v
2.7 Takt time 27
2.8 Yamazumi chart 27
2.9 Spageti Diagram 28
2.10 Ishikawa Diagram 29
3. RESEARCH METHODOLOGY
30
3.1 Company Background 30
3.2 Identification of product Family 31
3.3 Development of Current State Map 32
3.3.1 Observation 33
3.3.2 Time Study 33
3.3.3 Steps in developing CSM 34
3.4 Determination of Wasteand Analysing Problem Area 38
3.4.1 Spaghetti diagram 39
3.4.2 Yamazumi chart 41
3.4.2.1 Takt time 41
3.4.3 Ishikawa Diagram 42
3.5 Development of Future State Map 42
4. RESULT AND DISCUSSION
43
4.1 Product selection 43
4.1.1 Production flow process 43
4.1.2 Data Collection 46
4.2 Current State Map 50
4.2.1 Analysis of CSM 51
4.2.2 Takt Time 53
4.2.2 Root Cause Analysis 54
4.3 Identification and Analysis of problem 57
4.3.1 Primary process 57
4.3.2 Plating process 58
4.3.3 Inspection Process 59
4.3.3 Checking Process 60
4.4 Suggestion for improvement 61
4.5 Development FSM 70
5. CONCLUSION AND RECOMMENDATIONS
72
5.1 Conclusion 72
5.2 Recommendation 73
REFERENCES 74
vi
LIST OF TABLES
TABLE TITLE
PAGE
2.1 Application of LM in Manufacturing
26 3.1
Cycle time recording sheet 33
4.1 Cycle time for primary process 1
46 4.2
Cycle time for primary process 2 47
4.3 Cycle time for primary process 3
47 4.4
Cycle time for primary process 4 47
4.5 Cycle time for primary process 5
47 4.6
Cycle time for primary process 6 48
4.7 Cycle time for quality inspection process
48 4.8
Cycle time for checking process 48
4.9 Cycle time for palletizing process
49 4.10
Average Data Collection 49
4.11 Requirement data
49 4.12
Why why Analysis 56
4.13 The suggestion step to implement 5’s
68 4.14
Comparison between CSM and FSM 70
vii
LIST OF FIGURES
FIGURE
TITLE PAGE
1.1 Poor arrangement of workplace
3 1.2
Product waiting for the next process 3
1.3 Product of ball pin
4 2.1
Principle of LM 7
2.2 Example VSM Common Icon
11 2.3
Example of CSM 12
2.4 Example of FSM
13 2.5
Example of spaghetti diagram 29
3.1 Project methodology
31 3.2
Process of ball pin manufacturing 32
3.3 Stop watch for data collection
34 3.4
First step in developing CSM 35
3.5 Second step in developing CSM
35 3.6
Third step in developing CSM 35
3.7 Fourth step in developing CSM
36 3.9
Fiftht step in developing CSM 36
3.9 Sixtht step in developing CSM
37 3.10 Seventh step in developing CSM
38 3.11 Last step in developing CSM
38 3.12 Track routing for ball pin product
40 3.13 Ishikawa diagram
42 4.1
Primary process Workstation 1 44
4.2 Plating process Workstation 2
44 4.3
Quality inspection process Workstation 3 45
4.4 The Current State Map CSM
50 4.5
Percentage of value added activity and non value added activity 52
viii
4.6 Yamazumi Chart
53 4.7
Ishikawa Diagram 55
4.8 Primary process in VSM
58 4.9
Plating process in VSM 59
4.10 Inspection process in VSM 60
4.11 Checking process in VSM 61
4.12 Raw material wait for the primary process 62
4.13 Effect of the machine problem 63
4.14 Ball pin stuck at the rail track
63 4.15 Location to locate the product after primary process
63 4.16 The sign board at the primary process
64 4.17
Waiting product 65
4.18 aDefect product, b Tag for rejected product
65 4.19
Condition at plating process 66
4.20 Recommended layout for placed product at plating process
66 4.21
Poor arrangement 67
4.22 Workplace area
67 4.23
Poor labeling 68
4.24 Example of template
69 4.25 The
Future State Map FSM 72
ix
LIST OF ABBREVIATIONS
SOP -
Standard of procedure CSM -
Current State Map FSM -
Future State Map VSM -
Value Stream Mapping LM
- Lean Manufacturing
VA -
Value Added NVA -
Non Value Added NNVA-
Necessary but non-value adding EOQ -
Economic Order Quantity JIT
- Just In Time
SMED - Single Minute Exchange Die
FIFO - First In First Out
AQL - Acceptance Quality Limit
x
LIST OF PUBLICATIONS
NO PUBLICATION
1 Effendi Mohamad,
Siti Nur F atihah Ab Rasid
, Teruaki Ito , Mohd Amran Md Ali, Mohd Amri Sulaiman, Mohd Ashadi
Azam, Adi Saptari, , 2014, An initiative to implement lean manufacturing using value stream mapping in textile
manufacturing company, 24
th
Design Engineering Systems Division Annual Conference, Japan Society of Mechanical
Engineers,17
th
-19
th
September, University of Tokushima,Japan
1
CHAPTER 1
INTRODUCTION
1.1 Background of Study