Transcript Thinking People System

Thinking People System (TPS)
Implementation Program
BY: Vendor Improvement Section, Vendor Development Dept, Group Procurement
Program Objective
 Implementation of TPS Element - Standardized Work
 Takt Time
 Work Sequence
 ≥ 85% Manpower Efficiency
 Implementation of Jishuken
 Quality related Jishuken
 Delivery related Jishuken
Jishuken Requirement
 Two week’s cycle per project. At each end of project,
present to Proton GP
 Judging criteria as per Attachment
 As a handout,
 8D reporting will be required (refer to Attachment for
sample of 8D report)
 QAF
Sample of Jishuken Schedule
 1st Day = Data Analysis & Identify problem/process
 2nd Day = Training operator & line leader on how and what to do
 3rd Day = Map out current process condition (VSM or Fish bone







diagram-why why analysis
4th Day = Map out future state/ proposal state (VSM or Process
flow) and list what to do (Kaizen)
5th Day = Fabrication and installation
6th Day =
7th Day =
Corrective action to stabilize improvement
8th Day =
9th Day = Documentation preparation -8D and Presentation slide
10th Day = Present to PROTON
Three Level of Kaizen
 Kaizen of Method
 Improve working sequence/process or operator
movement
 Kaizen of Tool
 Replace, improve or implement new tool
 Kaizen of environment/surrounding
 Base on 5S and placement of material.
Standard Work Requirement
 All vendors will be assigned to groups according to
manufacturing category (e.g. rubber, metal, painting
etc.)
 Program will be conducted as tutorial class (facilitator
will be from Proton GP, NPC, or Kaizen Institute)
 Documentation Required:
 QAF
 Time Measurement Check Sheet
 Standard Work Combination Table (SWCT)
 Calculation Required:
 Manpower Efficiency
 Manpower Requirement
Recap
Time Measurement Check Sheet
 Identify standard time allowed for every process, for
each operator
 Take 10 readings for each process. Minimum value will
be chosen.
 Standard time = min value + allowance. Allowance is
determined by each Company and must be justified
Standard Work Combination Table (SWCT)
 Analysis each work sequences (for muda)
2. WORK
SEQUENCES
& PROBLEM
Process
KANCIL
No
Process Sequence
2 Berjalan Ke Kereta
3 Letak Part Pada Kereta
4 Pasang Fr Openning Trim Lh
5 Pasang Fr Garnish Lh
6 Pasang Rr Openning Trim Lh
7 Berjalan Ke Rack
9
5. ‘X MIN’MINIMUM TIME
Measurement Date
FOR EACH
TIME MEASUREMENT SHEET
PROSESS. Measurer Name
FINAL 1-OPENNING TRIM LH
1 Lihat Production Sheet, Ambil Part Di Rack
8
How to Fill Up Time Measurement
1. DETAIL CHECK
SHEET
3. CYCLE TIME
READINGS (in this
example, 15 readings)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Serial NO.
