v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables x
List of Figures xii
List of Abbreviations xiii
CHAPTER 1 : INTRODUCTION
1 1.1
Background of Study 1
1.2 Problem Statement
2 1.3
Objectives 3
1.4 Scope of Study
3 1.5
Significance of This Study 4
CHAPTER 2 : LITERATURE REVIEW
5 2.1
Lean Manufacturing LM 5
2.1.1 Lean Principle 6
2.2 Waste
8
vi
2.3 Semi-Structured Interview
9 2.4
Brainstorm 10
2.5 Overall Equipment Effectiveness OEE
10 2.5.1 Calculating OEE
11 2.5.2 Visualizing OEE and the Losses
12 2.5.3 Availability
13 2.5.4 Performance
13 2.5.5 Quality
14 2.6
Six Big Losses 14
2.7 Total Productive Maintenance TPM
16 2.7.1 TPM Implementation
17 2.7.1.1 5S
17 2.7.1.2 Autonomous Maintenance Jishu Hozen
18 2.7.1.3 Planned Maintenance
18 2.7.1.4 Kaizen
19 2.7.1.5 Quality Maintenance
19 2.7.1.6 Training
20 2.7.1.7 Office TPM
20 2.7.1.8 Safety, Health and Environment
20 2.8
Data Collection 20
2.9 Interviews
22 2.10 Observation
22 2.11 Conclusion
23
vii
CHAPTER 3 : METHODOLOGY
24 3.1
Overview of the Methodology 25
3.1.1 The Process Planning Flow Chart 25
3.2 The Explanation of Process Planning Flow Chart
26 3.2.1 Problem Statement Identification
26 3.2.2 Literature Review
27 3.2.3 Identify the Root Cause of Problem
28 3.2.3.1 Semi-Structured Interview
28 3.2.3.2 Brainstorming
29 3.2.3.2Ishikawa Diagram
34 3.2.3.4 Pareto Chart
36 3.2.4 Collecting Data
38 3.2.4.1 Downtime Data Availability
38 3.2.4.2 Daily Production Output Performance
38 3.2.4.3 Accepted Vs Rejected Output Quality
39 3.2.5 Calculating Data
40 3.2.6 Analyzing the Data
40 3.2.6.1 Line Graph
41 3.2.7 Proposing a Solution
42 3.2.7.1 Brainstorm
42 3.3
Conclusion 42
viii
CHAPTER 4 : RESULTS AND DISCUSSIONS
43 4.1
OEE Data Collection 44
4.1.1 OEE Data Collection: Machine C5 and D4 44
4.2 OEE Calculations for Machines
48 4.2.1 Availability
49 4.2.2 Performance
51 4.2.3 Quality
52 4.3
Kaizen Implementation 53
4.3.1 Data Collection Before Kaizen 53
4.3.2 Proposed Solutions 54
4.3.3 Implementation 55
4.3.3.1 Re-Set Pin Rail Gap 55
4.3.3.2 Re-Set the Air Blower Pressure 56
4.3.3.3 Installed Missing Cap Screw 58
4.3.3.4 Upgraded the Vibrator Controller 59
4.3.4 Data Collection After Kaizen 60
4.3.5 Data Analysis 61
4.3.6 Cost 63
4.3.6.1 Cost Loss 63
4.3.6.2 Potential Savings 65
4.4 Conclusions
66
ix
CHAPTER 5 : CONCLUSIONS AND FUTURE RECOMMENDATIONS
