TEAM 2QUICK CHANGEOVERCOMPUTER STITCHING

Project start: : April 07th, 2011Final Update : June 15th, 2011

Team Member :M. TAUFIK Bubuh BRian F ImasEason Zhang Desi

CONTENTSTeam MemberTeam 2 OverviewActivities ScheduleProcess Flow ChartTime Observation and Bar ChartSet Up Change over chartSeparate Internal - External time analysisCurrent Status and Change over time target5Why Analysis worksheetShift Internal to External ActivitiesIdea to Streamline Internal and External ActivitiesImplementation ScheduleImplementation Result

QCO Overview

Team2 : To Reduce Changeover of computer stitching

Current SituationIt was take long time to change the mold every time model change is happen

Current QCO timeBased on data collected on April 07th, 2011 total CO time is 416 Seconds

Target

To reduce change over time to 208 seconds on April 14th, 2011 and 146 seconds on June 7th, 2011

Project Team 2

To reduce computer stitching change over by eliminate wasteObjective

Meeting and implementation on work floor every 3 days from 03.00 to 04.00 pmAttendees : All team member plus PIC of improvement area

Meeting Overview

ScheduleNo Description

April May June

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 311 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 Training QCO                                                                                                                                                               

2 Computerize                                                                                                                                                                

3 Select Changeover process on work floor                                                                                                                                                               

4 Prepare Implementation                                                                                                                                                               

5 2nd QCO Implementation                                                                                                                                                               

6 Analysis and make step improvement                                                                                                                                                               

7 Idea Implementation to reduce COT                                                                                                                                                               

8 Create new change over procedure                                                                                                                                                               

9 Prepare QCO implementation                                                                                                                                                               

10Make Improvement step                                                                                                                                                                

11Implement 3rd QCO                                                                                                                                                                

12Wrap Up and Documentation                                                                                                                                                                

13Wrap Up and Documentation                                                                                                                                                                

132nd Phase observation                                                                                                                                                                

Baseline Analysis Process Flow Chart C/O

2nd Analysis Process Flow Chart C/O

3rd Analysis Process Flow Chart C/O

Team 2

Change Over Time Observation Sheet (Baseline)

Team 2

Change Over Time Observation Sheet (2nd)

Team 2

Change Over Time Observation Sheet (3rd)

Additional facts during CO observation Difficult to call mechanic, Mechanic is not stand by in Workplace

Pemanggilan Mekanik Terlalu lama karena mekanik tidak stand by ditempat

Waiting for mechanic to come

Menunggu Mekanik Datang

No SOP for CO Process

Tidak Ada SOP Untuk CO Proses

Must Install the Program if the program not been saved in Computer

Pergantian program bila data belum tersimpan di komputer

The Last Process can’t run, Mold not available enough in tool box

Proses Sebelumnya terhambat, Mold tidak tersedia

2 size of mold for all footwear size

2 Ukuran Mold Untuk semua Size

Limited skill of mechanic

Mekanik dengan skill terbatas

Mechanic Tools is not complete

Tooling/Alat Mekanik tidak lengkap

Mold Sparepart not complete

Sparepart Mold tidak lengkap

Take a long time to do Pattern Cutting

Cutting Pola Pada Saat COT memakan Waktu Lama

If program available, so you just adjust and set the machine

Jika program sudah ada tinggal set mesin saja

Cutter dull/ no available stock

Pisau Kurang tajam/Stock tidak Ada

Matarial waste when do thread cutting

pemotongan benang yang terlalu panjang

No stock for material testing

Material Untuk Test tidak tersedia

No available Qc to Check mold result and material test

QC Tidak Ada untuk check hasil dari ganti mold dan test bahan

Machanic and Operator not wearing Safety tool while working

Mekanik dan Operator tidak memakai APD (earplug)

Workplace not set in order

Workplace tidak tertata rapi (not Set In Order)

If necessary color thread change must be done if there’s any different color

Pergantian Warna benang perlu dilakukan jika warna beda

Machine maintenance is not well May happen any rework

Perawatan mesin yang kurang baik, memungkinkan terjadinya rework

Takes a long time to set computer program because limited mechanic skill

Untuk set program memekan waktu lama karena skill mekanik terbatas

Takes a long time to change the mold because more rework happen

Pergantian mold Memakan waktu lama karena berkali kali rework

No SOP to set computer program

SOP Untuk Set Mesin/program tidak ada

Take s a long time to cementing because out of glue

Proses lem sangat lama karena lem habis

Machine test necessary when CO is done

Test Kinerja mesin ketika CO sudah selesai

Changeover improvement wall chart

Team2

Improvement Steps Separate Internal - External time analysis

Current Status and Change over time target

5Why Analysis worksheet

Shift Internal to External Activities

Idea to Streamline Internal and External Activities

Implementation Schedule

Implementation Result

QCO Analysis Internal – External time

Project Elements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TotalTotal COT

