16 major losses hiprflsb15
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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
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