Thinking People System (TPS) Implementation ProgramBY: Vendor Improvement Section, Vendor Development Dept, Group Procurement

Program ObjectiveImplementation of TPS Element -

Standardized WorkTakt TimeWork Sequence≥ 85% Manpower Efficiency

Implementation of JishukenQuality related JishukenDelivery related Jishuken

Jishuken RequirementTwo week’s cycle per project. At each end of

project, present to Proton GPJudging criteria as per AttachmentAs a handout,

8D reporting will be required (refer to Attachment for sample of 8D report)

QAF

Sample of Jishuken Schedule1st Day = Data Analysis & Identify problem/process2nd Day = Training operator & line leader on how and what

to do3rd Day = Map out current process condition (VSM or Fish

bone diagram-why why analysis4th Day = Map out future state/ proposal state (VSM or

Process flow) and list what to do (Kaizen)5th Day = Fabrication and installation 6th Day = 7th Day = Corrective action to stabilize improvement8th Day =9th Day = Documentation preparation -8D and Presentation

slide10th Day = Present to PROTON

Three Level of KaizenKaizen of Method

Improve working sequence/process or operator movement

Kaizen of ToolReplace, improve or implement new tool

Kaizen of environment/surroundingBase on 5S and placement of material.

Standard Work RequirementAll vendors will be assigned to groups

according to manufacturing category (e.g. rubber, metal, painting etc.)

Program will be conducted as tutorial class (facilitator will be from Proton GP, NPC, or Kaizen Institute)

Documentation Required: QAFTime Measurement Check SheetStandard Work Combination Table (SWCT)

Calculation Required:Manpower Efficiency Manpower Requirement

Time Measurement Check SheetIdentify standard time allowed for every

process, for each operatorTake 10 readings for each process. Minimum

value will be chosen.Standard time = min value + allowance.

Allowance is determined by each Company and must be justified

Standard Work Combination Table (SWCT)Analysis each work sequences (for muda)

Recap

C

17.48

20

19

8.36

40.17 18.26

1.27 2.12

12

Pasang Rr Openning Trim Lh

11.64 12.51 15.95 10.59 7.59 10.59 11.63 13.30 9.827.59

8.70 10.64 9.42 8.99

20.4652.91 47.81 52.34 45.01

38.0152.61 40.2247.26 42.07 53.55 46.07 42.23 38.01 40.93 58.02 58.47

6.0010.18

1.07 3.50

2.81

17

1.14

10.11 9.44

122.58 123.79 116.91 99.43

A B

138.51 133.40 126.61 129.34124.29 121.51 121.22 153.85135.74 132.27 129.54 125.38

2.01 1.27 2.21 2.81 3.03 2.04 2.00 2.20 3.39 3.01 2.01 1.87 2.47 2.82 1.90

51.01 43.2157.80 56.92 40.71 48.59 49.1150.42 47.41 58.97 51.16 52.97 50.71 49.17 50.61

1.872.002.28 2.45 2.97 3.04 1.56 2.00 2.99 3.95 3.24 2.44 1.72 1.841.14

3.24 2.07 1.071.98 2.612.19 3.31 3.88 2.69 3.04 4.44 2.09 1.98

10.75 11.6114.86 10.84 10.40 16.18 10.4715.41 11.82 15.32 11.57 12.64 10.9112.0110.18

4.57

9 10

Berjalan Ke Rack

85 6

Lihat Production Sheet, Ambil Part Di Rack

Berjalan Ke Kereta

Letak Part Pada Kereta

11 RankRangeXmin12 14 1513Process Sequence 3 41 2 7

5

Process

KANCIL

1

Pasang Fr Garnish Lh

4

2

3

Pasang Fr Openning Trim Lh

No

6

8

9

13

11

10

3

5

TOTAL

16

6

7

14

15

18

7

1

4

2

Measurer NameTIME MEASUREMENT SHEETFINAL 1-OPENNING TRIM LH

Measurement DateSerial NO.

