OMAR JIBRAN ENGINEERING INDUSTRIES LTD.

Date: July 2nd, 2020

THINGS TO DO OBEYA
th
Data Set is from June 25 -30th
Duration was 1 hour and 5 minutes, in which we also discussed the Successes and Challenges
of June; what to focus on in July.

1. SAFETY: NO ACCIDENT IN LAST WEEK!

A) Accident- __0__ Accident . Which M?__- _. Report? N/A __Lost Time: N/A-GOOD
AA: Temp Worker (Accident) to be trained by Master Trimmer, and feedback to
Supervisor.
Responsible: TZ/HK/TB
Deadline: 9.7
B) First Aid Kit- Not Discussed
C) Trend-in June only one accident, in one week. Worker is okay. GOOD.
D) Hot Work Permit- reviewed documents. Process is OK.
AA: design a check sheet (safety, not related to PPE). Review EHS L4.
Responsible: TZ
DD: 9.7

2. QA: A) EXTERNAL Quality Members were in IMC. Note: Please try to keep Obeya 12pm
time free.
I do not have all the accurate external data, please fill highlighted area.
A. External- QFB__ Replied? __ Why slipped?
SQA_0__ CS__0__ Parts Booth__0__ Bumper Booth____. Any LSR?
External- _?__ Painted Bumpers rejected in IMC???
To my record, I have receipt of QFB on Nozzle Assy Defroster, Date 29 th June.
I believe A. Talha has sent reply with RCA/CPA, correct?

B) INTERNAL was 3 % vs 2.25% Target. S/Up : _2.4_%_2.54__ I/P: IMPROVING!

(PLEASE VERIFY) RCA?
(Last week was 5%). What was the main reason for improvement? (MN/TB/AM)??
AA: Display Part/Machine Monitoring for 100 ton IMM, part: Cover Front D/H, and any
relevant part (please discuss).
Responsible: MN/TZ
C) How much rejection caught at PSI for this week? __ pcs.

3. SUPPLY CHAIN: Fariz and New HOD (absent 2 days) both did not attend. No fruitful
discussion. Supply Chain I strongly request we meet weekly in Obeya.
OK’S MESSAGE TO SUPPLY CHAIN: DO DAILY WORK DAILY, UPDATE DAILY. (I refer to
last week’s panic of moulding/v2v. This will help prevent “surprises”.)
A. Critical Parts (IMC)- AGAIN YARIS Reason: Bins – NOT GOOD
AA: to increase weekly target to 200 per week.
RCA/CPA: Frequent mpwr assignment changes; frequent re-training
AA: Display, for June, the teams’ attendance, skill level, and no of assignment
changes.
Responsible: FH Deadline: 9.2
B. Grill/Logo from GI-Status- 1.6 days FG for Grill Radiator Low Grade, 1.6, due to Bin.
C. Open Demands – A. Stick Paddle B. Band Saw Blade C. 1850 ton D. Bins (Open, OK), E.
Walker – NOT GOOD/MODERATE. DEMANDS (A-E) OPEN LAST 4 WEEKS.
D. GRN’s being signed within 2 days of issuance to Dept- Not discussed.
A. Shipping- was on-time; no delays reported.
 OMAR JIBRAN ENGINEERING INDUSTRIES LTD.

4. PRODUCTION: ON-TIME; TARGETS SHOWN AND AVERAGES FOR THE MONTH ON

SHEETS.; GOOD DISCUSSION! (8.5 mins)
1. Plan vs Actual- Average of __95%___attained vs Target of 98%. Variance was
__2.75%. Last wk was 95.5%. TARGET NOT ATTAINED, BUT,
STABLE/IMPROVING.
M/C Issues: Not discussed
RCA/CPA: N/A
Monitoring:
2. Internal Rejection- 3% vs 2.25% (with start-up). IMPROVING (PLEASE VERIFY)
OK assigned TB and HK to:
a) Verify daily the R/M prep and dry process (filled form, PRD + QA).
AA: Schedule a GEMBA. (PENDING)
Responsible: OK, AM, HK Deadline: Week of 29th
3. Regrind Mgmt- Avg Lumps 24 kg/day, Regrind Now 280 kg/day (last wk 235) &
Avg Rejection is 165 kg/day.NO IMPROVEMENT. (need to take up D/H rejection)
RCA: a) Machine- Jali for Crusher is NG. b) Man- only 2 permanent workers
coming.
AA: OK Machine and arrangement of temporary workers
DD: 9.7
Responsible: TB Reminder: Need Regrind Tm’s attendance and skill on the
board.
New target will be _____. Decide with HK and TB. Consider part weight (pending
until AA is done)
4. Untrimmed Parts- 0 GOOD
5. Mold Change Times – NO STANDARD. IMPROVE.
AA: a) To identify/quantify all small molds.
b) Take 3 mo average tool-change time.
c) The Core connection (only variant)actual time to be taken.
d) Small molds to have time range of change, to reflect if core
connection required or not.
Responsible: HK/TB
DD: 7.2

