LIE BALACIG AT A PACKIG PROCESS OF MEDICAL PRODUCTS
By
BOO CHEE KEE
SUPERVISOR: MR. MOHD FATHULLAH BI GHAZLI @ GHAZALI
Report submitted in partial fulfillment of the requirements for the
Degree of Bachelor of Engineering (Manufacturing Engineering)
APRIL
2010
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ACKOWLEDGEMETS
First of all, I would like to take this opportunity to express my greatest thank to my project supervisor, Mr. Mohd Fathullah bin Ghazli @ Ghazali who guided me, giving me full support and helping me while doing my Final Year Project. I also would like to express my gratitude Lecture Nor Zaiazmin bin Yahaya for his invaluable guidance and support me while learning Witness software and allow me to use all the equipment provided at the laboratory. My appreciation also goes to all the Manufacturing Laboratory staff for their encouragement and constructive comments.
Special thanks go to my friends, staff and lectures in University Malaysia Perlis (UniMAP) for their kind support and invaluable co-operation during my final year project. I am very grateful for their comments and suggestions about my logbook and final report. I also wish to recognize the determined efforts and patience of my beloved family especially to my mum and dad for their encouragement and understanding.
During my study in UniMAP for almost four years, I become to appreciate the vital nature of manufacturing engineering, design engineering and technology as an academic subject that is exciting, challenging and important as any other discipline.
Finally, it is hoped that this final report will assist others to understand the concepts of final year project and thus make the learning process both effective and enjoyable. At last, I would like to highlight my apology for any mistake I had made. Thank you very much.
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APPROVAL AD DECLARATIO SHEET
This project report titled Line Balancing at A Packing Process Of Medical Products was prepared and submitted by Boon Chee Keen (Matrix umber: 071050105) and has been found satisfactory in terms of scope, quality and presentation as partial fulfillment of the requirement for the Bachelor of Engineering ( Manufacturing Engineering ) in Universiti Malaysia Perlis (UniMAP).
Checked and Approved by
( Mr. Mohd Fathullah bin Ghazli @ Ghazali) Project Supervisor
School of Manufacturing Engineering Universiti Malaysia Perlis
APRIL 2010
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GARIS PERIMBAGA DI PROSES PEMBUGKUSA DALAM PRODUK PERUBATA
ABSTRAK
Tujuan utama untuk menyiapkan laporan ini adalah untuk merekod semua kemajuan dan keputusan yang diperolehi ketika dalam tempoh yang ditetapkan untuk menyiapkan tugasan ini. Projek yang dikendalikan untuk kedua dua semester, semester 1 dan 2 2009/2010 ini ialah untuk Garis Perimbangan di proses Pembungkusan dalam produk perubatan dan mengkaji pengendalian dan menyokong susun system pembuatan. Projek ini diselia oleh Mr. Mohd Fathullah bin Ghazli @ Ghazali, selaku penyelia projek.
Laporan ini menerangkan perkembangan keseluruhan projek dan informasi seperti kaedah Yamazumi Board yang digunakan selain menggunakan perisian Witness 2003 untuk tujuan simulasi proses. Tujuan projek ini adalah menyesuaikan pembuatan ‘lean’
teknik untuk dapat menyimbangan process secara teknologi memajukan.
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LIE BALACIG AT A PACKIG PROCESS OF MEDICAL PRODUCTS
ABSTRACT
The main purpose for preparing this report is to record all the progress and results obtained during the period required to complete this task. Project conducted for the two semester, semester 1 and 2 for 2009/2010 is in the Line Balancing at a Packing process of Medical Product and review the operation and support of the manufacturing system layout. The project is supervised by Mr.. Fathullah Mohd Ghazali bin Ghazli @, as the project supervisor. This report describes the development of the whole project, and information such as methods used Yamazumi Board other than using Witness in 2003 for the purpose of the simulation process. The purpose of this project is adjusting manufacturing 'Lean' techniques in order to develop the balance technological process.