7. RANK – HIGHEST
RANK GOES TO
HIGHEST RANGE
VALUE
15
Xmin
Range
Rank
10.18
6.00
3
0.00
10.18
1.07
3.50
5
0.00
1.07
1.14
2.81
6
4.37
5.51
38.01 20.46
1
4.37
42.38
7.59
8.36
4
4.37
11.96
40.17 18.26
57.80 56.92 40.71 48.59 51.01 50.42 47.41 58.97 51.16 52.97 50.71 49.178. 50.61
43.21 49.11
ALLOWANCE
-
2
4.37
44.54
7
0.00
1.27
10.18 14.86 10.84 10.40 16.18 15.41 11.82 15.32 11.57 10.75 11.61 12.01 10.47 12.64 10.91
4.57
2.19
3.31
3.88
2.69
3.04
2.28
2.45
2.97
3.04
1.56
2.00
47.26 42.07 53.55 46.07 42.23 38.01
11.64 12.51 15.95 10.59
2.01
1.27
2.21
2.81
4.44
2.09
1.98
1.98
2.61
3.24
2.07
1.07
3.08
2.99
3.95
3.24
1.14
2.44
1.72
1.84
2.00
1.87
6. RANGE = MAX TIME – MIN TIME
40.93 58.02 58.47
52.34 45.01 52.61 40.22
(for 52.91
each 47.81
process)
7.59 10.59 11.63 13.30
3.03
2.04
2.00
2.20
8.70 10.64
3.39
3.01
9.42
2.01
8.99 10.11
1.87
9.44
Problems
Amirul Izhar & Affandy
9.82
SET BY EACH1.27
2.47 2.82 1.90
COMPANY BUT
MUST BE
JUSTIFIED
2.12
Allowance Standard
1
OPERATOR BUKA PLASTIK PART
8
OPERATOR MELAMBATKAN PROSES
10
9. STANDARD TIME = Xmin + ALLOWANCE
11
12
13
14
15
16
17
18
19
20
TOTAL
A
B
135.74 132.27 129.54 125.38 124.29 121.51 121.22 153.85 138.51 133.40 126.61 129.34 122.58 123.79 116.91 99.43
C
17.48
17.48
116.91
1. DETAIL CHECK
SHEET
MOD EL
SEC TION
Example of Standard
Work Combination Table
5. This is a
standard
Legend
2. WORK
STANDARD WORK COMBINATION TABLE
SEQUENCES
3. FILL UP CYCLE TIME
OPERATION SEQUENCE FLOW
ACCORDING TO
CATEGORY
TAC T TIME
TEAM L EAD ER
JOB C ON TEN TS
PR OD . EXEC
AM / MGR
D ATE
MAN U AL
AU TO
WAL K
TT
PR OC ESS N O.
PR OC ESS N AME
SEQ
4. PLOT
TAKT TIME
TIME
MAN U AL AU TO
1
Setting 3 part
8.6
2
Install 2 part
3.8
3
Install 5 clip for Lwr Interference
10.8
4
Install 7 fius
11.2
5
Install air cond hose
1.4
CT
63.2"
WAL K
4
10
20
30
40
5. LINE FOR
EVERY PROCESS
(remember to use
appropriate lines as
per legend!)
50
60
90"
70
80
1.4
6
Install sub-assy gear
12.6
7
Install console box and impact 2 pcs
8.4
8
Impact RR Seat and impact 2 bolt
2.2
2.8
9
TOTAL TIME
59
4.2
6. IDENTIFY
WAITING TIME
(MUDA)
90
Sample Calculation of Manpower Efficiency
Efficiency
=
Total cycle time
x 100
Takt time x No Of Workers
(4+4+12+4+16+4+4+4 )
=
=
( 15 x 8 )
52
120
=
43 %
x 100
x 100
Sample Calculation of Manpower
Requirement
Manpower Requirement =
Total cycle time
Takt Time
= [(11X4) + 4 + 4]/ 15
= 3.47 people
VENDOR GROUPING
GROUP 1 (CASTING)
COMPANY
Location
ALUMINIUM ALLOY INDUSTRIES SDN BHD
NILAI
SENA DIECASTING INDUSTRIES SDN BHD
SEMENYIH
HICOM DIECASTINGS SDN BHD
SHAH ALAM
HICOM ENGINEERING SDN BHD
SHAH ALAM
RIGHT WAY INDUSTRIAL (M) SDN. BHD.
SHAH ALAM
LC RIMS MANUFACTURING SDN. BHD.
SG.BULOH
VENDOR GROUPING
GROUP 2 (PAINTING)
COMPANY
Location
ACE POLYMERS (M) SDN. BHD.
SG. BULOH
SIPRO PLASTIC INDUSTRIES SDN. BHD.
