ISHIKAWA DIAGRAM
Network Pwb wire Preparation
Improvement - 4
Improvement - 6
Front grill assembly process
Schedule
FISH BONE CAUSE ANALYSIS
WHY choose this theme?
- Provided jig
- Process layout change
- Improved motion time
Subwoofer packing
Subwoofer supply conveyor
Main Assembly Layout
Tangible result
Improvement - 2
Improvement - 8
Improvement - 10
- Motion Improvement
Monitoring Of Improvement
Possible causes of low Production
Output and effects (line balancing)
Data Analysis 2 of VIZIO
Possible causes of low Production
Output and effects
Our Team Name & Logo
Subwoofer and sound bar pairing process
Before
After
STANDARDIZATION
After
MACHINE
Improvement - 12
After
MAN
Before
AFTER MAIN ASSEMBLY LAYOUT
Before
After
ITEM
SAVE
COST (RM)
MAIN ASSEMBLY LAYOUT
FINAL
CALCULATION
Insufficient facility
and layout
(Cause sets transferring
& waiting loss)
FINAL
38.06 sec
38.06 X 0.6245 X 450 X 20 X 3 / 60
RM 10,695
Contract worker attendance
turn out insufficient
Eliminate transfer loss
IMPROVE PRODUCTION
YIELD
TOTAL PREPARATION TIME
3.Appearance
4.Packing
RM 7,200
2.Inspection
1.Fix & screw soundbar
TOTAL FINAL ASSEMBLY
2 M/P
2 X RM1200 X 3
New worker training loss
Conveyor too long
28.37 sec
28.37 X 0.6245 X 450 X 20 X 3 / 60
RM 7,972
Front grill pressing machine
TOTAL PACKING
Brainstorming Ideas
PREPARATION
RM 25,867
Grand Total
1) Stick felt to Network Pwb wire one by one.
Push
* Jig design similar to ladder type , as to simplify and reduce hand motion.
Part arrangement
change
Improved 5S
Part arrangement
change
Improved conveyor
PREPARATION
4
6
7
8
12
13
14
15
16
18
4
1
2
3
5
9
10
11
17
19
20
1
2
3
5
1.Existing conveyor line not enough capacity to
cope with the production plan.
2.Production line capacity low.
3.To reduce unnecessary loss on process occured
in production.
4.To improve production & factory efficiency by
strengthen line balancing & facility.
13
14
15
16
17
18
19
B
S
T
Prod. Staff need to pickup Sub Woofer & Sound Bar near to pairing unit place.
E
4
5
3
One P/S is required to place Sub Woofer on working bench. Only 4 unit can be placed.
SAVE
RM25,867
( 3 MONTH )
20
Pull
Eliminate All distractions
32 METER
1
2
1) Make small hanger using Box File Clip to hang HDPE Bag.
Working method impropriate
1) Adjust the positioning Pairing Unit.
2) PS only require to turn & pickup
Sound Bar.
3) Readjust Ac Cord Connector Height
Conveyer design improved will be benchmark for standardization of similar product. ( Plan new project method for new model 2013 )
Plan straight line layout to reduce MP & get optimum quantity.
12
11
10
9
8
7
6
5
4
3
2
1
- TO INCREASE QUANTITY BY 10%
- TO REDUCE LOSS TIME
1) HDPE Bag hang on Pipe & Joint for PS to pick & cover Sub Woofer.
2) This bag easily fall down on floor as it's smooth surface.
Design matter cause
material defect
(Button stuck problem)
one time.
2) Input Sub Woofer to Pairing Inspection using new conveyor
3) Same manpower used to support at packing area.
Nature of job distribution
not smooth
Jig is located beside conveyor.
INCREASE PRODUCTION
OUTPUT QUANTITY
BIAQ BETOI!!!
Jig is directly located on the conveyor.
Reduce hand and body motion time.
Reduce push and pull jig process and body
turning motion.
Manpower vs process
not match
Start the Task
3)Using 3 steps Jig by modifying single jig so that 3 wire can be prepared at a time.
6.Hi-pot & vibration test
7.Fix speaker
5.Preparation
8.Transfer next station
2) Make new Single Jig for preparation.
METHOD
MATERIAL
start 2 line-->
Target Achieved
FUTURE PLAN
Line Balancing
Improvement - 3
Speaker unit preparation
Improvement - 5
INTANGIBLE BENEFIT
Group Profile
- Motion Improvement
Packing Layout
Subwoofer packing
Sound bar packing process
10 meter pairing process
PDCA cycle
Result of improvement
Data Analysis 1 of VIZIO
Monitoring Of Improvement
Possible causes
Improvement - 1
Improvement - 7
Improvement - 9
Improvement - 11
BEFORE PACKING LAYOUT
After
Before
After
AFTER
BEFORE PACKING LAYOUT
Loss time 3
Carton Transfer Slow
Effect The Packing Jobs
Carton transfer slow effect the packing jobs
Monitor progress
Loss time 3
7
AUTO
SEALING M/C
Warehouse
ROLLER CONVEYOR
BELT CONVEYOR
Carton Preparation
8
9
Packing
3
Packing
4
2
6
Wrapping Sound Bar
4
3
Appearance
10
Meter
Pairing
Sound
Bar Unit From Gr.Floor
Mathew (Facilitator)
7
Warehouse
502
Carton
Preparation
Packing
2
386
Packing 1
A
ROLLER CONVEYOR
Part arrangement
change
Improved 5S
How does it occurs?