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TABLE OF COTETS
Page
ACKOWLEDGMET i
APPROVAL AD DECLARATIO SHEET ii
ABSTRAK iii
ABSTRACT iv
TABLE OF COTETS v
LIST OF TABLES ix
LIST OF FIGURES x
CHAPTER 1 ITRODUCTIO
1.1 Introduction to Line Balancing at a Packing Process of medical products 1
1.2 Company Background 1
1.3 Product Manufactured of Covidien 3
1.4 Fabrication of Catheters 4
1.5 Packing Station Introduction 5
1.6 Objective 6
1.7 Problem Statement 7
1.8 Study Scope 7
1.9 Project Planning 8
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CHAPTER 2 LITERATURE REVIEW
2.1 Introduction 9
2.2 Research On Specification 10
2.3 Implementation in manufacturing 10
2.3.1 Push Stratery 11
2.3.2 Pull strategy 12
2.3.3 Yamazumi 12
2.3.4 Flow charts 13
2.3.5 Kaban 14
2.4 Software Review 14
CHAPTER 3 METHODOLOGY
3.1 Introduction 17
3.2 Understanding of Project Title 20
3.3 Conduct Information Seeking 20
3.4 Actual Production Observations 21
3.5 Critical Factor Identification 21
3.6 Data Collection & Analysis 22
3.7 Data Interpretation 22
3.8 Propose Improvement 23
3.9 Revise Data and Simulation 23
3.10 Documentation 23
3.11 Presentation 24
3.12 Step to Achieve First Objective 24
3.12.1 Understand the Process 24
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3.12.2 Collect Data and Information on Process 25
3.12.3 Analysis 25
3.12.4 Simulation 25
3.13 Step to Achieve Second Objective 25
3.13.1 Understand the Process 26
3.13.2 Collect Data and Information on Process 26
3.13.3 Analysis 27
3.13.4 Simulation 27
3.12.5 Validation 27
CHAPTER 4 RESULTS AD DISCUSSIO
4.1 Introduction 28
4.2 Result of Work Time 29
4.3 Work Process Flow 30
4.4 Results Current State 31
4.4.1 Result Flow Chart 31
4.4.2 Operator Step and Time 33
4.4.3 The Bar Chart of Current State 34
4.4.4 Witness Simulation 35
4.4.5 Station Statistic 36
4.4.6 Operator Statistic 37
4.5 Experimentation 5 Operator 39
4.5.1 Result Flow Chart 39
4.5.2 Operator Step and Time 41
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4.5.3 The Bar Chart 42
4.5.4 Witness Simulation 43
4.5.5 Station Statistic 44
4.5.6 Operator Statistic 45
4.6 Experimentation 4 Operator 47
4.6.1 Result Flow Chart 47
4.6.2 Operator Step and Time 49
4.6.3 The Bar Chart 50
4.6.4 Witness Simulation 51
4.6.5 Station Statistic 52
4.6.6 Operator Statistic 53
4.7 Experimentation Yamazumi Board 55
4.7.1 Result Flow Chart 55
4.7.2 Operator Step and Time 57
4.7.3 The Bar Chart 58
4.7.4 Witness Simulation 59
4.7.5 Station Statistic 60
4.7.6 Operator Statistic 61
4.8 Validation 63
CHAPTER 5 COCLUSIO AD RECOMMEDATIO
5.1 Conclusion 64 5.2 Recommendation 65
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REFERECES 66
APPEDIX 69
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LIST OF TABLES
Tables o. Page
4.1 Flow Chart (Current State) 32
4.2 Operator Step and Time (Current State) 33
4.3 Station Statistic (Current state) 36
4.4 Operator Statistic (Current state) 37
4.5 Flow Chart (5 Operator) 40
4.6 Operator Step and Time (5 Operator) 41
4.7 Station Statistic (5 Operator) 44
4.8 Operator Statistic (5 Operator) 45
4.9 Flow Chart (4 Operator) 48
4.10 Operator Step and Time (4 Operator) 49
4.11 Station Statistic (4 Operator) 52
4.12 Operator Statistic (4 Operator) 53
4.13 Flow Chart (Yamazumi Board) 56
4.14 Operator Step and Time (Yamazumi Board) 57
4.15 Station Statistic (Yamazumi Board) 60
4.16 Operator Statistic (Yamazumi Board) 61
4.17 Compare of Experimentation 63
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LIST OF FIGURES
Figures o. Page
1.1 Cather 3
1.2 Closed System 4
1.3 Packing Station Structure 5
1.4 Current Packing Station’s layout 6
2.1 Pull and Pull 10
2.2 Witnesss 2003 Sofware 14
2.3 Witness Screen and View Let Gallery 16
3.1 Process Improvement Study in Actual Production Plant 18
3.2 Step to Achieve Objective 19
3.3 First Objective 24
3.4 Second Objective 26
4.1 1 Box 29
4.2 Work Process Flow 30
4.3 Bar Chart (Current state) 34
4.4 Witness Simulation (Current state) 35
4.5 Station Statistic Chart (Current state) 36 4.6 Station Statistic Status Chart (Current state) 37 4.7 Operator Statistic Chart (Current state) 38 4.8 Operator Statistic Status Chart (Current state) 38
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4.9 Bar Chart (5 Operator) 42
4.10 Witness Simulation (5 Operator) 43
4.11 Station Statistic Chart (5 Operator) 44
4.12 Station Statistic Status Chart (5 Operator) 45
4.13 Operator Statistic Chart (5 Operator) 46
4.14 Operator Statistic Status Chart (5 Operator) 46
4.15 Bar Chart (4 Operator) 50
4.16 Witness Simulation (4 Operator) 51
4.17 Station Statistic Chart (4 Operator) 52
4.18 Station Statistic Status chart (4 Operator) 53
4.19 Operator Statistic Chart (4 Operator) 54
4.20 Operator Statistic status Chart (4 Operator) 54
4.21 Bar Chart (Yamazumi board) 58
4.22 Witness Simulation (Yamazumi board) 59
4.23 Station Statistic Chart (Yamazumi board) 60
4.24 Station Statistic Status Chart (Yamazumi board) 61
4.25 Operator Statistic Chart (Yamazumi board) 62 4.25 Operator Statistic StatusChart (Yamazumi board) 62
