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Greentex indonesia utama lean implementation
The document outlines Pt. Greentex Indonesia Utama's plans to implement Lean systems and principles to achieve benefits like higher quality, lower costs, and shorter lead times. It discusses identifying and eliminating waste opportunities. It also provides information on improvement proposals, activities, metrics, and responsibilities for quality control across different departments like sewing, cutting, and maintenance. Visual standards and preventative maintenance procedures are established to reduce defects from issues like oil leaks and skips stitches. The implementation of a maintenance information system and expanding successful lines from single to multi-process "Lean Lines" are also covered.
Greentex indonesia utama lean implementation
- 1. PT. GREENTEX INDONESIAUTAMA LEAN IMPLEMENTATION
- 2. Lean System inPt. Greentex Indonesia Utama LEAN is business phylosophy based on the systematic elimination of waste by an empowered workforce. LEAN if implemented properly can get BENEFIT such as : higher quality, lower cost, shorter leadtime, greater flexibility and mutual trust & respect
- 3. Identify The Waste= Opportunity
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- 7. FACTORY MGR SEWING MGR PRODUCTION HEAD CHIEF SPV OPERATOR MECHANIC LEADER LINE MECHANIC CUTTING& SAMPLE MGR HEAT TRANSFER HT OPERATOR LOADING SPV LOADING OPERATOR WAREHOUSE FABRIC MGR Stable Quality, Competitive Cost Dan On Time Delivery How To Achieve It? What’s the Metric/Measurement Tools? How To Control It? How To Achieve It? What’s the Metric/Measurement Tools? How To Control It? How To Achieve It? What’s the Metric/Measurement Tools? How To Control It? How To Achieve It? What’s the Metric/Measurement Tools? How To Control It? How To Achieve It? What’s the Metric/Measurement Tools? How To Control It?
- 8. QUALITY CONDITION FOR 2 HRS REJECT> 15% RESPONSIBLE LEADER TO FOLLOW UP SEWING SPV INLINE QC FOR 3 HRS REJECT > 15% SEWING SPV SEWING CHIEF FOR 4 HRS REJECT > 15% SEWING CHIEF QC CHIEF FOR 5 HRS REJECT > 15% SEWING MGR FOR 6 HRS REJECT > 15% SEWING MGR QA MGR MORE THAN 6HRS REJECT > 15% FACT MGR
- 9. FOCUS ON TOPDEFECT, 2 LOCATION
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- 13. USING LONG SLEEVEGLOVE
- 17. PREVENTIVE MAINTENANCE STANDARDTO OVERCOME OIL LEAKED ISSUE BASED ON MACHINE SUPPLIER & MECHANIC RECOMMENDATION 1 BLN 3 BLN 6 BLN 1 TH Kekencangan mur pada cover atas mesin Mur kencang dan pas tidak ada sela untuk aliran minyak Kencangkan mur cover 97 V Pastikan mur pada cover mesin sudah ok setelah setting atau perbaikan Gasket cover atas Kondisi gasket tidak putus /sobek Sambung gasket menggunakan lem three bond 1212 12 V Selang minyak Selang dalam kondisi bagus tidak bocor / pecah Ganti selang jika bocor /pecah 10 V Sumbu serap minyak Sumbu dalam keadaan baik /daya serap baik Ganti sumbu dengan ukuran kecil jika daya serapnya tidak baik 4 V Gasket cover samping Kondisi gasket tidak putus /sobek Sambung gasket menggunakan lem three bond 