greentex indonesia utama lean implementation

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PT. GREENTEX INDONESIA UTAMA LEAN IMPLEMENTATION

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Page 1: Greentex indonesia utama lean implementation

PT. GREENTEX INDONESIA UTAMA LEAN IMPLEMENTATION

Page 2: 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

Page 3: Greentex indonesia utama lean implementation

Identify The Waste = Opportunity

Page 4: Greentex indonesia utama lean implementation

Improvement Proposal

Page 5: Greentex indonesia utama lean implementation

IMPROVEMENT ACTIVITY

Page 6: Greentex indonesia utama lean implementation

QUALITY MINDSET & TARGET

Page 7: Greentex indonesia utama lean implementation

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?

Page 8: Greentex indonesia utama lean implementation

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

Page 9: Greentex indonesia utama lean implementation

FOCUS ON TOP DEFECT, 2 LOCATION

Page 10: Greentex indonesia utama lean implementation

10 Min Meeting

Page 11: Greentex indonesia utama lean implementation
Page 12: Greentex indonesia utama lean implementation

REDUCE CLEANLINESS ISSUE

Page 13: Greentex indonesia utama lean implementation

USING LONG SLEEVE GLOVE

Page 14: Greentex indonesia utama lean implementation
Page 15: Greentex indonesia utama lean implementation
Page 16: Greentex indonesia utama lean implementation
Page 17: Greentex indonesia utama lean implementation

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

Page 18: Greentex indonesia utama lean implementation

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

Page 19: Greentex indonesia utama lean implementation
Page 20: Greentex indonesia utama lean implementation

REDUCE SKIP STITCH ISSUE

Page 21: Greentex indonesia utama lean implementation

OPERATOR

52 Sec = 63 pcs / hrs 41 Sec = 80pcs / hrs

SELF CHECKING

DON’T CHECK

VS

Heming Bottom

Page 22: Greentex indonesia utama lean implementation
Page 23: Greentex indonesia utama lean implementation

OPERATOR

Page 24: Greentex indonesia utama lean implementation

OPERATOR

Page 25: Greentex indonesia utama lean implementation
Page 26: Greentex indonesia utama lean implementation

MECHANIC IMPROVEMENT

Page 27: Greentex indonesia utama lean implementation

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

Page 28: Greentex indonesia utama lean implementation

MAINTENANCE INFORMATION SYSTEM

Page 29: Greentex indonesia utama lean implementation

EXPAND LEAN LINE BEST PRACTICE

Page 30: Greentex indonesia utama lean implementation

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

Page 31: Greentex indonesia utama lean implementation

Total Team = 10 persons with The Leader

Page 32: Greentex indonesia utama lean implementation

CUTTING IMPROVEMENT

Page 33: Greentex indonesia utama lean implementation

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