v
TABLE OF CONTENT
CONTENT PAGE
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables x
List of Figure xi
List of Abbreviations xiii
1.0 INTRODUCTION 1
1.1 Background
1 1.2
Problem Statement 2
1.3 Objectives
3 1.4
Scope of Study 3
1.5 Research methodology
3 1.6
Importance of study 4
1.7 Report Outline
4
2.0 LITERATURE REVIEW 5
2.1 Productivity
5 2.2
Lean Management 6
2.3 Lean Manufacturing
7 2.4
Waste Muda 9
2.5 Lean Tools and Techniques
11 2.5.1 AFSO21
11 2.5.1.1 Value Stream Mapping
11 2.5.1.2 Rapid Improvement Events
11
vi 2.5.1.3 Sort, Straighten, Shine, Standardize, Sustain and Safety
12 2.5.1.4 Standard Work
12 2.5.2 Lean Enterprise Architecture
12 2.5.3 Just-In-Time JIT
13 2.5.4 Kaizen
14 2.5.4.1 Kaizen and Management
14 2.5.5 5S Implementation
15 2.5.5.1 5S Principles:
16 2.5.6 Other Lean Tools and Techniques
17 2.6
Value Stream Mapping 18
2.6.1 VSM Phases 18
2.6.2 VSM tools and techniques 23
2.6.3 Process Activity Mapping 25
2.6.3.1 Types of operation 26
2.6.4 VSM Implementation Journey 27
2.6.4.1 Case Study 1: Partsco 27
2.6.4.2 Case Study 2: ABS STEEL 32
2.6.4.3 Case Study 3: Cottonseed oil Industry, India. 34
2.6.4.4 Case study 4: Telephone Manufacturer. 35
2.7 AdvantagesBenefits of Lean Implementations
36 2.7.1 MIT Lean Aerospace initiative
36 2.7.2 National Institute of Standards and Technology
37 2.7.3 Lathin’s Finding
37 2.7.4 XR Associates Findings
37 2.7.5 Nystuen Findings
38 2.7.6 Freudenberg –NOK
38 2.7.7 Kotelnikov’s Findings
38 2.8
Summary 40
3.0 METHODOLOGY 41
3.1 Strategic Planning of Study
41 3.1.1
Gantt Chart 43
3.2 Data Gathering
43 3.2.1 Primary Source
43
vii 3.2.1.1
Discussion 43
3.2.1.2 Area to Area Value Stream Mapping
43 3.2.1.3
Time Study 45
3.2.1.4 Interview the Personnel
45 3.2.1.5
Development of General Value Stream Mapping 45
3.2.2 Secondary Source
46 3.3
Data Analysis 46
3.4 Kaizen Proposal
47
4.0 COMPANY BACKGROUND 48
4.1 Background
48 4.2
Organization Group Structure 49
4.3 Corporate Information
50 4.4
Main Business 50
4.4.1 Composites Manufacturing 51
4.5 CTRM Process Flow
51 4.5.1 Panel Process Flow
51 4.5.2 Manufacturing Section For One Panel Flow
52 4.6
Summary 53
5.0 RESULT 54
