Reducing cleanliness defect_GRB
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This document discusses efforts to reduce cleanliness issues on a NOS line through a Kaizen approach. It outlines a problem of oil leaks from sewing machines contaminating garments. Countermeasures included discussing the issue with suppliers to address machine design weaknesses, reducing oil supply, and developing standardization through checklists for cleaning machines and ensuring proper maintenance. Charts show defects from oil reduced after implementing the changes. The financial impact of resolving the issue saved over 700 million rupiah over a 27 day period through increased production.
Reducing cleanliness defect_GRB
- 3. WHAT WE DO
- 4. A3 PROBLEM SOLVING_PILOT ON NOS LINE
- 5. POINT OF OCCURENCE Measles Chart Before Sewing
- 8. POINT OF OCCURENCE OIL LEAKED MACHINE BASED ON TYPE OF MACHINE & BRAND (UNIT) Overlock Kansai Overlock Pegasus Overdeck Kansai Overdeck Pegasus
- 10. Discuss With Supplier 1. Machine with production year 2009- 2010 have design weakness on oil leake 2. Corrective action to this problem is by reduce oil supply in 2 point : upper machine and bottom machine that supply oil to as looper 3. Others corrective action will be eliminate foam inside oil drain in upper body to ensure oil can be drain effectively 4. Needle bar seal have to be feasible to ensure no oil leak issue in needle bar 1. Present oil viscosity is 10, standard 22 2. There are 2 type of oil leak : Normal & Abnormal . Normal leak happen at needle bar & as looper. Abnormal happen at upper body & side of the . Potential problem because wrong treatment when take a part oily machine 3. Normal leak won’t happen if seal at needle bar & as looper still feasible 4. For overlock machine oil supply have to reduce until a half 5. On afternoon operator should be clean needle bar
- 12. Develop Standardization Trough Checklist ILUSTRASI GAMBAR JARUM 1 1 TOMBOLOFF PASTIKAN MESIN DALAM KEADAAN MATI ( OFF ) MANUAL OPERATOR SN/DN (JARUM 1/2) STANDAR PERAWATAN MESIN NO NAMA BAGIAN MESIN CARA PERAWATAN ALATYANG DIGUNAKAN PELAKSANA WAKTU PERAWATAN 2 TIANGMESIN BERSIHKAN TIANG BENANG DARI DEBU & KOTORAN LAP KERING OPERATOR 3 CUP BENANG BERSIHKAN CUP BENANG DARI DEBU & KOTORAN LAP KERING OPERATOR 5 BODYBELAKANG BERSIHKAN BODY BELAKANG MESIN DARI KOTORAN & DEBU LAP KERING OPERATOR 6 SAMPINGMESIN BERSIHKAN SAMPING BODY MESIN DARI KOTORAN & DEBU LAP KERING OPERATOR 7 BODYDEPAN BERSIHKAN BODY DEPAN MESIN DARI KOTORAN & DEBU LAP KERING OPERATOR 8 SEPATUMESIN BERSIHKAN SEPATU MESIN DARI KOTORAN & DEBU LAP KERING OPERATOR LAP KERING & KUAS 11 MEJA MESIN BERSIHKAN MEJA MESIN DARI KOTORAN & DEBU LAP KERING OPERATOR OPERATOR OPERATOR OPERATOR 9 VANBELT BERSIHKAN PENUTUP VANBELT DARI KOTORAN & DEBU LAP KERING 10 MESIN DALAM BERSIHKAN BAGIAN DALAM MESIN DARI KOTORAN & DEBU 12 NYALAKAN MESIN TEKAN TOMBOL ON UNTUK MENYALAKAN MESIN MANUAL OPERATOR 5 MENIT SEBELUM MULAI BEKERJA & 5 MENIT SEBELUM BEL PULANG 4 MONITOR OTOMATIS BERSIHKAN MONITOR OTOMATIS DARI DEBU & KOTORAN LAP KERING 1 2 3 4 6 7 9 5 8 10 11 12 ILUSTRASIGAMBAR JARUM1 7 MURDIPLATMESIN PASANGKEMBALI MUR PADAPLATDENGAN MENGGUNAKANOBENG BESAR OBENGBESAR OPERATOR KUAS OPERATOR 6 OPERATOR 4 OPERATOR 3 DALAMMESIN/ GIGIMESIN AMBILKOTORONYANG MENGGUMPALDI GIGI MESIN/BAGIANDALAM MESIN PINSET SAAT OPERATOR MENDAPAT JADWAL KEBERSIHAN PLAT (1 MINGGU1 X )5 MENIT SETELAHBEL ISTIRAHAT OPERATOR 5 PLATMESIN BERSIHKANPLATDENGAN KUAS PLATMESIN TUTUPKEMBALI PLAT HINGGASESUAI DENGAN POSISI AWAL (TIDAKTERBALIK) MANUAL(TANGAN) 1 MURDIPLATMESIN BUKAMUR MENGGUNAKANOBENG BESAR OBENGBESAR DALAMMESIN/ GIGIMESIN BERSIHKANSISA KOTORAN/DEBUPADA GIGI MESINDENGANKUAS KUAS OPERATOR 2 PLATMESIN GESER/LEPASPLATMESIN MANUAL(TANGAN) OPERATOR STANDARPEMBERSIHANPLAT&GIGIMESIN SN/DN(JARUM1/2) NO NAMABAGIANMESIN CARAMELAKUKANKEGIATAN ALATYANGDIGUNAKAN PELAKSANA WAKTUPERAWATAN 1 2 3 4 5 6 7
- 13. Develop Standardization Trough Checklist 1 PEMANTAUAN SUPERVISOR ,CHIEF & MEKANIK BERSAMA2 MELAKUKAN PEMANTAUAN KEGIATAN BERSIH2 0 SPV SEWING , CHIEF SEWING & MEKANIK SAAT MUSIK BERSIH2 BERBUNYI 2 PENGECEKAN SUPERVISOR & MEKANIK BERSAMA2 MELAKUKAN PENGECEKAN KESEMUA MESIN & MEMBERIKAN SANGSI ( JARUM 1 ,JR2 SEKOCI DIAMBIL OBRAS DLL CABUT BENANG ) JIKA DITEMUKAN MESIN YANG TIDAK MEMENUHI STANDAR KEBERSIHAN FORM CEKLIST KEBERSIHAN MESIN MEKANIK & SUPERVISOR 5 MENIT SETELAH OPERATOR PULANG CARA PENGECEKAN HASIL TRAINING ILUSTRASI GAMBAR NO JENIS KEGIATAN CARA MELAKUKAN KEGIATAN ALAT YANG DIGUNAKAN PELAKSANA WAKTU PERAWATAN STANDAR BERSIH PADA PLAT & GIGI MESIN " TIDAK DITEMUKAN KOTORAN MENGGUMPAL DIDALAM PLAT & GIGI 1 2 STANDAR BERSIH PADA MESIN " TIDAK DITEMUKAN KOTORAN / DEBU YANG MENEMPEL DI BAGIAN MESIN"
- 14. Develop Standardization Trough Checklist
- 15. Develop Standardization Trough Checklist
- 17. % Oil Defect NOS Line