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Thinking People System (TPS) Implementation ProgramBY: Vendor Improvement Section, Vendor Development Dept, Group Procurement
Program ObjectiveImplementation of TPS Element -
Standardized WorkTakt TimeWork Sequence≥ 85% Manpower Efficiency
Implementation of JishukenQuality related JishukenDelivery related Jishuken
Jishuken RequirementTwo week’s cycle per project. At each end of
project, present to Proton GPJudging criteria as per AttachmentAs a handout,
8D reporting will be required (refer to Attachment for sample of 8D report)
QAF
Sample of Jishuken Schedule1st Day = Data Analysis & Identify problem/process2nd Day = Training operator & line leader on how and what
to do3rd Day = Map out current process condition (VSM or Fish
bone diagram-why why analysis4th Day = Map out future state/ proposal state (VSM or
Process flow) and list what to do (Kaizen)5th Day = Fabrication and installation 6th Day = 7th Day = Corrective action to stabilize improvement8th Day =9th Day = Documentation preparation -8D and Presentation
slide10th Day = Present to PROTON
Three Level of KaizenKaizen of Method
Improve working sequence/process or operator movement
Kaizen of ToolReplace, improve or implement new tool
Kaizen of environment/surroundingBase on 5S and placement of material.
Standard Work RequirementAll vendors will be assigned to groups
according to manufacturing category (e.g. rubber, metal, painting etc.)
Program will be conducted as tutorial class (facilitator will be from Proton GP, NPC, or Kaizen Institute)
Documentation Required: QAFTime Measurement Check SheetStandard Work Combination Table (SWCT)
Calculation Required:Manpower Efficiency Manpower Requirement
Time Measurement Check SheetIdentify standard time allowed for every
process, for each operatorTake 10 readings for each process. Minimum
value will be chosen.Standard time = min value + allowance.
Allowance is determined by each Company and must be justified
Standard Work Combination Table (SWCT)Analysis each work sequences (for muda)
Recap
C
17.48
20
19
8.36
40.17 18.26
1.27 2.12
12
Pasang Rr Openning Trim Lh
11.64 12.51 15.95 10.59 7.59 10.59 11.63 13.30 9.827.59
8.70 10.64 9.42 8.99
20.4652.91 47.81 52.34 45.01
38.0152.61 40.2247.26 42.07 53.55 46.07 42.23 38.01 40.93 58.02 58.47
6.0010.18
1.07 3.50
2.81
17
1.14
10.11 9.44
122.58 123.79 116.91 99.43
A B
138.51 133.40 126.61 129.34124.29 121.51 121.22 153.85135.74 132.27 129.54 125.38
2.01 1.27 2.21 2.81 3.03 2.04 2.00 2.20 3.39 3.01 2.01 1.87 2.47 2.82 1.90
51.01 43.2157.80 56.92 40.71 48.59 49.1150.42 47.41 58.97 51.16 52.97 50.71 49.17 50.61
1.872.002.28 2.45 2.97 3.04 1.56 2.00 2.99 3.95 3.24 2.44 1.72 1.841.14
3.24 2.07 1.071.98 2.612.19 3.31 3.88 2.69 3.04 4.44 2.09 1.98
10.75 11.6114.86 10.84 10.40 16.18 10.4715.41 11.82 15.32 11.57 12.64 10.9112.0110.18
4.57
9 10
Berjalan Ke Rack
85 6
Lihat Production Sheet, Ambil Part Di Rack
Berjalan Ke Kereta
Letak Part Pada Kereta
11 RankRangeXmin12 14 1513Process Sequence 3 41 2 7
5
Process
KANCIL
1
Pasang Fr Garnish Lh
4
2
3
Pasang Fr Openning Trim Lh
No
6
8
9
13
11
10
3
5
TOTAL
16
6
7
14
15
18
7
1
4
2
Measurer NameTIME MEASUREMENT SHEETFINAL 1-OPENNING TRIM LH
Measurement DateSerial NO.