5. 5S Assignment DD: 22/06- GIRLS’ ASSY IS LOOKING BETTER (MY OPINION), BUT NG BINS
NEED REPAIRING.
A. Ali Masood to get Before and After pictures posted on Obeya Board. GENTLE
REMINDER
B. Review of bins produced for Production Purpose (FH & AM)-done on 25.6

MAINTENANCE:

1. % Machine Break-Down (BD): __3.3__% MC BD- 18 HOURS (last week was 1.95%.
Target OF 2.5% ) PLEASE IMPROVE
2. % Down-Time: 7.38%- 40 HRS DT WORSENED
RCA: 3.74% loss due to K-E (or, 20.5 hrs). K-E loss trend: wk 2 0.41%, wk 3 1.3%,
wk 4 was 3.74%
AA: Evaluate the K-E loss per week trend this month. Do we go for generator?
Responsible: TB Deadline: 7.2
3. Issues of the Week
 OMAR JIBRAN ENGINEERING INDUSTRIES LTD.
a) 3000 ton- Problem: Bush of Toggle Arm came out.
b) 250 ton- Problem: Pressure Card
AA: OK suggests IMM Monitoring for also 250 ton, and, that we discuss with NF.
Responsible: TZ Deadline: 7.2

MOLD MAINTENANCE - P2: NOT DISCUSSED. (Note: Ali Masood was monitoring start-up of
Fog Lamp 1.8 which was critical for quality issues)
1. Breakdown _23_hrs, OR 1.08% MODERATE/GOOD Trend: FROM JULY 19’ TO NOW, BD
REDUCED FROM 1.64% TO 0.21%; A REDUCTION OF 80%, VERY GOOD TREND FOR THE
YEAR. CREDIT TO TAHIR, KAMAL AND MDM.

2. P2- Total___ (HRS)___ PM:_____CORR:_____

____ man hrs / __ P2 jobs = _____hrs per job.
AA: To insert targets in the sheet for PM time for Small, Medium and Big Molds (Legend).
Each job will have its Standard time, and Actual time (two columns).

3. Problem Mold(s): N/A

4. High-Flash Molds: N/A

PROJECTS: NOT DISCUSSED. TZ, KINDLY UPDATE.

1. AA: TZ to display all working for budget and logistics of installation for 1850 ton in
Press Shop (labor, equipment, material, contractors, etc) DD: 2/7

PRODUCT DEVELOPMENT: Not discussed. In coming Obeya 2.7, we will focus on when
exactly IMC feedback came, the delay in feedback, its precise impact upon the agreed time-
frame.

S No Project CF APP DIM/DR ACF

1 278-x (11 OK NG OK 2 parts FB;
parts) rest OK
2 645-B (13 NG (only 4 Awaited NG (NG all Awaited
parts) OK) (expected except
mid-June Bumper &
before Grill)
recent
trouble)

D) Rs 700,000 requirement for aluminum pipes. Vendor: Lucky Aluminum.

Problem: Credit rescinded.
AA: TS to prioritize the requirement for Walker first. Rs. __________.
E) New RFQ for (Model Isuzu D Max), 8 parts
AA: TS to discuss with Mold makers, CEO, and then prepare Quotations for RFQ.
DD: Next Obeya June 25th

HRD & ADMINISTRATION:

1. Attendance – reviewed PRD Data. NOT GOOD/IMPROVE
AA: provide the average. Remove Holidays (basic). Then analyze the 4 days’ highlighted.
Were there any common absentees of the 4 days? If so, discipline them, first.
Responsible: WA DD: 9.2
Also, to show Attendance for all June (software), with analysis.
 OMAR JIBRAN ENGINEERING INDUSTRIES LTD.
2. Turnover – accurate turn-over is still not provided. NOT GOOD
3. Payroll Errors- OK until further notice
4. Orientation & Induction: Not displayed. NOT GOOD
5. Training- not displayed, NOT GOOD (Note: SM to join from 6.2, who is
responsible)

REHABILITATION DIVISION: Not discussed

1.Sales- Why did Umair report 3.7m target in Obeya, wk 3?
Rs 2.7 m attained of Rs 3.4m planned or 72% MODERATE
RCA: Bottle-neck is our transport mode to LHR, where we waited for nickel anode
consignment and the truck. Stock transfer and sale was delayed, but only this method
ensures OK cost.
6. (New)- Sales Orders and Delivery (Monitoring) –
_-_ sales orders received. _-_ fulfilled. Balance_-_ orders for delivery
7. Collection on Sales Orders: Of __ fulfilled, __ party NG; __% OK.__________.
(Note: OK is setting a target of 95% OK)

TRANSPORT: OK – RASHID ALI EXCUSED HIMSELF. BD AND PM DATA, TAKEN MANUALLY BY

TEAM, IS PROVIDED. TO BE INCLUDED.

TRAINING: SM TO JOIN FROM MONDAY. WA TO SEND A MAN TO SM’S HOME. DONE??