Professional Documents
Culture Documents
Problem Solving
Problem Solving
Problem Solving
IN
MANUFACTURING
KEY PERFORMANCE INDICATOR in MANUFACTURING :
1. SAFETY
2. QUALITY
3. DELIVERY
4. EFFICIENCY
1. SAFETY
Safety of product to send to Customer
Safety in Manufacturing process (safety for the employees)
2. QUALITY
Customer Satisfaction (Measured using PRR (Product Return Rate)
First Pass Yield, MDR (Manufacturing Defect Rate), DPMO (Defect Part per
million opportunities) and others
Good product deliver to Customer
3. DELIVERY
On time delivery to Customer
4. EFFICIENCY
Productivity (KE, NEE/OEE), Electricity and many others
Eliminate Waste
SAMPLE PROBLEM IN MANUFACTURING :
1. In Safety :
- Accident occurred during production / manufacturing process.
- Product burn and explode and impact to customer injury.
2. In Quality :
- Defect product leakage to customer (Functional Not Good)
- High defect rate in manufacturing process.
- Cost Non Quality
3. In Delivery
- Late delivery to customer.
4. Efficiency
- Low productivity, a lot of Waste , etc.
EFFECT
CAUSE
1.b. BRAIN STORMING :
20
Percent
60
15
40
10
5 20
0 0
Process
Short Solder
25% No Solder
58%
50.00%
40.00%
Percentage
30.00%
NEE
OEE
20.00%
10.00%
0.00%
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
NEE 22.49% 26.98% 28.46% 37.14% 36.25% 32.59% 37.99% 38.93% 35.55% 40.10% 42.51%
OEE 24.54% 29.02% 30.17% 40.46% 40.06% 36.94% 39.94% 41.57% 40.89% 43.91% 46.46%
Month
COMPREHENSIVE PROBLEM SOLVING TOOLS / METHOD THAT COMMONLY USE
IN MANUFACTURING :
3. 8D METHODOLOGY
- D1 : Define the team D5 : Define the problem correction
- D2 : Describe the Problem D6 : Implement and check problem correction
- D3 : Contain the problemD7 : Prevent the problem
- D4 : Identify the root cause D8 : Close the problem
DMAIC METHODOLOGY :
1. DEFINE
2. MEASURE
3. ANALYZE
4. IMPROVE
5. CONTROL
1. SORTING (SEIRI)
2. STRAIGHTENING / SETTING IN ORDER TO FLOW (SEITON)
3. SHINE (SEISO)
4. STANDARDIZE (SEIKETSU)
5. SUSTAIN (SHITSUKE)
5S SAMPLE :
Stencil arranged following order Simple database for searching stencil ICT fixture arranged in rack
in rack stencil with addressing
Component arranged in bin with detail Loading list document arranged tidy in Document arranged follow order
Identification and location. Rack cabinet.