Amirul Izhar & Affandy Problems
116.9117.48
1.07
5.51
42.38
11.96
44.54
1.270.00
4.37
4.37
4.37
3.08
Allowance Standard
10.180.00
0.00
4.37
1 OPERATOR BUKA PLASTIK PART
OPERATOR MELAMBATKAN PROSES 8
3. CYCLE TIME READINGS (in this
example, 15 readings)
5. ‘X MIN’-MINIMUM TIME
FOR EACH PROSESS.
6. RANGE = MAX TIME – MIN TIME (for each process)
7. RANK – HIGHEST RANK GOES TO
HIGHEST RANGE VALUE
8. ALLOWANCE - SET BY EACH
COMPANY BUT MUST BE
JUSTIFIED
9. STANDARD TIME = Xmin + ALLOWANCE
How to Fill Up Time Measurement1. DETAIL CHECK SHEET
2. WORK SEQUENCES & PROBLEM
3. CYCLE TIME READINGS (in this
example, 15 readings)
5. ‘X MIN’-MINIMUM TIME
FOR EACH PROSESS.
6. RANGE = MAX TIME – MIN TIME (for each process)
3. CYCLE TIME READINGS (in this
example, 15 readings)
5. ‘X MIN’-MINIMUM TIME
FOR EACH PROSESS.
8. ALLOWANCE - SET BY EACH
COMPANY BUT MUST BE
JUSTIFIED
6. RANGE = MAX TIME – MIN TIME (for each process)
3. CYCLE TIME READINGS (in this
example, 15 readings)
5. ‘X MIN’-MINIMUM TIME
FOR EACH PROSESS.
MANUAL
AUTO
WALK
59 4.2TOTAL TIME
2.2
2.8
9
1.4
6 12.6
7 8.4
8
10.8
4 11.2
5 1.4
1 8.6
2 3.8
3
SEQ J OB CONTENTSTIME
MANUAL AUTO WALK
MODEL SECTION TACT TIME PROCESS NO.
PROCESS NAME
STANDARD WORK COMBINATION TABLE TEAM LEADER PROD. EXEC AM / MGR
OPERATION SEQUENCE FLOWDATE
Setting 3 part
Install 2 part
Install 5 clip for Lwr Interference
Install 7 fius
Install air cond hose
Install sub-assy gear
Install console box and impact 2 pcs
Impact RR Seat and impact 2 bolt
4 10 20 30 40 50 60 70
CT 63.2"
80 90
TT 90"
Example of Standard Work Combination Table
1. DETAIL CHECK SHEET
2. WORK SEQUENCES
4. PLOT TAKT TIME
6. IDENTIFY WAITING TIME
(MUDA)
3. FILL UP CYCLE TIME ACCORDING TO
CATEGORY
5. This is a standard Legend
5. LINE FOR EVERY PROCESS(remember to use
appropriate lines as per legend!)