Amirul Izhar & Affandy Problems

116.9117.48

1.07

5.51

42.38

11.96

44.54

1.270.00

4.37

4.37

4.37

3.08

Allowance Standard

10.180.00

0.00

4.37

1 OPERATOR BUKA PLASTIK PART

OPERATOR MELAMBATKAN PROSES 8

3. CYCLE TIME READINGS (in this

example, 15 readings)

5. ‘X MIN’-MINIMUM TIME

FOR EACH PROSESS.

6. RANGE = MAX TIME – MIN TIME (for each process)

7. RANK – HIGHEST RANK GOES TO

HIGHEST RANGE VALUE

8. ALLOWANCE - SET BY EACH

COMPANY BUT MUST BE

JUSTIFIED

9. STANDARD TIME = Xmin + ALLOWANCE

How to Fill Up Time Measurement1. DETAIL CHECK SHEET

2. WORK SEQUENCES & PROBLEM

3. CYCLE TIME READINGS (in this

example, 15 readings)

5. ‘X MIN’-MINIMUM TIME

FOR EACH PROSESS.

6. RANGE = MAX TIME – MIN TIME (for each process)

3. CYCLE TIME READINGS (in this

example, 15 readings)

5. ‘X MIN’-MINIMUM TIME

FOR EACH PROSESS.

8. ALLOWANCE - SET BY EACH

COMPANY BUT MUST BE

JUSTIFIED

6. RANGE = MAX TIME – MIN TIME (for each process)

3. CYCLE TIME READINGS (in this

example, 15 readings)

5. ‘X MIN’-MINIMUM TIME

FOR EACH PROSESS.

MANUAL

AUTO

WALK

59 4.2TOTAL TIME

2.2

2.8

9

1.4

6 12.6

7 8.4

8

10.8

4 11.2

5 1.4

1 8.6

2 3.8

3

SEQ J OB CONTENTSTIME

MANUAL AUTO WALK

MODEL SECTION TACT TIME PROCESS NO.

PROCESS NAME

STANDARD WORK COMBINATION TABLE TEAM LEADER PROD. EXEC AM / MGR

OPERATION SEQUENCE FLOWDATE

Setting 3 part

Install 2 part

Install 5 clip for Lwr Interference

Install 7 fius

Install air cond hose

Install sub-assy gear

Install console box and impact 2 pcs

Impact RR Seat and impact 2 bolt

4 10 20 30 40 50 60 70

CT 63.2"

80 90

TT 90"

Example of Standard Work Combination Table

1. DETAIL CHECK SHEET

2. WORK SEQUENCES

4. PLOT TAKT TIME

6. IDENTIFY WAITING TIME

(MUDA)

3. FILL UP CYCLE TIME ACCORDING TO

CATEGORY

5. This is a standard Legend

5. LINE FOR EVERY PROCESS(remember to use

appropriate lines as per legend!)

Sample Calculation of Manpower Efficiency

Efficiency = Total cycle timeTakt time x No Of Workers

(4+4+12+4+16+4+4+4 )

( 15 x 8 )

52

120

= 43 %

x 100=

= x 100

x 100

Sample Calculation of Manpower Requirement

Manpower Requirement = Total cycle time

Takt Time

= [(11X4) + 4 + 4]/ 15

= 3.47 people

VENDOR GROUPINGGROUP 1 (CASTING)

COMPANY Location

ALUMINIUM ALLOY INDUSTRIES SDN BHD NILAI

SENA DIECASTING INDUSTRIES SDN BHD SEMENYIH

HICOM DIECASTINGS SDN BHD SHAH ALAM

HICOM ENGINEERING SDN BHD SHAH ALAM

RIGHT WAY INDUSTRIAL (M) SDN. BHD. SHAH ALAM

LC RIMS MANUFACTURING SDN. BHD. SG.BULOH

GROUP 2 (PAINTING)