SHAH ALAM
SG PETANI
TECK SEE PLASTIC SDN BHD
SHAH ALAM
DELLOYD AUTO PARTS MFG SDN BHD
JLN KEBUN,KLANG
HICOM TECK SEE MANUFACTURING (M) SDN BHD
SHAH ALAM
HIL INDUSTRIES BERHAD
SHAH ALAM
BKT MERTAJAM
USRA TAMPI(M) SDN. BHD.
SHAH ALAM
SIME KANSAI PAINT SDN BHD
KLANG
PPG COATING (M) SDN BHD
PJ
VENDOR GROUPING
GROUP 3 (PLASTIC)
COMPANY
Location
TS HI-TECH SEAT SDN BHD
JLN KEBUN,KLANG
BEHRANG,PERAK
USRA INDUSTRIES SDN BHD
SHAH ALAM
APM PLASTICS SDN. BHD.
PORT KLANG
EP POLYMERS (M) SDN BHD
SHAH ALAM
AUTOVISOR PLASTICS SDN. BHD.
SHAH ALAM
AZMAN HAMZAH PLASTIK SDN BHD
SHAH ALAM
KB TEKNIK SDN. BHD.
ULU YAM
NIFCO MANUFACTURING (M) SDN BHD
BKT RAJA
RAYA PLASTIK INDUSTRI SDN. BHD.
SHAH ALAM
VENDOR GROUPING
GROUP 4 ( ELECTRICAL)
COMPANY
Location
PATCO RAYA TRADING SDN. BHD.
SHAH ALAM
SANDEN AIR CONDITIONING (MALAYSIA) SDN BHD
SHAH ALAM
NETSTAR ADVANCED SYSTEMS SDN. BHD.
AMPANG
APM AUTO ELECTRICS SDN BHD
BT.CAVES
PROREKA (M) SDN. BHD.
PUCHONG
REXAR TECHNOLOGIES SDN BHD
SUBANG
DELLOYD TECHNOLOGY RESOURCES (M) SDN BHD
KLANG
MULTI-CODE ELECTRONICS INDUSTRIES (M)
BERHAD
KLANG
APM COIL SPRING SDN BHD
PORT KLANG
VENDOR GROUPING
GROUP 5 ( ELECTRICAL)
COMPANY
Location
SIEMENS VDO INSTRUMENTS MY SDN BHD
PULAU PINNAG
MALAYSIAN AUTOMOTIVE LIGHTING SDN BHD
BAYAN LEPAS,PP
CLARION (M) SDN. BHD.
PULAU PINANG
UMW ADVANTECH SDN BHD
SHAH ALAM
SPEKTRALINK AUTO ELECTRONIC SDN.BHD
SRI KEMBANGAN
AUTO PARTS MANUFACTURERS CO SDN BHD
(RADIATOR DIVISION)
SRI KEMBANGAN
ARMSTRONG AUTO PARTS
PULAU PINANG
VENDOR GROUPING
GROUP 6 (METAL)
COMPANY
Location
PHN INDUSTRY SDN. BHD.
SHAH ALAM
AUTOMOTIVE INDUSTRIES SDN BHD
SHAH ALAM
ORIENTAL SUMMIT INDUSTRIES SDN.BHD.
SHAH ALAM
POWER STEEL & ELECTRO-PLATING WORKS SDN
BHD
SHAH ALAM
CNC METAL MACHINING SDN BHD
PUCHONG
IBK FASTENERS (M) SDN BHD
PJ
VENDOR GROUPING
GROUP 7 (METAL)
COMPANY
Location
SAPURA BRAKE TECHNOLOGIES SDN BHD
BANGI
SAPURA MACHINING CORPORATION SDN BHD
BANGI
KYB-UMW STEERING MALAYSIA SDN BHD
BANTING
KYB-UMW MALAYSIA SDN BHD
KUALA LANGAT
SYARIKAT METAL INDUSTRIES OF MALAYSIA SDN
BHD
BERANANG
INGRESS PRECISION SDN. BHD.
