LEAN MANUFACTURING
DEVELOPMENT
No FIFO No Work Standard Difficult to identify parts Unsafe conditions
Safety issue Productivity issue
Inventory Cost issue Workability issue
No Standard
Quality issue
Supplier Current Condition
Currently 2 nd Tier company still struggle with
Fundamental Manufacturing issues → Need strong effort to develop 2 nd Tier
Beginner Learner
Junior KaizenMan
Senior KaizenMan
Kaizen Master
Beginner (1) Learner (2) Junior Kaizenman (3) Senior Kaizenman (4) Kaizen Master (5)
Knowledge Know Understand Technical
Concept (Basic)
Understand Technical Concept (Intermediate)
Understand Technical Concept (Advance)
Masterized Kaizen Knowledge
Skill (Capable to implement)
Basic Rule & Standards (5R, Safety, Work
Standard)
Set up & PDCA JIT, abnormality respon, SW (Shipping & Production)
Set up & PDCA JIT, abnormality respon,
SW (Shipping – R/M)
Level Up + Leadership capability
At various Industrial type (Mfg and Non-Mfg)
LEVEL 1
LEVEL 2
LEVEL 3 LEVEL 4 LEVEL 5
Area Own Process Experience Multi process & Commodity Experience
MIN. TARGET
[ Kaizen Man ]
Dev Lead Time
1 year 2 yrs 3 yrs
6 yrs
People Development Level
12 yrs
Level 1 Level 2 Level 3 Level 4 Level 5
Pre-Basic Manufacturing
Basic
Manufacturing
Stable Manufacturing
Lean Manufacturing
1)Have a Safety Map that is visualized in shop with clear kaizen activity.
2)Work area, work equipment, and process machine are always kept clean (Shine).
3)Pulling & Fill Up for0,5 Shift productionat each line
4)Use visualization tool of 1 delivery cycle
abnormalityfor respond at each line/process
5)Follow SWbut still high CT fluctuation & unbalance job among MP
1)Safety signs are well visualized in the shop and can guarantee no Unsafe Condition.
2)Always keep the 3R condition backed up by check sheet 5R patrol activity by the Work Leader (Standardize).
3)Pulling & Fill Up for 1 Hour Collected kbn Prod. at each line
4)Use visualization tool of 1 hour abnormalityfor respond at each line /process
5)Follow SW but still over 1 MP usage due to idle time
1)Achieved zero accident for 1 year
2)Making 5R a culture through campaigns, training, banners, slogans, etc. (Sustain)
3)Pulling & Fill Up for every 1box/kbn Production at each line
4)Use visualization tool of 1 hour abnormalityfor respond at each line /process
5)Follow SW & each operator CT can meet as target
Strong Manufacturing
2 yrs
3 yrs
Traditional Manufacturing
Level 0
Dev Lead Time
MIN TARGET (AUTOMOTIVE)
1)Still found potential dangers Rank A and Rank B in shop.
2)The shop condition is messy and many items are mixed.
3)Push System by Monthly Plan
4)All abnormality not visualized
5)No SOP/WI as Work Standard
1)Having a formal document concerning standards of safety signs and PPE standards
2)There are only items that are still used In the work area (Sort).
3)Already setup Store for Finished Goods
4)1 Day abnormality can seen at F/G Store only 5)Use SOP/WI as Work
Standard
1)Implementing PPE that meet to the standard and process characteristics 2)The location of goods
already has a standard and a clear addressing (Set In) 3)Pulling & Fill Up for 1 Day
Del. & Prod. at each line 4)1 Day abnormality can
seen at each line /process 5)Use Standardized Work
sheet
1) Safety 2) 5S
3) Lead-time
4) Abnormality Detection 5) Work Standard
Genba Development Level [ Genba Operation ]
① Management Activity
Genba Assessment (Before & After activity improvement)
② Safety & 5S ③ Productivity
④ Just In Time
⑤ Jidouka
0 1 2 3 4 5
Management Activity
Safety & 5S
Productivity Just in Time
Jidouka
LEVEL LEAN MANUFACTURING
TARGET BEFORE AFTER
TRAINING
In-Class Training
•5S
•Safety
•Basic TPS
• Standardized
• MIFC & Heijunka
Genba Observation (Maping Problem)
•5S
•Safety
• Standardized
•Just In Time & Jidouka
Kaizen Implementation
•5S
•Safety
•Model Line Development (Shipping, Production, Logistic)
2 weeks 3 weeks 4 weeks
1. Basic knowledge (in class training) 2. Practice by genba observation
People Development
Data Order Admin
Waiting Post Heijunka
Post
Pr ep ar e R e ad y
Shipping Area Truck Station
Customer Supplier
Chuter Collecting
Post
Every time ... ‘ Volume ... pcs
X - Y - Z X - Y - Z
C.T = T.T
∑MP =∑C.T T.T
Pull System
Assy Line
Warehouse Store
LINE MODEL DEVELOPMENT
Jishuken Activity
Genba Development
PRODUCTION SHIPPING
MATERIAL
STEP DEVELOPMENT ACTIVITY
TARGET :
Good Implement Lean Manufacturing Minimize Loss
CURRENT :
So many loss in Manufacturing process (7 MUDA)
A. People Recruitment
B. People Training
C. Line Model Development
D. Plant
Development
GAP
1. Min 5 years experienced
2. Have Spirit/ yaruki to always kaizen
1. Basic knowledge (in class training) 2. Practice by genba observation
Jishuken Activity
Continous Improvement
PEOPLE DEVELOPMENT GENBA DEVELOPMENT
BENEFIT
5S & Safety Level Up
Before After
Shortening Lead Time ( JIT )
Before After
Productivity
Before After Manufacturing Cost
Before After Delivery Performance
Before After Quality ( rejection ratio )
Before After
