Major Losses in HIP Shine Bathroom Fittings

Khondoker Shafiqul Islam UllashAssistant Manager (Operation)RFL-RPL (Shine-Bathware)Email: rfl936@prangroup.comMobile: 01924-601330

What are Losses?

“Losses in the production environment are those areas where the greatest amounts of Materials and Time is wasted.”

- kunio shirose, 1989

16Major Losses Which Obstruct Production Efficiency

u 5 Major Losses Obstructing

Manpower Efficiency

u 3 Major Losses Obstructing

Material & Energy Utilization

u 8 Major Losses Obstructing

Equipment Efficiency

5 Major Losses Obstructing Manpower Efficiency:

1. Management Loss

16 Major Losses - continued

• Canteen• Punch• Id Card• Salary Line• Frequently Decision Change

Now Punch Active Machine is in HIP-B15 & Others Improvement Work is on Going

5 Major Losses Obstructing Manpower Efficiency:1. Management Loss

2. Operating Motion Loss

16 Major Losses - continued

Developed & Maintain Some SOP to minimize Material Handling Time

Previous Present

5 Major Losses Obstructing Manpower Efficiency:1. Management Loss

2. Operating Motion Loss 3. Line Organization Loss

16 Major Losses - continued

Developed & follow some Guide Line to Solve this loss

*** New appointed Operator Will work easy work First the Day by Day We will provide Critical Work

5 Major Losses Obstructing Manpower Efficiency:

1. Management Loss2. Operating Motion Loss3. Line Organization Loss

4. Logistics Loss

16 Major Losses - continued

OIL

5 Major Losses Obstructing Manpower Efficiency:1. Management Loss2. Operating Motion Loss3. Line Organization Loss4. Logistics Loss

5. Measurement & Adjustment Loss

16 Major Losses - continued

Another Initiative to Reduce Measurement & Adjustment Loss Material Losses

1. Huge dust contain in Tap Body2. Rejection Percentage High

1. Very Efficient2. No Dust or other particle in Tap Body3. Rejection percentage reduce

Previous Present

3 Major Losses Obstructing Material & Energy Utilization:

1. Energy Loss

16 Major Losses - continued

Save Huge time For Mold Load Unloading

3 Major Losses Obstructing Material & Energy Utilization:

1. Energy Loss

2. Die, Tool, & Fixture Loss

16 Major Losses - continued

Material Lick in Mold

Limit Switch Check

Ejector Pin Check

Product Eject Accurately from Mold

Skilled Operator

Careful During working

Creating Awareness Our Production People:

Next Time We will Take a Training on This Bellow Point

3 Major Losses Obstructing Material & Energy Utilization:

1. Energy Loss

2. Die, Tool, & Fixture Loss

3. Material Loss

16 Major Losses - continued

Wrong ! Mixing of Raw Materials

Create Consciousness about

Mold Wrong Mixing

Maintain Mixture Log Book And Always Checked by QC

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

1. Machine Failure / Breakdown

Tooling Failures Unplanned Maintenance General Breakdowns Equipment Failure

Instruction to Check Machine Status

Carefully Before Start Production.

Very soon we will make a Check List

2. Set-Up & Adjustment LossSet-Up : Losses due to changeoverAdjustment : Minor process adjustments

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Setup/Changeover Material Shortages Operator Shortages Major Adjustments Warm-Up Time

Set a Standard Time For

Mold Load Unload

3. Startup Loss/startup Reject:

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Incorrect AssemblyAdjustment lossCreated Awareness Our Production People :

Sl. No Accessories Name Name Of Mold/Product Length (mm)

width(mm)

Standard Machine Cavity Loading

TimeUnloading

Time

Total Standard Loding

Unloading Time

Standard Rejection Pcs

1 Royel dreanag net body Royel dreanag net body 300 250 250 1 45 35 80 8

2 Royel dreanag net Royel dreanag net 300 230 250 2 44 32 76 8

- - - - - - - - - - -

- - - - - - - - - - -

- - - - - - - - - - -

130 Elegant Tissue Holder (TH3-1)

Elegant Tissue holder cover 420 380 160 2 40 25 65 13

236 Elegant Tissue Holder (TH3-2)

Elegant Tissue holder body 330 280   1 35 25 60 10

Standard Time for Shine 132 Mold’s Load, Unload & Rejection

It Saves Huge Time & Rejection & Increase Production

4. Consumable Parts Change Loss :

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Running maintenance Electrical

fuse problem Heater problem etc.

Mechanical Valve Problem Hydraulic Oil problem etc.

We Can’t Overcome 100% But we are more e Careful on This area and Improving

5. Minor Stoppage & Idling Loss:Losses we have a tendency to “put up with”

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Obstructed Product Flow Component Jams Miss feeds Sensor Blocked Delivery Blocked Cleaning/Checking

We Can’t Overcome 100% But we are more e Careful on This area and Improving

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

6. Speed Loss:

P-1Capacity 90 PCS

P-3 C30 pcs P-4Capacity

90pcs

P-2C. 45pcs

P-2C. 45pcs

P-3 C30pcs

P-3 C30 pcs

P-1Capacity 90 PCS

P-4Capacity

90pcs

P-2C. 45pcs P-3 C30pcs Final Product

30Pcs

Final Product90Pcs

Effect of Time Study & Line Balancing on Slot Handle Tap S1

Jan-16   Feb-16Date A-Shift B-Shift   Date A-Shift B-Shift01.01.16 1920 2120   01.02.16 2416 2580

02.01.16 1760 1360   02.02.16 2720 2840

03.01.16 1920 1560   03.02.16 2972 3180

4.01.16

Inventory

1960   04.02.16 3342 2480

05.01.16 0   05.02.16 2532 Off day06.01.16 1920   06.02.16 121007.01.16 1920   07.02.16 2216 2646

08.01.06 1950 1440   08.02.16 2310 2440

09.01.16 2080

Factory Day

  09.02.16 0 2500

10.1.16 2140   10.02.16 2680 2450

11.01.16 2140 2200   11.02.16 2440 2730

12.01.16 1720     12.02.16 Off day 2668

13.01.16 1572     13.02.16 2372

14.01.16 1680 1840   14.02.16 2630 2400

Total 35,202.00   Total 58,754.00

Production Increasing 23,552 PCS which Market Value 9,42,080.00 Taka!

7. Defect & Rework Loss:

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Accurate product

Never Need to

Rework

Created Awareness Our Production People :

8. Planed Stoppage

8 Major Losses Obstructing Equipment Efficiency:

16 Major Losses - continued

Maintain a Schedule For Planed

Stoppage which is very Effective to

Minimizing Loss

Team Work

Productivity

Team Work Concept Creating In Assembly

SAFELY work on Going

It helps to Identify where we need to Take Action Very Visually

Please Work Safely & Return Home SAFELY

Safety Creating In Assembly