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JIS http://www.jim-harvey.com/speech-structure-the-strategy-reco

Jamco Improvement Strategy Powerpoint Slides
by

Andrew Lim

on 2 January 2015

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Transcript of JIS http://www.jim-harvey.com/speech-structure-the-strategy-reco



Pros
How it will help
Jigs stored by monuments
High capacity
Easy to return
Colour coding helps in checking
Jamco Improvement Strategy

Objectives
Identify and Eliminate waste

Observe, evaluate and improve manufacturing process

Create Training video

Implement Improvement Plans

Objectives
Agenda
1. Transportation

2. Over-processing
3. Defects
4. Waiting
5. Motion

Types of Waste
2. Straighten
3. Shine

4. Standardize
5. Sustain

The 5S
Time Observation Chart
Spaghetti Chart
Evaluation Form
1. Sort

Identifying the problem
Evaluation
Improvement Plan
Jig Organising Concept
Current Situation
Idea 1 (Accordion)
Idea 2
Comparison Table
Conclusion
Idea 4 (Wardrobe)
Goals
Remove unused jigs
Remove foreign objects
Ease the process of locating & retrieving a jig
Presentable storage area
600 jigs storage
How problems can be resolved
Categorize by monuments
Use of colour codings
Use of RFID to locate
Motorized trolley
Pros
Looks neat when stowed
Space saving
Easy access
Cons
Heavy
Costly
Space constraints
Complicated
Recommendation of Automated Machines
Elumatec Machine
Reduce manpower
Increase productivity
Increase precision
Versatile software compatibility
Combine 3 processes together
Auto Changing of tools
Pros
Elumatec Machine
Elumatec Machine
Cost analysis
A
Equipment
B
Manpower
Exisiting
Proposed
Manual Marking
Milling &
Mitre Saw
Total
Double Mitre Saw
Profile
Machining
Centre
Total
Remarks
6
4
10
2
2
4
6
Savings
*Both machines require only one person to operate
Elumatec Machine
Cost analysis
C
Manpower Cost
Exisiting
Proposed
Total
Profile
Machining
centre
Total
Savings
i
ii
Total Wages per Month
Inclusive of CPF at 16%
Total Wages per Year
(excluding AWS)
$20,211.84
$13,474.56
$33,686.40
$242,542.08
$161,694.72
$404,236.80
$6,737.28
$6737.28
$80,847.36
$80,847.36
$13.474.56
$20,211.84
$242,542.08
$161,694.72
Elumatec Machine
Cost analysis
D
Productivity
Existing
Proposed
Total
Total
Savings
Inhouse Parts
i
ii
iii
Subcon Parts
Est. Output per day
No. of Parts to Fabricate
e.g MI73-1(1 ShipSet)
180
400
No. of Days to Fabricate
[ ii / i ]
2000
1333
iv
v
No. of Subcon Parts,
e.g. MI73-1 (1 ShipSet)
Est. cost of Subcon Parts,
e.g. MI73-1 (1 ShipSet)
582
195
$70,800.07
$23,599.07
11.11
3.33
220
7.78
$47,201.00
Elumatec Machine
Cost analysis
E
Financing
Proposed
Double Mitre Saw
Profile
Machining
Centre
Total
Savings
i
Cost of Equipment
ii
Annual Depreciation over 7 years
iii
20% equipment cash downpayment
Hire purchase
iv
DBS Hire Purchase at 80% loan quantum
less: Government Grant
(PIC- Cash Payout)
vi
Yearly repayment of the Total Loan
$78,100.00
$11,157.14
$15,620.00
$62,480.00
$(20,000.00)
$(40,693.00)
$(69,620.00)
$348,100.00
$270,000.00
$38,571.43
$54,000.00
$216,000.00
$(80,000.00)
$49,728.57
$69,620.00
$278,480.00
$(100,000.00)
Double
Mitre Saw
Elumatec Machine
Cost analysis
F
Expected savings/(Loss)
Proposed
Manpower Cost (iv)
Productivity
Savings
Total
Savings
i
Manpower Cost + Production Savings
ii
Less: Financing Charges
Result
$242,542.08
$179,429.64
$289,743.08
$47,201.00
$(110,313.44)
$(110,313.44)
$289,743.08
Positive Outcome !
Accordion
Bicycle rack
Idea 3
Pros
Simple
Easy to store
Low cost to make
Able to fit all types of jigs
Cons
Strenuous to hang and store jigs
Overhanging jigs may be hazardous
Limited amount to hang
Hanger
Idea 4
Pros
Simple
Neat (hidden behind doors)
Only show on-going projects
Cons
Irregular jigs may not fit in
Small jigs need special storage
Wardrobe
Nut insert Feasibility Analysis
Design Consideration
Largest dimension of jig:
Width: 78.4cm
Length: 234cm
Thickness: 2cm
Proposed Ergonomics:
1 cm gap for finger allowance
Layout:
1m walking space
between each storage
Space issues
Safety issues
Storage area untidy
Safety hazards
Difficult to locate jigs
Misuse of jig storage area
Eye sore
Andrew Lim
Victor Tjang
Angus Chan
Sayraz Khan
Jamco FYP group 3
Project code: MAE-14544

