TEAM 2

QUICK CHANGEOVER
COMPUTER STITCHING
Team Member :
M. TAUFIK Bubuh B
Rian F Imas
Eason Zhang Desi

Project start: : April 07th, 2011

Final Update : June 15th, 2011
CONTENTS
Team Member
Team 2 Overview
Activities Schedule
Process Flow Chart
Time Observation and Bar Chart
Set Up Change over chart
Separate Internal - External time analysis
Current Status and Change over time target
5Why Analysis worksheet
Shift Internal to External Activities
Idea to Streamline Internal and External Activities
Implementation Schedule
Implementation Result
QCO Overview
Team2 : To Reduce Changeover of computer stitching

Current Situation
It was take long time to change the mold every time model change is happen

Current QCO time

Based on data collected on April 07th, 2011 total CO time is 416 Seconds

Target
To reduce change over time to 208 seconds on April 14th, 2011 and
146 seconds on June 7th, 2011
Project Team 2

Objective To reduce computer stitching change over by eliminate waste

Meeting Meeting and implementation on work floor every 3 days

Overview from 03.00 to 04.00 pm
Attendees : All team member plus PIC of improvement area

Schedule
April May
June
No Description
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 Training QCO

2 Computerize

3 Select Changeover process on work floor

4 Prepare Implementation

5 2nd QCO Implementation

6 Analysis and make step improvement

7 Idea Implementation to reduce COT

8 Create new change over procedure

9 Prepare QCO implementation

10
Make Improvement step

11
Implement 3rd QCO

12
Wrap Up and Documentation
13
Wrap Up and Documentation

13
2nd Phase observation
Baseline Analysis Process Flow Chart C/O
2nd Analysis Process Flow Chart C/O
3rd Analysis Process Flow Chart C/O
Team 2
Change Over Time Observation Sheet (Baseline)
Team 2
Change Over Time Observation Sheet (2nd)
Team 2
Change Over Time Observation Sheet (3rd)
Additional facts during CO observation
Difficult to call Waiting for mechanic No SOP for CO Must Install the The Last Process 2 size of mold for all
mechanic, Mechanic is to come Process Program if the can’t run, Mold not footwear size
not stand by in program not been available enough in
Workplace
Menunggu Mekanik Tidak Ada SOP Untuk saved in Computer tool box 2 Ukuran Mold Untuk
Datang CO Proses semua Size
Pemanggilan Mekanik
Terlalu lama karena Pergantian program bila Proses Sebelumnya
mekanik tidak stand by data belum tersimpan di terhambat, Mold tidak
ditempat komputer tersedia
Limited skill of Mechanic Tools is not Mold Sparepart not Take a long time to do If program available, Cutter dull/ no
mechanic complete complete Pattern Cutting so you just adjust and available stock
set the machine
Mekanik dengan skill Tooling/Alat Mekanik Sparepart Mold tidak Cutting Pola Pada Saat Pisau Kurang
terbatas tidak lengkap lengkap COT memakan Waktu Jika program sudah tajam/Stock tidak Ada
Lama ada tinggal set mesin
saja

Matarial waste when No available Qc to No stock for material Machanic and Workplace not set in If necessary color
do thread cutting Check mold result testing Operator not wearing order thread change must be
and material test Safety tool while done if there’s any
different color
pemotongan benang Material Untuk Test working Workplace tidak tertata
yang terlalu panjang QC Tidak Ada untuk tidak tersedia rapi (not Set In Order)
Pergantian Warna benang
check hasil dari ganti Mekanik dan Operator perlu dilakukan jika warna
mold dan test bahan tidak memakai APD beda
(earplug)
Machine maintenance is Takes a long time to set Takes a long time to No SOP to set Take s a long time to Machine test
not well computer program change the mold computer program cementing because necessary when CO is
May happen any rework because limited because more rework out of glue done
mechanic skill happen
SOP Untuk Set
Perawatan mesin yang
Mesin/program tidak Proses lem sangat Test Kinerja mesin
kurang baik, Untuk set program Pergantian mold
memungkinkan terjadinya memekan waktu lama Memakan waktu lama ada lama karena lem habis ketika CO sudah
rework karena skill mekanik karena berkali kali rework selesai
terbatas
Changeover improvement wall chart
Team2
Improvement Steps
Separate Internal - External time analysis
Current Status and Change over time target
5Why Analysis worksheet
Shift Internal to External Activities
Idea to Streamline Internal and External Activities
Implementation Schedule
Implementation Result
QCO Analysis
 Internal – External time

Total Improvem
Project Elements 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Total
COT ent (%)
Baseline
Internal
04/07/201 60 4 10 10 53 31 6 64 27 265
1 (1st Time
QCO) 416 Baseline
External ime 45 3 42 31 12 13 5 151