Improvement (%)

Baseline 04/07/201

1 (1st QCO)

Internal Time

60 4 10 10 53 31 6           

64 27 

265

416 Baseline

External ime             

45 3 42 31 12 13   

5 151

04/14/201

1 (2nd QCO)

Internal Time  

4   

3 20 17 2 

10 2 

10       68

211 49%External ime 54

 57 12

       10

   10

       143

06/10/2011 (3rd QCO)

Internal Time

  2     3 15 17 2   7 2   7       55

173 58%External ime 24   49 13         13     19         118

Team1

Current Status and Change Over Target

Baseline : 416 “Target 2 : 211”Achievement : 173”

Actual Graph

QCO Analysis 5W1H

Improvement (Brain Storming)

Kaizen Idea for Streamline Internal Time

Provide Schedule before CO, Make Sure all team ready for COSiapkan Schedule QCO, agar semua pihak terlibat bisa siap

(Eason Zhang 04/07/2011)QCO/0407/I/1

Do Intensive Maintenance for machine.Lakukan perawatan mesin lebih intensif sehingga tidak mengganggu proses kerja

(Rian F 04/07/2011)QCO/0407/I/2

Provide Mold, Pattern, and tooling before COMempersiapkan Mold, pattern dan Tooling terlebih dahulu sebelum CO

(Rian F 04/07/2011)QCO/0407/I/3

QC must stand by to check the Quality of COQC harus ada untuk memastikan kualitas ganti mold

(taufik 04/07/2011)

Do Programmable Training To mechanic Lakukan Training program pada mekanik

(Imas 04/07/2011)

Improvement (Brain Storming) Kaizen Idea for Streamline Internal Time

QCO/0407/E/6

QCO/0407/E/8

Provide SOP for COT procedure Sediakan SOP untuk prosedure COT Mesin

(Desi 04/07/2011)QCO/0407/E/1

Provide SOP for COT procedure Sediakan SOP untuk prosedure COT Mesin

(Desi 04/07/2011)QCO/0407/E/2

Use the right tools to attach the mold Pakailah tooling yang tepat untuk memasang mold

(Rian F 07/04/2011)QCO/0407/E/3

Provide Mold box based on style / model Sediakan tempat penyimpanan mold sesuai dengan style / model

(Bubuh 04/07/2011)QCO/0407/E/4

Do 6S TrainingLakukan training 6S

(Taufik 04/07/2011)QCO/0407/E/5

Save program setting on the disk, No reset program if there is a model changeSave settingan program pada disk sehingga tidak perlu setting ulang ketika ada pergantian model

(Eason 04/07/2011)QCO/0407/E/7

Provide Material for Stitching TestMaterial buat test harus disiapkan lebih dahulu

(Bubuh 04/07/2011)QCO/0407/E/9

4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011

Team2

Idea Implementation Schedule

Select & Record Element of CO

Shift Internal to External Activities

All crew that responsible for QCO gathering before COT (CI, QC,Operator, mechanic)

Prepare tools with much stock and make sure tools is compatible

Prepare mold and Pattern before COT

Make Improvement Step

2nd Element & time record

3rd Element & time record

Team2

Idea Implementation Schedule

Team2

Idea Implementation GalleryPropose : Provide Mold, Pattern, and tooling before COAttendance : Team 2 and MechanicIdea Linked : QCO/0407/I/3Idea Owner : Rian FLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Provide the right tools and mold for the next CO

04/21/2011

Propose : Use the right tools to attach the mold Attendance : Team 2 and MechanicIdea Linked : QCO/0407/E/3Idea Owner : RianLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Preparation for next CO

04/21/2011

Propose : Provide Mold box based on style / model Attendance : Team 2 and MechanicIdea Linked : QCO/0407/E/4Idea Owner : BubuhLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Mold box is already but still mix with tooling04/21/2011

Team2

Idea Implementation GalleryPropose : Save program setting on the disk, No reset program if

there is a model changeAttendance : Team 2 and MechanicIdea Linked : QCO/0407/E/7Idea Owner : Rian FLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : they provide 2 different disk for different machine04/21/2011