COMPANY Location

ACE POLYMERS (M) SDN. BHD. SG. BULOH

SIPRO PLASTIC INDUSTRIES SDN. BHD.SHAH ALAMSG PETANI

TECK SEE PLASTIC SDN BHD SHAH ALAM

DELLOYD AUTO PARTS MFG SDN BHD JLN KEBUN,KLANG

HICOM TECK SEE MANUFACTURING (M) SDN BHD SHAH ALAM

HIL INDUSTRIES BERHADSHAH ALAM

BKT MERTAJAM

USRA TAMPI(M) SDN. BHD. SHAH ALAM

SIME KANSAI PAINT SDN BHD KLANG

PPG COATING (M) SDN BHD PJ

VENDOR GROUPING

VENDOR GROUPINGGROUP 3 (PLASTIC)

COMPANY Location

TS HI-TECH SEAT SDN BHDJLN KEBUN,KLANGBEHRANG,PERAK

USRA INDUSTRIES SDN BHD SHAH ALAM

APM PLASTICS SDN. BHD. PORT KLANG

EP POLYMERS (M) SDN BHD SHAH ALAM

AUTOVISOR PLASTICS SDN. BHD. SHAH ALAM

AZMAN HAMZAH PLASTIK SDN BHD SHAH ALAM

KB TEKNIK SDN. BHD. ULU YAM

NIFCO MANUFACTURING (M) SDN BHD BKT RAJA

RAYA PLASTIK INDUSTRI SDN. BHD. SHAH ALAM

VENDOR GROUPINGGROUP 4 ( ELECTRICAL)

COMPANY Location

PATCO RAYA TRADING SDN. BHD. SHAH ALAM

SANDEN AIR CONDITIONING (MALAYSIA) SDN BHD SHAH ALAM

NETSTAR ADVANCED SYSTEMS SDN. BHD. AMPANG

APM AUTO ELECTRICS SDN BHD BT.CAVES

PROREKA (M) SDN. BHD. PUCHONG

REXAR TECHNOLOGIES SDN BHD SUBANG

DELLOYD TECHNOLOGY RESOURCES (M) SDN BHD KLANG

MULTI-CODE ELECTRONICS INDUSTRIES (M) BERHAD

KLANG

APM COIL SPRING SDN BHD PORT KLANG

VENDOR GROUPINGGROUP 5 ( ELECTRICAL)

COMPANY Location

SIEMENS VDO INSTRUMENTS MY SDN BHD PULAU PINNAG

MALAYSIAN AUTOMOTIVE LIGHTING SDN BHD BAYAN LEPAS,PP

CLARION (M) SDN. BHD. PULAU PINANG

UMW ADVANTECH SDN BHD SHAH ALAM

SPEKTRALINK AUTO ELECTRONIC SDN.BHD SRI KEMBANGAN

AUTO PARTS MANUFACTURERS CO SDN BHD (RADIATOR DIVISION)

SRI KEMBANGAN

ARMSTRONG AUTO PARTS PULAU PINANG

VENDOR GROUPINGGROUP 6 (METAL)

COMPANY Location

PHN INDUSTRY SDN. BHD. SHAH ALAM

AUTOMOTIVE INDUSTRIES SDN BHD SHAH ALAM

ORIENTAL SUMMIT INDUSTRIES SDN.BHD. SHAH ALAM

POWER STEEL & ELECTRO-PLATING WORKS SDN BHD

SHAH ALAM

CNC METAL MACHINING SDN BHD PUCHONG

IBK FASTENERS (M) SDN BHD PJ

VENDOR GROUPINGGROUP 7 (METAL)

