami atau berlaku semasa sesuatu tugas dijalankan , sejak memulakan kerja sehingga tugas tersebut dapat menghasilkan produk . 15

16. Peta Kerja Keseluruhan Peta kerja keseluruhan digunakan untuk menganalisis suatu sistem kerja yang bersifat keseluruhan . Kegiatan kerja ini umunya melibatkan sebahagian besar atau semua fasilitas produksi yang diperlukan dalam membuat suatu produk tertentu . Dengan demikian peta ini dapat digambarkan keseluruhan / sebahagian besar proses beserta karakteristiknya yang dialami suatu bahan hingga menjadi produk akhir . Peta ini juga dapat memberikan Gambaran mengenai interaksi atau hubungan antara kelompok kegiatan operasi . 16

17. Diagram Aliran (Flow Diagram ) Merupakan penggambaran flow process chart [FPC] dalam layout. Memberikan gambaran visual yang lebih jelas . Tool of analysis untuk mengevaluasi layout dengan prinsip menekan aktivitas material handling 17

18. Faedah Diagram Aliran Faedah : 1. Untuk mengevaluasi proses-proses kerja semasa dengan jelas 2. Untuk perbaikan layout fasilitas kerja 18

19. Contoh Flow DIAGRAM 19

20. Carta Aliran Kerja 20

21. Cutting (2man power) Plane/Rip (3man power) Final Plane (2man power) Cut Rebat /Drill 1 (1man power) Drill 2/Longkang (1man power) Drill 3/Router (1man power) Running R (2man power) Checking (2man power) DMC sanding (3man power) Sponge sanding (2man power) Sealer (3man power) Sanding checking (5man power) Brush sanding (2man power) DMC 2 (2man power) Matt (4man power) Checking & packing (4man power ) 21

22. Wood Circle Material Process & Flow Below is the current process of the wood circle. This flow shows the processes, material flow, and manpower to complete the product. To complete this product, the production line needs to complete 19 processes for the machining and finishing process. But for this part 1 (Long up) has 17 processes only. 22

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24. Below are the process times for Wood Circle. The total cycle time that we need to complete 1 set of the wood circle is 3275sec/set equal to 54.58min/set. From this cycle time we can see the bottom neck for this wood circle is from Sanding/ Checking process. Part/ Process cut r. plane F. Plane C. Rebat Drill 1&2 Drill 1/2/3 Mortiser L & Drill 3 Run R Router Checking Dmc Sponge Sanding Sealer Sanding/ Checking Brush sanding Dmc2 Matt Qc/ Packing Total time/set Part 1 (Long up) 20 20 30 30 80     60 46 36 78 16 100 22 170 70 30 30 80 918 Part 1 (Long down) 20 20 30 30 80         36 78 16 80 22 240 70 30 30 76 858 Part 2 (up) 12 14 16 28 52       54   46 10 66 14 150 44 14 20 60 600 Part 2 (down) 12 14 16 28 52       42   46 10 60 14 160 44 14 20 60 592 Part 2 (center) 6 7 8 14   36 16   15   21 5 30 7 80 15 7 10 30 307 Total time 70 75 100 130 264 36 16 60 157 72 269 57 336 79 800 243 95 110 306 3275 24

25. Wood Circle Material Process & Flow Below is our future process of wood circle. This flow shows the processes, material flow, and manpower to complete the product. We are planning to combine two processes to become one process. As a result, we can save our movement and waiting from one process to other processes. The processes that we combine are : 1. Cut Rebat + Drill 1 2. Drill 2 + Longkang • For this process, we combine the cut rebat process and drilling to cut the movement time. 3. Drill 3 + Router • For this process, we rearranged the router machine near to drilling machine so that we could combine the two processes and reduce the movement of the wood. Before this, we run DMC sanding two times with two machines. Now, we also combine these two DMC sanding to cut the motion of the wood. 25

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27. We also recognized some non-value added from the whole process of the production line that we have faced before : Transportation We had some issues with the lorry driver not covering the canvas cloth to protect the wood when the delivery process to the customer and when rains, the plastic that covers the wood is wet. The customer reject the delivery on that day Motion We use the jet to move one pallet of wood from one process to another process Waiting Sometimes, non-continuous process, and the item needs to wait due to lack of manpower or capabilities of machines 27 Non- Value Added Activity

28. Over-processing For the wood circle, the wood needs to be checked two times due to the condition of the wood. One time in the machine department and one more at the sanding & checking. We already know that the bottom neck for the wood circle process is at the sanding checking and we invested new machine ( 12 Head 4-side Straight Line sanding Machine Model – TD-Line-J4S4W4) to cut the production process of the wood circle. This new machine will cut the Dmc , Sponge sanding, sanding/checking, and Dmc2 process. So that, the process time to complete the item will be reduced.   28

29. Non-value added Description Time Needed Transportation Handling Delivery : 30min Uturn back : 30min Rework checking : 180min Motion Material movement Jet move wood pallet from one machine to another machine   Approximately 5min Waiting Non continous process Adjust machine : Approximately : 30min/machine   Over processing Sanding & Checking Process time : 800sec/set 29 Summary of Non-Value Added Activity