Propose : DO 6S trainingAttendance : B5 CL and WSIdea Linked : QCO/0407/E/5Idea Owner : TaufikLocation : PYI 2nd Floor Meeting room Date/Time : April 14th , 2011 (10:00 – 11:30) Description : Introduce 6S

04/12/2011

Propose : Provide Material For Stitching TestAttendance : Team 2 and MechanicIdea Linked : QCO/0407/E/9Idea Owner : BubuhLocation : Production lineDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Provide material for stitching test for next CO04/21/2011

Team2

Idea Implementation GalleryPropose : Implement 2nd QCOAttendance : Team 2, Mechanic , QIP and local supervisorDate/Time : April 21th , 2011 (14:15 – 15:30) Description : Implement 2nd QCO

Propose : Attach and Socialize QCO SOP for Current ProjectAttendance : Team 2 , Mechanic, QIP, Local SupervisorIdea Owner : Team 2Location : Production lineDate/Time : June 1st , 2011 (09.00– 09.37) Description : Socialize and Attach SOP for QCO

Propose : Socialize QCO Preparation ChecklistAttendance : Team 2 and Local SupervisorIdea Owner : Team 2Location : Production lineDate/Time : June 1st , 2011 (13.12– 13.23) Description : Socialize and Attach SOP for QCO

04/21/2011

06/01/2011

06/01/2011

Team2

Idea Implementation GalleryPropose : Implement 3rd QCOAttendance : Team 2, Mechanic , QIP and local supervisorDate/Time : June 11th , 2011 (13:08 – 13:26) Description : Implement 3rd QCO

06/11/2011

Team2

Idea Implementation GalleryPropose : Make Process SOPMaker : Team 2Description : Make Qco SOP Process Remark : Version 2 (Standardize)

Team2

Idea Implementation Gallery

Propose : Make Setting Machine SOPMaker : Team 2Description : Make Setting Machine SOPRemark : Version 1

QCO Preparation Checklist

Date :

QCO Process :

line :

QCO Team

No Item Person Check Remark

1 TPM Mechanic 2

2 QIP 1

3 line Supervisor 1

4 CI&IE Team 1

1

Tools

No Item QTY Check Remark

1 Mechanic Tools 1

2 Mold (same as CO model) 1

3 Pattern (insole board) 3

4 Scissor 1

5 Double tape 1

6 Test Material 3

7 Stopwatch 1

8 Camera 1

9 Observation Sheet 1

10 Ballpoint 2

11 QCO SOP 1

Approved by, Checked by,

name name

Propose : Make Preparation Check ListMaker : Team 2Description : Make Preparation Check ListRemark : Version

Team2

Idea Implementation Gallery

Team 2

SOP Before – AfterSeq.

NumberChangeover Element

1Calling Mechanic Memanggil Mekanik

2Take Tooling Ambil Tooling

3Pattern Measurement Mengukur Pola

4Cutting Pattern Memotong Pola

5Cementing Pattern Lem Pola

6Cementing again (rework) Rework Lem

7Attaching Pattern Memasang Pola

8Open Mold Buka Mold

9Saving Mold Simpan Mold

10Attaching New mold Pasang mold baru

11Setting the Program Setting Program

12Pattern test Test Pola

13Stitching test Test Jahit

14Cutting Pattern Memotong Pola

15Attaching Thread Pasang Benang

16Material Test Test Bahan

Seq. Number Changeover Element

1Open Mold Buka Mold

2Saving Mold Simpan Mold

3Attaching New mold Pasang mold baru

4Setting the Program Setting Program

5Cutting Thread Memotong Benang

6Attaching New Thread Memasang Benang Baru

7Attaching Bobbin Memasang Sekoci

8Take Test Material Ambil Material Test

9Stitching Test Test Jahit

10QC Check Periksa Kualitas

11Saving Tested Material Simpan bahan hasil test

12Stitching Material Test Jahit

13QC Check Periksa Kualitas

Total CO TimeBaseline : 416”2nd QCO : 211”Final : 173”

Team 2

Process Change Over Time Recorded & Analysis

Se

con

d

April 7th April 14th June 11th

Baseline : 416 “Target 2 : 211”Final : 173”

Team 2

Streamline External Time Implementation Schedule

4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011

Select & Record Element of CO

Shift Internal to External Activities

All crew that responsible for QCO gathering before COT (CI, QC,Operator, mechanic)

Prepare tools with much stock and make sure tools is compatible

Prepare mold and Pattern before COT

Make Improvement Step

2nd Element & time record

3rd Element & time record

Done Not Done

4/7/2011 4/13/2011 4/14/2011 4/23/2011 4/24/2011

Select & Record Element of CO

Shift Internal to External Activities