Sample Calculation of Manpower Efficiency
Efficiency = Total cycle timeTakt time x No Of Workers
(4+4+12+4+16+4+4+4 )
( 15 x 8 )
52
120
= 43 %
x 100=
= x 100
x 100
Sample Calculation of Manpower Requirement
Manpower Requirement = Total cycle time
Takt Time
= [(11X4) + 4 + 4]/ 15
= 3.47 people
VENDOR GROUPINGGROUP 1 (CASTING)
COMPANY Location
ALUMINIUM ALLOY INDUSTRIES SDN BHD NILAI
SENA DIECASTING INDUSTRIES SDN BHD SEMENYIH
HICOM DIECASTINGS SDN BHD SHAH ALAM
HICOM ENGINEERING SDN BHD SHAH ALAM
RIGHT WAY INDUSTRIAL (M) SDN. BHD. SHAH ALAM
LC RIMS MANUFACTURING SDN. BHD. SG.BULOH
GROUP 2 (PAINTING)
COMPANY Location
ACE POLYMERS (M) SDN. BHD. SG. BULOH
SIPRO PLASTIC INDUSTRIES SDN. BHD.SHAH ALAMSG PETANI
TECK SEE PLASTIC SDN BHD SHAH ALAM
DELLOYD AUTO PARTS MFG SDN BHD JLN KEBUN,KLANG
HICOM TECK SEE MANUFACTURING (M) SDN BHD SHAH ALAM
HIL INDUSTRIES BERHADSHAH ALAM
BKT MERTAJAM
USRA TAMPI(M) SDN. BHD. SHAH ALAM
SIME KANSAI PAINT SDN BHD KLANG
PPG COATING (M) SDN BHD PJ
VENDOR GROUPING
VENDOR GROUPINGGROUP 3 (PLASTIC)
COMPANY Location
TS HI-TECH SEAT SDN BHDJLN KEBUN,KLANGBEHRANG,PERAK
USRA INDUSTRIES SDN BHD SHAH ALAM
APM PLASTICS SDN. BHD. PORT KLANG
EP POLYMERS (M) SDN BHD SHAH ALAM
AUTOVISOR PLASTICS SDN. BHD. SHAH ALAM
AZMAN HAMZAH PLASTIK SDN BHD SHAH ALAM
KB TEKNIK SDN. BHD. ULU YAM
NIFCO MANUFACTURING (M) SDN BHD BKT RAJA
RAYA PLASTIK INDUSTRI SDN. BHD. SHAH ALAM
VENDOR GROUPINGGROUP 4 ( ELECTRICAL)
COMPANY Location
PATCO RAYA TRADING SDN. BHD. SHAH ALAM
SANDEN AIR CONDITIONING (MALAYSIA) SDN BHD SHAH ALAM
NETSTAR ADVANCED SYSTEMS SDN. BHD. AMPANG
APM AUTO ELECTRICS SDN BHD BT.CAVES
PROREKA (M) SDN. BHD. PUCHONG
REXAR TECHNOLOGIES SDN BHD SUBANG
DELLOYD TECHNOLOGY RESOURCES (M) SDN BHD KLANG
MULTI-CODE ELECTRONICS INDUSTRIES (M) BERHAD
KLANG
APM COIL SPRING SDN BHD PORT KLANG
VENDOR GROUPINGGROUP 5 ( ELECTRICAL)
COMPANY Location
SIEMENS VDO INSTRUMENTS MY SDN BHD PULAU PINNAG
MALAYSIAN AUTOMOTIVE LIGHTING SDN BHD BAYAN LEPAS,PP
CLARION (M) SDN. BHD. PULAU PINANG
UMW ADVANTECH SDN BHD SHAH ALAM
SPEKTRALINK AUTO ELECTRONIC SDN.BHD SRI KEMBANGAN
AUTO PARTS MANUFACTURERS CO SDN BHD (RADIATOR DIVISION)
SRI KEMBANGAN
ARMSTRONG AUTO PARTS PULAU PINANG
VENDOR GROUPINGGROUP 6 (METAL)
COMPANY Location
PHN INDUSTRY SDN. BHD. SHAH ALAM
AUTOMOTIVE INDUSTRIES SDN BHD SHAH ALAM
ORIENTAL SUMMIT INDUSTRIES SDN.BHD. SHAH ALAM