Internal
04/14/201 4 3 20 17 2 10 2 10 68
1 (2nd Time
QCO) 211 49%
External ime 54 57 12 10 10 143
06/10/201
Internal
1 (3rd 2 3 15 17 2 7 2 7 55
QCO) Time
173 58%
External ime 24 49 13 13 19 118
Team1
Current Status and Change Over Target

Baseline : 416 “
Target 2 : 211”
Achievement : 173”

Actual Graph
QCO Analysis
 5W1H
Improvement (Brain Storming)
Kaizen Idea for Streamline Internal Time
Provide Schedule before CO,
Make Sure all team ready for
CO
Siapkan Schedule QCO, agar semua
pihak terlibat bisa siap
(Eason Zhang 04/07/2011)
QCO/0407/I/1
Do Intensive Maintenance for
machine.
Lakukan perawatan mesin
lebih intensif sehingga tidak
mengganggu proses kerja
(Rian F 04/07/2011)
QCO/0407/I/2
Provide Mold, Pattern, and
tooling before CO
Mempersiapkan Mold,
pattern dan Tooling terlebih
dahulu sebelum CO
(Rian F 04/07/2011)
QCO/0407/I/3
Improvement (Brain Storming)
 Kaizen Idea for Streamline Internal Time
Provide SOP for COT Provide SOP for COT Use the right tools to attach
procedure procedure the mold
Sediakan SOP untuk prosedure COT Sediakan SOP untuk prosedure COT Pakailah tooling yang tepat untuk
Mesin Mesin memasang mold

(Desi 04/07/2011) (Desi 04/07/2011) (Rian F 07/04/2011)

QCO/0407/E/1 QCO/0407/E/2 QCO/0407/E/3

Provide Mold box based on Do 6S Training Do Programmable Training

style / model Lakukan training 6S
To mechanic
Sediakan tempat penyimpanan mold
Lakukan Training program pada
sesuai dengan style / model
mekanik
(Taufik 04/07/2011)
(Bubuh 04/07/2011) QCO/0407/E/5 (Imas 04/07/2011 )
QCO/0407/E/4 QCO/0407/E/6

Save program setting on the disk, No QC must stand by to check Provide Material for Stitching
reset program if there is a model
change the Quality of CO Test
Save settingan program pada disk QC harus ada untuk memastikan Material buat test harus disiapkan
sehingga tidak perlu setting ulang kualitas ganti mold lebih dahulu
ketika ada pergantian model
(taufik 04/07/2011) (Bubuh 04/07/2011)
QCO/0407/E/8 QCO/0407/E/9
(Eason 04/07/2011)
QCO/0407/E/7
Team2
Idea Implementation Schedule

Select & Record

Element of CO
Shift Internal to
External Activities

Prepare tools with much stock

and make sure tools is
All crew that responsible for compatible
QCO gathering before COT
(CI, QC,Operator, mechanic) Prepare mold and Pattern
before COT

2nd Element & time

record
Make Improvement Step
3rd Element &
time record

4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011

Team2
Idea Implementation Schedule
Team2
Idea Implementation Gallery
Propose : Provide Mold, Pattern, and tooling before CO
Attendance : Team 2 and Mechanic
Idea Linked : QCO/0407/I/3
Idea Owner : Rian F
Location : Production line
Date/Time : April 21th , 2011 (14:15 – 15:30)
Description : Provide the right tools and mold for the next CO
04/21/2011

Propose : Use the right tools to attach the mold

Attendance : Team 2 and Mechanic
Idea Linked : QCO/0407/E/3
Idea Owner : Rian
Location : Production line
Date/Time : April 21th , 2011 (14:15 – 15:30)
Description : Preparation for next CO
04/21/2011

Propose : Provide Mold box based on style / model

Attendance : Team 2 and Mechanic
Idea Linked : QCO/0407/E/4
Idea Owner : Bubuh
Location : Production line
Date/Time : April 21th , 2011 (14:15 – 15:30)
04/21/2011 Description : Mold box is already but still mix with tooling
Team2
Idea Implementation Gallery
Propose : Save program setting on the disk, No reset program if
there is a model change
Attendance : Team 2 and Mechanic
Idea Linked : QCO/0407/E/7
Idea Owner : Rian F
Location : Production line
Date/Time : April 21th , 2011 (14:15 – 15:30)
04/21/2011 Description : they provide 2 different disk for different machine

Propose : DO 6S training
Attendance : B5 CL and WS
Idea Linked : QCO/0407/E/5
Idea Owner : Taufik
Location : PYI 2nd Floor Meeting room
Date/Time : April 14th , 2011 (10:00 – 11:30)
Description : Introduce 6S
04/12/2011