1212 143 V Seal tiang jarum Seal tiang jarum kondisi bagus tidak pecah /aus Ganti seal tiang jarum 10 V Penutup seal minyak Seal kencang dan tidak mengeluarkan minyak Lem dengan Three bond 1212 10 V Oil/Minyak 22 Viskositas Ganti minyak dengan standar kualitas ( 22 Viskositas ) 900 V 1186 Waktu perawatan Actual TOTAL WAKTU CEK BOCORAN MINYAK STANDAR PERAWATAN BERKALA MESIN KAMPUT KANSAI ( MENCEGAH BOCOR MINYAK ) KeteranganGAMBAR BAGIAN YANG DICEK STANDAR CARA CEK ALAT TINDAKAN PHOTO WAKTU CHECK ( Detik ) WAKTU PERAWATAN PER INVOICE
- 18. VISUAL STANDARD SINGLENEEDLE MACHINE IN-OUT 11. WHEEL 10.PEDAL 7.NEEDLE GUARD & FEED DOG 8.BOBBIN CASE 3. ON / OFF BUTON 2.PULLEY GUARD 6. SEAL COVER 4.MACHINE HOLDER 5. THREAD TENSION 9.PULLEEY GUARD / DYNAMO 1.THREAD CUP VISUAL STANDARD IN-OUT MACHINE
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- 21. OPERATOR 52 Sec =63 pcs / hrs 41 Sec = 80pcs / hrs SELF CHECKING DON’T CHECK VS Heming Bottom
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- 27. PRESENT MECHANIC SKILLMATRIX SN,DN, OVERDECK, KANSAI BUTTON HOLE SN,DN, Velcro OVERLOC, OVERDECK, KANSAI,OD RAMPU OVERLOC, OVERDECK ODRampu KANSAI, OVERDECK ALL MACHINE TYPE KANSAI 1 9 8 2 9 8 3 9 5 4 9 2 5 9 2 6 9 3 7 9 2 8 B 9 3 9 B 9 4 10 B B 9 9 11 B B 9 9 12 9 0 13 9 2 9 2 5 4 6 1 7 6 10 5 5 MECHANIC SKILL MATRIX MACHINE OVERDECK G O A L Q1 Q2 Q3 Q4 SKILL NAME/PROCESS 1.NEEDLEBAR HEIGHT STANDARD 8.FABRIC CHARACTERISTI C 9.NEEDLE& PLATE STANDARD 10.AUTOMATIC KNIVE STANDARD 11.PULLER MECHANISM No. 2.NEEDLEBAR HEIGHT STANDARD 3. ROTARY/HOOK SETTING 4.LOOPER SETTING STANDARD 5.THREAD SETTING 6.THREAD SETTING 7.SPIDER SETTING/HOLD ER YUSUF ALWI SINGGIH AMIRUDIN CARITO ROHMAN HASYIM SUHENDAR ISMAIL IWAN ADI RANDY SUBKI RESULT OF TRAINING (HASIL TRAINING) Beginning of Year (Awal Tahun) 100% Performance : High skill, can train to others, can solve difficult machine problems, need no supervision Middle of Year(Pertengahan Tahun) 75% Performance : Need less supervision, can fix most of machine breakdown issue End of Year(Akhir Tahun) 50% Performance : Still need supervision, can do minor machine breakdown 25% Performance :Trainee TARGET SKILL LEVEL MECHANIC NAME
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- 29. EXPAND LEAN LINE BESTPRACTICE
- 30. Lean Dept atGreentex … This NOS HOUSE in sewing line transfer into 8 NOS line criteria : 1.At least 2 process connected (Loading, sewing and finishing) 2.Inventory controlled 3.Andon system 4.Appropriate metrics 5.ISQ (In Station Quality) 6.Standardize Work 7.5S & Visual Management 8.Manage As Single Entity
- 31. Total Team =10 persons with The Leader
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- 33. S E W I N G L I N E Sewing Loading Rack Loading ADM Line 6 Line7 Andon Lamp Andon Lamp 1 2 4 5 7 8 11 10 3 6 9 12 Loading Supermarket 1 2 4 5 7 8 11 10 3 6 9 12 Embroidery Line 6 Line 7 1 2 4 5 7 8 11 10 3 6 9 12 HT/FUSING 1 2 4 5 7 8 11 10 3 6 9 12 Cutting 1 Cutting Table Kanban Post Cutting Kanban Post Fabric 1 Andon Lamp PT. GREENTEX INDONESIA UTAMA PULL SYSTEM PLAN Andon Lamp Andon Lamp