POWER STEEL & ELECTRO-PLATING WORKS SDN BHD
SHAH ALAM
CNC METAL MACHINING SDN BHD PUCHONG
IBK FASTENERS (M) SDN BHD PJ
VENDOR GROUPINGGROUP 7 (METAL)
COMPANY Location
SAPURA BRAKE TECHNOLOGIES SDN BHD BANGI
SAPURA MACHINING CORPORATION SDN BHD BANGI
KYB-UMW STEERING MALAYSIA SDN BHD BANTING
KYB-UMW MALAYSIA SDN BHD KUALA LANGAT
SYARIKAT METAL INDUSTRIES OF MALAYSIA SDN BHD
BERANANG
INGRESS PRECISION SDN. BHD. NILAI
INDUSTRIAL QUALITY MANAGEMENT SDN BHD SHAH ALAM
VENDOR GROUPING
GROUP 8 (METAL)Z
COMPANY Location
AUTOKEEN SDN. BHD. SHAH ALAM
PROFEN SDN. BHD. SHAH ALAM & B BTG
BURNMARK INDUSTRIES SDN BHDSHAH ALAM
BKT BERUNTUNG
AVENTUR DOOR SYSTEM SDN BHD SHAH ALAM
PEPS-JV (M) SDN BHD - REVENUE AC BTG. KALI
PESAKA NURI (M) SDN BHD BTG. KALI
PAN BAY RAWANG
BRIMAL STAMPRESS ENGINEERING SDN BHD SHAH ALAM
VENDOR GROUPING
GROUP 9 (METAL)
COMPANY Location
CHEMTUBE (M) SDN. BHD. KLANG
ORTECH MALAYSIA SDN. BHD. P.KLANG
RECOMTEC SDN BHD P.KLANG
APM SHOCK ABSORBERS SDN. BHD. KLANG
APM SPRINGS SDN BHD KLANG
SAPURA AUTOMOTIVE INDUSTRIES SDN BHD KLANG
BELTON SDN BHD SG.SIPUT,PERAK
BLOXWICH (MALAYSIA) SDN BHD PERAK
GKN DRIVELINE MALAYSIA SDN. BHD. PRAI,P.PINANG
VENDOR GROUPING
GROUP 10 (RUBBER,CARPET & LABEL)
COMPANY Location
NAKAGAWA RUBBER INDUSTRIES SDN. BHD SHAH ALAM
PARAGON CAR CARPETS & COMPONENTS SDN BHD
CHERAS
AUTOLIV HIROTAKO SAFETY SDN BHD SRI KEMBANGAN
AUTOLIV HIROTAKO SRS SDN BHD SRI KEMBANGAN
HIN GETAH (M) SDN. BHD. KL
KUMPULAN JEBCO (M) SDN. BHD. SG. BULOH
TECHNOMEIJI RUBBER SDN. BHD. NILAI
WENCO INDUSTRIES SDN. BHD. PUCHONG
NOBEL INDUSTRIES SDN. BHD. SHAH ALAM
VENDOR GROUPING
GROUP 11(RUBBER & CARPET)
COMPANY Location
CARPETS INTERNATIONAL MALAYSIA KL
WSA ENGINEERING SDN. BHD. RAWANG
PONG CODAN RUBBER (M) SDN. BHD. RAWANG
FUDEX RUBBER PRODUCTS (M) SDN BHD MELAKA
SRI KOTA RUBBER MFG SDN. BHD. MELAKA
GOODYEAR MARKETING & SALES SDN.BHD. SHAH ALAM
CONTINENTAL SIME TYRE MARKETING SDN BHD PETALING JAYA
SILVERSTONE BERHAD SHAH ALAM
SEGINIAGA RUBBER IND. SDN BHD BTG BERJUNTAI
VENDOR GROUPINGGROUP 12(OTHERS)
COMPANY Location
JOHNSON CONTROLS AUTOMOTIVE SEATING (M) SDN BHD
SHAH ALAM
KEJURUTERAAN EMAS SDN. BHD. CHERAS
MALAYSIAN SHEET GLASS SDN. BHD. SG BULOH
MARUTECH ELASTOMER INDUSTRIES SDN BHD PETALING JAYA
MCIS SAFETY GLASS SDN. BHD. SEREMBAN
MENANG NUSANTARA SDN. BHD. BALAKONG
PERMANENT PREMIUM SDN. BHD. SHAH ALAM
ROKISAR SDN. BHD. AMPANG