COMPANY Location

SAPURA BRAKE TECHNOLOGIES SDN BHD BANGI

SAPURA MACHINING CORPORATION SDN BHD BANGI

KYB-UMW STEERING MALAYSIA SDN BHD BANTING

KYB-UMW MALAYSIA SDN BHD KUALA LANGAT

SYARIKAT METAL INDUSTRIES OF MALAYSIA SDN BHD

BERANANG

INGRESS PRECISION SDN. BHD. NILAI

INDUSTRIAL QUALITY MANAGEMENT SDN BHD SHAH ALAM

VENDOR GROUPING

GROUP 8 (METAL)Z

COMPANY Location

AUTOKEEN SDN. BHD. SHAH ALAM

PROFEN SDN. BHD. SHAH ALAM & B BTG

BURNMARK INDUSTRIES SDN BHDSHAH ALAM

BKT BERUNTUNG

AVENTUR DOOR SYSTEM SDN BHD SHAH ALAM

PEPS-JV (M) SDN BHD - REVENUE AC BTG. KALI

PESAKA NURI (M) SDN BHD BTG. KALI

PAN BAY RAWANG

BRIMAL STAMPRESS ENGINEERING SDN BHD SHAH ALAM

VENDOR GROUPING

GROUP 9 (METAL)

COMPANY Location

CHEMTUBE (M) SDN. BHD. KLANG

ORTECH MALAYSIA SDN. BHD. P.KLANG

RECOMTEC SDN BHD P.KLANG

APM SHOCK ABSORBERS SDN. BHD. KLANG

APM SPRINGS SDN BHD KLANG

SAPURA AUTOMOTIVE INDUSTRIES SDN BHD KLANG

BELTON SDN BHD SG.SIPUT,PERAK

BLOXWICH (MALAYSIA) SDN BHD PERAK

GKN DRIVELINE MALAYSIA SDN. BHD. PRAI,P.PINANG

VENDOR GROUPING

GROUP 10 (RUBBER,CARPET & LABEL)

COMPANY Location

NAKAGAWA RUBBER INDUSTRIES SDN. BHD SHAH ALAM

PARAGON CAR CARPETS & COMPONENTS SDN BHD

CHERAS

AUTOLIV HIROTAKO SAFETY SDN BHD SRI KEMBANGAN

AUTOLIV HIROTAKO SRS SDN BHD SRI KEMBANGAN

HIN GETAH (M) SDN. BHD. KL

KUMPULAN JEBCO (M) SDN. BHD. SG. BULOH

TECHNOMEIJI RUBBER SDN. BHD. NILAI

WENCO INDUSTRIES SDN. BHD. PUCHONG

NOBEL INDUSTRIES SDN. BHD. SHAH ALAM

VENDOR GROUPING

GROUP 11(RUBBER & CARPET)

COMPANY Location

CARPETS INTERNATIONAL MALAYSIA KL

WSA ENGINEERING SDN. BHD. RAWANG

PONG CODAN RUBBER (M) SDN. BHD. RAWANG

FUDEX RUBBER PRODUCTS (M) SDN BHD MELAKA

SRI KOTA RUBBER MFG SDN. BHD. MELAKA

GOODYEAR MARKETING & SALES SDN.BHD. SHAH ALAM

CONTINENTAL SIME TYRE MARKETING SDN BHD PETALING JAYA

SILVERSTONE BERHAD SHAH ALAM

SEGINIAGA RUBBER IND. SDN BHD BTG BERJUNTAI

VENDOR GROUPINGGROUP 12(OTHERS)

COMPANY Location

JOHNSON CONTROLS AUTOMOTIVE SEATING (M) SDN BHD

SHAH ALAM

KEJURUTERAAN EMAS SDN. BHD. CHERAS

MALAYSIAN SHEET GLASS SDN. BHD. SG BULOH

MARUTECH ELASTOMER INDUSTRIES SDN BHD PETALING JAYA

MCIS SAFETY GLASS SDN. BHD. SEREMBAN

MENANG NUSANTARA SDN. BHD. BALAKONG

PERMANENT PREMIUM SDN. BHD. SHAH ALAM

ROKISAR SDN. BHD. AMPANG