greentex indonesia utama lean implementation
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PT. GREENTEX INDONESIA UTAMA LEAN IMPLEMENTATION
Lean System in Pt. 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
Identify The Waste = Opportunity
Improvement Proposal
IMPROVEMENT ACTIVITY
QUALITY MINDSET & TARGET
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?
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
FOCUS ON TOP DEFECT, 2 LOCATION
10 Min Meeting
REDUCE CLEANLINESS ISSUE
USING LONG SLEEVE GLOVE
PREVENTIVE MAINTENANCE STANDARD TO 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
cover97 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 /pecah10 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
jarum10 V
Penutup seal
minyak
Seal kencang dan
tidak
mengeluarkan
minyak
Lem dengan
Three bond 121210 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 )
KeteranganGAMBARBAGIAN
YANG DICEKSTANDAR CARA CEK ALAT TINDAKAN PHOTO
WAKTU CHECK
( Detik )
WAKTU PERAWATAN PER
INVOICE
VISUAL STANDARD SINGLE NEEDLE 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
REDUCE SKIP STITCH ISSUE
OPERATOR
52 Sec = 63 pcs / hrs 41 Sec = 80pcs / hrs
SELF CHECKING
DON’T CHECK
VS
Heming Bottom
OPERATOR
OPERATOR
MECHANIC IMPROVEMENT
PRESENT MECHANIC SKILL MATRIX
SN,
DN
,
OVE
RDEC
K,
KAN
SAI
BUTT
ON
HO
LE
SN,
DN
,
Velc
ro
OVE
RLO
C,
OVE
RDEC
K,
KAN
SAI,
OD
RAM
PU
OVE
RLO
C,
OVE
RDEC
K
OD
Ram
pu
KAN
SAI,
OVE
RDEC
K
ALL
MA
CHIN
E
TYPE
KAN
SAI
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
OVE
RDEC
K
G
O
A
L
Q1 Q2 Q3 Q4SKILL NAME/PROCESS1.
NEE
DLE
BA
R
HEI
GH
T
STA
ND
ARD
8. F
ABR
IC
CHA
RACT
ERIS
TI
C
9. N
EED
LE &
PLA
TE
STA
ND
ARD
10.
AU
TOM
ATI
C
KNIV
E
STA
ND
ARD
11.
PULL
ER
MEC
HA
NIS
M
No.
2. N
EED
LE B
AR
HEI
GH
T
STA
ND
ARD
3.
ROTA
RY/H
OO
K
SETT
ING
4. L
OO
PER
SETT
ING
STA
ND
ARD
5. T
HRE
AD
SETT
ING
6. T
HRE
AD
SETT
ING
7. S
PID
ER
SETT
ING
/HO
LD
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 SKILLLEVEL
MECHANIC NAME
MAINTENANCE INFORMATION SYSTEM
EXPAND LEAN LINE BEST PRACTICE
Lean Dept at Greentex … 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
Total Team = 10 persons with The Leader
CUTTING IMPROVEMENT
S
E
W
I
N
G
L
I
N
E
Sewing Loading
Rack
Loading ADM
Line 6 Line 7
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
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