Production output qty low, sets transferring & waiting loss.
Productivity up 10%.
Set target for the
Improvement item.
5
P
Addition on facility
by Implementation
of the process /
layout change
BELT CONVEYOR
Plan the activity
AUTO
SEALING M/C
9
8
CONVEYOR FOR TRANSFERING SUB WOOFER AFTER PAIRING
Using flip Jig to apply cushion.
Pairing
Packing 4
- Understanding of Line process group.
- Upgrade knowledge on Line Balancing.
- Learn new QC tools.
Packing 3
What is the root cause ?
limitation of the
conveyor system
not suit to the
model.
(Vizio sound bar)
10
1
PAIRING UNIT
Sub Woofer Input
Handling 1
Continue to implement straight
and understanding
INPUT = OUTPUT
to others audio production line.
Nature of job & job distribution
Sound bar unit
Loss time 2
2
Wrapping
Sound Bar
6
After
not even .
Place
Sub Woofer To Table
Place
Sub Woofer To
10 Meter pairing
Appearance
Loss time 1
From Gr.Floor
Possible causes of low Production
Output and effects
Stanble For Pairing
Pairing Unit For Pairing
4
3
KC Ewe
Part arrangement
change
Improved motion
Stick Cushion to Speaker unit inner baffle L & R manually at 3 position.
Ergonomic working method
Improved table height
INCREASE PRODUCTION
QUANTITY THROUGH:
- Create new conveyor system
- Process simplification
- Create fast & speed working
method through facility
improvement
7
AFTER PACKING LAYOUT
Packing 2
Carton Preparation
Packing 1
REDUCE WAITING TIME
1) Packing table height was lower than conveyor
Low Production Quantity
ROLLER CONVEYOR
AUTO SEALING M/C
1) Poor arrangement of Packing material.
2) Effect overall 5'S.
Warehouse
ROLLER CONVEYOR
8
5
9
Where this problem happens?
Audio Production Area
(Vizio sound bar line)
CONVEYOR FOR TRANSFERING SUB WOOFER AFTER PAIRING
Packing 3
Packing 4
ELIMINATE MOTION LOSS
Packing 1
LV Loo-1st speaker
Nikkie - prepare material
Pairing
2
5
Who is responsible
to increase production
output qty?
Prod. Eng’g, Officer,
Technicians, prod. staff
1) Front View of this process shows no facility / improvement done to support prod.
6
13.4
Wrapping Sound Bar
Appearance
4
10 Meter Pairing
3
Sound Bar Unit From Gr.Floor
1
Handling 1
10
1) Make new working table to place packing material in front of P/S (to bring parts/ component nearer to the working area)
Packing 2
Sub Woofer
Input
PRESENT
AC INLET HERE
.
1) Adjust current packing table height to same level of conveyor.
2) Make additional working table to speedup packing process.
1) P/S need to carry & place
Loss time 2
ADD NEW TABLE
after pairing insp.
Job distribution not even
C
- REDUCE PRODUCTION LOSS
- PROFIT FOR COMPANY
1
Loss time 1
D
1
Place subwoofer to table stanble for pairing
Place subwoofer to pairing unit
2) Able to support packing if
Do line balancing /
Process change / add
Facility / relayout
CONVEYOR FOR TRANSFERING SUB WOOFER AFTER PAIRING
P/S 10 support at Pairing
Pairing
Insp. (Fully ultilise P/S job)
10
PAIRING
UNIT
1) Rearrange parts as easy for PS to pickup.
SP Foo-line layout
HS Cheng -line layout
Shukery-process study
→ ADD NEW CONVEYOR TO INPUT SUBWOOFER FOR PAIRING
- For Apr~Jul 12, due to line capacity not enough need to do overtime to cover the balance set
PAIRING
UNIT
Check & Monitoring
the proposal
Why does it happens?
The output qty not tally against the tact time
Chg Present
& ADD 2nd
When it happens?
During production
running.
Sub Woofer Input
.
AC INLET for 2nd Pairing
- For Aug & Sep 12, need to setup new conveyer system to cater the production plan qty.
Jun 12
Aug 12
Sep 12
Apr 12
May 12
Sep 12
Jul 12
P/S no.10
ELIMINATE TRANSFERING LOSS
After
Input Sub Woofer ,
able to support Pairing Insp
KY Khoo -line layout
Lingam-line balancing
Zaini-data collector
Saniah-animator
Welcome to R-CATS presentation
3 JAN 2013