NILAI
INDUSTRIAL QUALITY MANAGEMENT SDN BHD
SHAH ALAM
VENDOR GROUPING
GROUP 8 (METAL)Z
COMPANY
Location
AUTOKEEN SDN. BHD.
SHAH ALAM
PROFEN SDN. BHD.
SHAH ALAM & B BTG
BURNMARK INDUSTRIES SDN BHD
SHAH ALAM
BKT BERUNTUNG
AVENTUR DOOR SYSTEM SDN BHD
SHAH ALAM
PEPS-JV (M) SDN BHD - REVENUE AC
BTG. KALI
PESAKA NURI (M) SDN BHD
BTG. KALI
PAN BAY
RAWANG
BRIMAL STAMPRESS ENGINEERING SDN BHD
SHAH ALAM
VENDOR GROUPING
GROUP 9 (METAL)
COMPANY
Location
CHEMTUBE (M) SDN. BHD.
KLANG
ORTECH MALAYSIA SDN. BHD.
P.KLANG
RECOMTEC SDN BHD
P.KLANG
APM SHOCK ABSORBERS SDN. BHD.
KLANG
APM SPRINGS SDN BHD
KLANG
SAPURA AUTOMOTIVE INDUSTRIES SDN BHD
KLANG
BELTON SDN BHD
SG.SIPUT,PERAK
BLOXWICH (MALAYSIA) SDN BHD
PERAK
GKN DRIVELINE MALAYSIA SDN. BHD.
PRAI,P.PINANG
VENDOR GROUPING
GROUP 10 (RUBBER,CARPET & LABEL)
COMPANY
Location
NAKAGAWA RUBBER INDUSTRIES SDN. BHD
SHAH ALAM
PARAGON CAR CARPETS & COMPONENTS SDN
BHD
CHERAS
AUTOLIV HIROTAKO SAFETY SDN BHD
SRI KEMBANGAN
AUTOLIV HIROTAKO SRS SDN BHD
SRI KEMBANGAN
HIN GETAH (M) SDN. BHD.
KL
KUMPULAN JEBCO (M) SDN. BHD.
SG. BULOH
TECHNOMEIJI RUBBER SDN. BHD.
NILAI
WENCO INDUSTRIES SDN. BHD.
PUCHONG
NOBEL INDUSTRIES SDN. BHD.
SHAH ALAM
VENDOR GROUPING
GROUP 11
(RUBBER & CARPET)
COMPANY
Location
CARPETS INTERNATIONAL MALAYSIA
KL
WSA ENGINEERING SDN. BHD.
RAWANG
PONG CODAN RUBBER (M) SDN. BHD.
RAWANG
FUDEX RUBBER PRODUCTS (M) SDN BHD
MELAKA
SRI KOTA RUBBER MFG SDN. BHD.
MELAKA
GOODYEAR MARKETING & SALES SDN.BHD.
SHAH ALAM
CONTINENTAL SIME TYRE MARKETING SDN BHD
PETALING JAYA
SILVERSTONE BERHAD
SHAH ALAM
SEGINIAGA RUBBER IND. SDN BHD
BTG BERJUNTAI
VENDOR GROUPING
GROUP 12
(OTHERS)
COMPANY
JOHNSON CONTROLS AUTOMOTIVE SEATING (M)
SDN BHD
KEJURUTERAAN EMAS SDN. BHD.
MALAYSIAN SHEET GLASS SDN. BHD.
MARUTECH ELASTOMER INDUSTRIES SDN BHD
Location
SHAH ALAM
CHERAS
SG BULOH
PETALING JAYA
MCIS SAFETY GLASS SDN. BHD.
SEREMBAN
MENANG NUSANTARA SDN. BHD.
BALAKONG
PERMANENT PREMIUM SDN. BHD.
SHAH ALAM
ROKISAR SDN. BHD.
AMPANG