SJPS/JPS
Purpose:
To gather primary data for analysis
To compare whether processes are done according to SJPS/JPS
Training video
Improvement plan
Consist of :
Time Observation
Spaghetti Chart
Evaluation Form
Problem 1 (Drilling/Milling)
50-60% of cycle time are of Non-value added activities

Excessive changing of drill bits

Needs technician to manually carry out the task
27 Training Videos
Idea 2 (Bicycle Rack)
Idea 3 (Clothes Hanger)
Idea 4 (Wardrobe)
Conclusion
Provide raw documentation ( 33 Processes )

Produced 27 training videos

Suggestions to improve current processes

3 Main improvement plans
Data Gathering
Comparing of Machines
Thank You !

Q&A?

Idea 1
(Accordion)
Idea 2
Bicycle Rack)
Idea 3
(Hanger)
Idea 4
(Wardrobe)
Conditions :
Feasibility
Simplicity
Cost
Design
Organize
Total/24
User-Friendly
Current Situation:
NVX 5060 II
Factors
DMC 635 V
ELUMATEC
SBZ 122/64
Productivity
Versatility
Software compatibility
Space requirement
Complexity
Total/15
22
11
18
9
Cons
Simple
DIY in-house
Less materials used
Flexible
Accommodate all sizes
Similar method used
Unsightly mess
Slanting of single jigs
Difficult to locate smaller jigs
Idea 1
Aim:
Produce primary data for 33 processes.
Sliding doors
Monument category
Colour coding
On-going projects
Slot for adjustments
Holes for extension
Jigs attached
Hooks
Additional Concept
Motorised Trolley
Benefits
Greater productivity

Reduce time, money and injury

Reduced risk of adverse publicity


Current Situation
Technician might need to walk to-and-fro if there is more than one jigs required
- Time per jig (1min 3secs) collect and return
Carrying of jigs may required two men operation
- Waste of man hours
- Kills momentum

12
10
10
Safety of technicians
Carrying heavy load causes long term injury

Visibility problem
Features
Enhanced by a hand pressure based speed control system
Emergency stop brake
Maximum and minimum speed settings
Battery discharge indicator and
Auto reverse alarm
Radio Frequency IDentification (RFID)
Advantages
Contactless
Writable data
Absence of line of sight
Support for multiple tag reads
Perform smart task
Extreme read accuracy

Possible Solutions
Epoxy Mixer :
Process Eliminated : Preparation of potting agent
Continuous mixing of the epoxy
Prevent epoxy from hardening
Can be used over and over again without cleaning
Time eliminated : 6min
Possible Solutions
Epoxy dispenser :
Process Eliminated : Applying of potting agent
Automation of applying potting agent
Currently no such machine for BMS 5-28 potting compund
Time eliminated : 1min 15s
Ranking:
Best
Worst
178,480.00
Amount Payable
$(110,313.00)
3 Main Improvement plans
Ideation
$11.20
Automation for Nut insert
Feasibility study :
To check which process can be eliminated with automation

Reduce time for individual steps taken for nut insert

To find possible automation solutions for processes that can be automated
- Good
- Average
- Poor
Activities which the customer did not paid for
Non value-added Activities (NVA)
Value added Activities (VA)
Activities which the customers paid for
Introduction of NVA & VA
Save approx.
60 hours
/month
Introduction
Identifying the problems
Evaluation of problem
Conclusion
Before identifying the problems
Non-value added (NVA)time :
Results from data gathering
Process
NVA time
Total time
Percentage of NVA
97.6%
4min 23s
4min 32s
Trim Cutting
Hole Marking
Drilling
Milling
1min 45s
1min 17s
73.3 %
2min 8s
3min 20s
64%
43.6%
39s
17s
Non-value added (NVA) time :
Process
NVA time
Total time
Percentage of NVA
63%
1min 4s
1min 42s
Installing nut insert
Problem 1 evaluation
Problem 1
Problem 2 (Installing of Nut Insert)
For Drilling and milling :
Motion
Repetitive changing of tools
For hole marking & Trim cutting :
Waiting
Waiting for machine
Problem 2 evaluation
For Nut insert :
Types of Waste
Motion
Repetitive putting of nut insert
Mixing epoxy manually
Problem 3 (Jig Storage)
Problem 3 evaluation
Finding jigs :
Types of Waste:
Motion, Waiting
Finding of Jigs
5s
Sort
straighten
shine
standardize
sustain
Storage area:
Pros
Types of waste
Machine model: EZ-3V
Cost analysis
Milling
Full transcript