30. Future Process Flow Part/ Process cut r. plane F. Plane C. Rebat Drill 1&2 Drill 1/2/3 Mortiser L & Drill 3 Run R Router Checking Dmc Sponge Sanding Sealer Sanding/ Checking Brush sanding Dmc2 Matt Qc/ Packing Total time/set Part 1 (Long up) 20 20 30 30 80     60 46 36 78 16 100 22 170 70 30 30 80 918 Part 1 (Long down) 20 20 30 30 80         36 78 16 80 22 240 70 30 30 76 858 Part 2 (up) 12 14 16 28 52       54   46 10 66 14 150 44 14 20 60 600 Part 2 (down) 12 14 16 28 52       42   46 10 60 14 160 44 14 20 60 592 Part 2 (center) 6 7 8 14   36 16   15   21 5 30 7 80 15 7 10 30 307 Total time 70 75 100 130 264 36 16 60 157 72 269 57 336 79 800 243 95 110 306 3275 30

31. Part/Process cut r.plane F.plane C.rebat C.Rebat / Drill 1 Drill 2 & Longkang Drill 2 & Router Drill 1/2 Drill 1/2/3 Mortiser Drill 3 & Router Run R Checking Dmc Sponge Sanding Sealer Sanding/ Checking Brush sanding Dmc 2 Matt Qc/ Packing Time/set Part 1 (Long up) 20 20 30   60 60         60 46 78 16 100 22 170 70 30 30 80 892 Part 1 (Long down) 20 20 30   60   66           78 16 80 22 240 70 30 30 76 838 Part 2 (up) 12 14 16 28       52       54 46 10 66 14 150 44 14 20 60 600 Part 2 (down) 12 14 16 28       52       42 46 10 60 14 160 44 14 20 60 592 Part 2 (center) 6 7 8 14         36 16   15 21 5 30 7 80 15 7 10 30 307 Total time 70 75 100 70 120 60 66 104 36 16 60 157 269 57 336 79 800 243 95 110 306 3229 31

32. From this new process time, we try to cut the machining process time. Compared to the old process time, we can save 46sec/sets. Current process time = 54.58min/sets Future process time = 53.82min/sets   We already know that the bottom neck for the wood circle process is at the sanding checking and we invested new machine ( 12 Head 4-side Straight Line sanding Machine Model – TD-Line-J4S4W4) to cut the production process of the wood circle. This new machine will cut the Dmc , Sponge sanding, sanding/checking, and Dmc2 process. So that, the process time to complete the item will be reduced. This machine just arrived in our factory and is now still in a test run. We don’t have new cycle time of this machine yet. But we know that this machine will help us to reduce the bottom neck and process time for Wood Circle. 32

33. Contoh Peta Aliran Proses 33

34. Bengkel 2 – Reka Peta Alirang Kerja Masa: 20 Kumpulan anda dikehendaki untuk reka Peta Aliran Kerja bagi IOI Palam Wood? 34

35. Definisi Peta Proses Kerja “ Suatu alat yang menggambarkan kegiatan atau aktiviti kerja secara sistematik dan jelas mengikut aliran tugas yang dijalankan saperti sediakala ” Contoh : Aktiviti Di Produksi Proses Kerja Sorting Proses Kerja Cutting Proses Kerja Plane/Rip 35

36. 5 Simbol Utama 36

37. Lambang/ Simbol Peta Kerja Berdasarkan ASME 1947 oleh Gilbert, symbol-symbol berikut digunapakai untuk mereka Peta Aliran Kerja : Simbol untuk Operasi Simbol untuk Transport/ Pengangkutan Simbol untuk Pemeriksaan /Quality Inspection Simbol untuk Penyimpanan / menunggu Simbol untuk Operasi gabungan 37

38. 7 Kriteria Proses Kerja Menerangkan tentang aktiviti-aktiviti proses utama . Proses menggunakan sumber yang berkaitan dengan kekangan . Mempunyai subproses yang berkaitan . Aktiviti untuk proses mempunyai kriteria masuk dan keluar Aktiviti dikendalikan secara urutan ( jujukan ). Mempunyai satu set prinsip yang menerangkan matlamat setiap aktiviti . Kawalan boleh dikenakan terhadap aktiviti , sumber atau produk . 38

39. Kebaikan Peta Kerja Boleh menentukan standard kerja yang efektif Menghapuskan operasi yang tidak perlu Menggabungkan operasi Menemukan urutan kerja / proses produksi yang lebih berkesan Menentukan mesin yang lebih ekonomis Menghilangkan waktu tunggu Setiap Langkah kerja ditentukan masanya 39

40. Reka Peta Proses Kerja Duty- Change Over Drilling Machine Task No. Urutan Aktiviti Kerja Simbol Masa Catatan Penambah - Baikan T.1 Check Model & Parts T.2 Adjust hand drill machine T.3 Adjust multiple drill machine T.4 Check wood against Sample & Mold T.5 Perform test run for 10 pieces T.6 Perform the Batch Run Task T.6 Every 50 pieces , inspect the hole position 40

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43. Contoh FPC 43

44. Reka Peta Sending Proses Duty- Sending Proses Task No. Urutan Aktiviti Kerja Simbol Masa Catatan Penambah - Baikan T.1 T.2 T.3 T.4 T.5 T.6 T.6 44

45. Bengkel 3 – Reka Peta Proses Kerja Masa:20 Kumpulan anda dikehendaki untuk reka Peta Proses Kerja untuk unit masing 45

46. Topic What did you learn or relearn, Write from an application point of view Summary of Learning 46

47. Topic What did you learn or relearn, Write from an application point of view Summary of Learning 47