Propose : Provide Material For Stitching Test

Attendance : Team 2 and Mechanic
Idea Linked : QCO/0407/E/9
Idea Owner : Bubuh
Location : Production line
Date/Time : April 21th , 2011 (14:15 – 15:30)
04/21/2011 Description : Provide material for stitching test for next CO
Team2
Idea Implementation Gallery
Propose : Implement 2nd QCO
Attendance : Team 2, Mechanic , QIP and local supervisor
Date/Time : April 21th , 2011 (14:15 – 15:30)
Description : Implement 2nd QCO

04/21/2011

Propose : Attach and Socialize QCO SOP for Current Project

Attendance : Team 2 , Mechanic, QIP, Local Supervisor
Idea Owner : Team 2
Location : Production line
06/01/2011
Date/Time : June 1st , 2011 (09.00– 09.37)
Description : Socialize and Attach SOP for QCO

Propose : Socialize QCO Preparation Checklist

Attendance : Team 2 and Local Supervisor
Idea Owner : Team 2
Location : Production line
Date/Time : June 1st , 2011 (13.12– 13.23)
06/01/2011 Description : Socialize and Attach SOP for QCO
Team2
Idea Implementation Gallery
Propose : Implement 3rd QCO
Attendance : Team 2, Mechanic , QIP and local supervisor
Date/Time : June 11th , 2011 (13:08 – 13:26)
Description : Implement 3rd QCO

06/11/2011
Team2
Idea Implementation Gallery
Propose : Make Process SOP
Maker : Team 2
Description : Make Qco SOP Process
Remark : Version 2 (Standardize)
Team2
Idea Implementation Gallery
Propose : Make Setting Machine SOP
Maker : Team 2
Description : Make Setting Machine SOP
Remark : Version 1
Team2 Propose : Make Preparation Check List
Idea Implementation Gallery Maker
Description
: Team 2
: Make Preparation Check List
Remark : Version
QCO Preparation Checklist

Date :
QCO Process :
line :

QCO Team
No Item Person Check Remark
1 TPM Mechanic 2
2 QIP 1
3 line Supervisor 1
4 CI&IE Team 1
1

Tools
No Item QTY Check Remark
1 Mechanic Tools 1
2 Mold (same as CO model) 1
3 Pattern (insole board) 3
4 Scissor 1
5 Double tape 1
6 Test Material 3
7 Stopwatch 1
8 Camera 1
9 Observation Sheet 1
10 Ballpoint 2
11 QCO SOP 1

Approved by, Checked by,

name name
Team 2
SOP Before – After
Seq. Number Changeover Element Seq. Number Changeover Element Total CO Time
Calling Mechanic Open Mold
1
Memanggil Mekanik
1
Buka Mold
Baseline : 416”
Take Tooling Ambil Saving Mold 2 QCO : 211”
nd
2 2
Tooling Simpan Mold Final : 173”
Pattern Measurement Attaching New mold
3 3
Mengukur Pola Pasang mold baru
Cutting Pattern Setting the Program
4 4
Memotong Pola Setting Program
Cementing Pattern Cutting Thread
5 5
Lem Pola Memotong Benang
Cementing again (rework) Attaching New Thread
6 6
Rework Lem Memasang Benang Baru
Attaching Pattern Attaching Bobbin
7 7
Memasang Pola Memasang Sekoci
Open Mold Take Test Material
8 8
Buka Mold Ambil Material Test
Saving Mold Simpan Stitching Test
9 9
Mold Test Jahit
Attaching New mold
10 QC Check
Pasang mold baru 10 Periksa Kualitas
Setting the Program
11 Saving Tested Material
Setting Program 11 Simpan bahan hasil test
Pattern test
12 Stitching Material
Test Pola 12
Test Jahit
Stitching test
13 QC Check
Test Jahit 13 Periksa Kualitas
Cutting Pattern
14
Memotong Pola
Attaching Thread
15
Pasang Benang
Material Test
16
Test Bahan
Team 2
Process Change Over Time Recorded & Analysis

Baseline : 416 “
Target 2 : 211”
Final : 173”
Second

April 7th April 14th June 11th

Team 2
Streamline External Time Implementation Schedule
Done
Not Done
Select & Record
Element of CO
Shift Internal to
External Activities

Prepare tools with much stock

and make sure tools is
All crew that responsible for compatible
QCO gathering before COT
(CI, QC,Operator, mechanic) Prepare mold and
Pattern before COT
2nd Element & time
record
Make Improvement
Step
3rd Element &
time record

4/7/2011 4/13/2011 4/14/2011 4/25/2011 4/26/2011

Select & Record
Element of CO
Shift Internal to
External Activities

4/7/2011 4/13/2011 4/14/2011 4/23/2011 4/24/2011