Its all about lean manufacturing tools

1. General Information
(Total Productive Maintenance)
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2. General Information

3. General Information
Coach’s Background
AJI WIJAYA KUSUMA, ST
Enthusiast & professional on Lean,
Improvement, people development
and motivation.
16 years experience in Apparel
Industry focus on practical lean
implementation, costing & capacity
management
471.wijayakusuma@gmail.com
+62 815 7898 6913
Aji Wijaya Kusuma
Lean Manufacturing
Industrial Engineering
Production Planning
Apparel CMT Costing & CPM
90%
90%
80%
85%
85%
Supplier Capacity Management
https://www.youtube.com/user/471WijayaKusuma/featured
https://www.facebook.com/Lets-LEAN-788239307962079

4. 4
ADA DAMPAK
NEGATIFKAH?

5. General Information
SOLUSI PATENKAH?

6. General Information
15-30 MENIT
MEMBERSIHKAN
SEPATU
NORMAL GA?
ADA OUTPUT HILANGKAH?

7. General Information
Jika output rata-rata per jam per
line = 100 pcs
Potensi Output Hilang = 50 x 20 =
1000 pcs
Total line 20
30 menit hilang = 50 pcs
10 hari kotor tinggi =
10 hari x 1000 pcs = 10.000 pcs

8. General Information
KITA harus memiliki kepekaan
terhadap LOSSES~KERUGIAN
LOSSES
menggerogoti
PROFIT

9. General Information
Konsumen OGAH
bayar LOSSES
KEPEKAAN Langkah awal
memerangi LOSSES
Membiarkan LOSSES
cerminan sikap kurangnya
OWNERSHIP~BODO AMAT

10. General Information
GARMENT
FACTORY
OR LAUNDRY
FACTORY
TRUST LOSS

11. General Information
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12. General Information
12
Tidak Adanya SISTEM PERAWATAN
Mesin yang EFEKTIF
Perawatan hanya jadi
tanggungjawab MEKANIK
Mentalitas ‘AKU PAKAI, KAMU
YANG PERBAIKI’
PERAWATAN tidak melibatkan
SELURUH PROSES/ORANG TERKAIT

13. General Information
(Total Productive Maintenance)
13

14. General Information
14
Pengertian TPM
Membangun BUDAYA PERUSAHAAN untuk meningkatkan efektivitas
mesin
MELIBATKAN semua department terkait dengan perawatan mesin
MELIBATKAN semua karyawan from Top to Down
Mencapai ZERO LOSSES melalui kegiatan kelompok-kelompok kecil

15. General Information
15

16. General Information
TPM di Industri
GARMENT
16
TPM
PERAWATAN
MANDIRI
(AUTONOMOUS
MAINTENANCE)
1. DATA
KERUSAKAN
MESIN
AKTUAL
PERAWATAN
MELALUI
PENCEGAHAN
(PREVENTIVE
MAINTENANCE)
UPGRADE
SKILL MEKANIK
KELOMPOK-
KELOMPOK
KECIL
PERBAIKAN
KASUS
KERUSAKAN
BERULANG

17. General Information
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18. General Information
18
Line :
TGL
JAM
KE
NAMA MESIN
NO. SERI
MESIN
LAMA
RESPONS
( MENIT )
LAMA
PERBAIKAN
( MENIT )
ANALISA MASALAH/AKAR MASALAH SPAREPART YG DIGANTI
TTD & NAMA
OPERATOR
TTD & NAMA
MEKANIK
DATA KERUSAKAN MESIN
2
1

19. General Information
19
NO. MESIN NO. SERI MESIN BRAND PEMBELIAN USIA MESIN (TAHUN) KETERANGAN LAMA KERUSAKAN TGL KERUSAKAN LINE
1347 4DOAJ '02024 JUKI 1-Feb-08 3 125 7-Feb
1334 4DOAJ 01997 JUKI 1-Feb-08 3 120 12-May 48
1322 4DOAJ 1975 JUKI 1-Feb-08 3 120 24-Feb
1457 2037202 KINGTEK 8-Apr-08 2 107 18-Mar 43
1394 4DOAJ'01986 JUKI 1-Feb-08 3 95 7-May 48
987 4DOZK05602 JUKI 29-Mar-07 3 92 6-Jun 48
1446 2037571 KINGTEK 8-Apr-08 2 85 8-Apr 49
1192 4DOAH 15070 JUKI 12-Nov-07 3 85 3-Mar
1271 4DOAH 15124 JUKI 12-Nov-07 3 66 14-Jun 48
1496 15370925 SIRUBA 25-Apr-08 2 65 17-Mar 53
1032 2048219 KINGTEK 11-May-07 3 65 25-Jan
1028 2048155 KINGTEK 11-May-07 3 62 6-Jan
NO. MESIN NO. SERI MESIN JENIS OBRAS BRAND PEMBELIAN USIA MESIN (TAHUN) KONDISI LAMA KERUSAKAN TGL KERUSAKAN LINE
4187 2050443 O4 SIRUBA 27-Jan-01 10 OK 151 24 Juni 2011 5
4461 0270267 O4 PEGASUS 27-Oct-07 3 OK 93 07 Februari 2011
4271 10166052 O4 SIRUBA 17-May-06 4 OK 90 16 Agustus 2011 24
4501 PEGASUS O4 0309025 19-Mar-08 2 OK 75 09 Maret 2011
4355 0230933 O4 PEGASUS 23-Mar-07 3 OK 70 12 April 2011 17
4437 0270221 O4 PEGASUS 27-Oct-07 3 OK 70 29 April 2011 54
4531 0309337 O5 PEGASUS 19-Mar-08 2 OK 66 06 Januari 2011
414 155512 R O4 - - - OK 65 24 Maret 2011 36
SN
O4
3

20. ADD A FOOTER 20
Tgl KETERANGAN
29-Sep Line 6
Line 6
Line 7
No Status Rencana Berikutnya/SIAPA/TGL
No Akar Masalah Siapa No STANDAR SOLUSI
1
Mekanik hanya mengencangkan
baut rotari yang kendor tidak cek
posisi rotari & hook
Leader mekanik
2
1-Oct
2. RENCANA TINDAKAN 4. STANDARDISASI
Rincian Tindakan Kapan MASALAH
Evaluasi hasil meeting /Leader mekanik
( singgih ) /mulai 3 october daily
Rincian Tindakan
Meeting dengan mekanik jika ditemukan
masalah yang sama mekanik harus
mengecek posisi rotari & hook dengan
posisi jarum
2-Oct
FORM ANALISA MASALAH & SOLUSI MEKANIK Week 1 Oct
1. ANALISA SEBAB-AKIBAT Line 1 - 8 3. MONITOR PROSES & HASIL
Kerusakan
mesin/Respon
Mekanik SEBELUM
Kerusakan
mesin/Respon
Mekanik SESUDAH
65 18
45
1
Meeting dengan mekanik jika
ditemukan masalah yang sama
mekanik harus mengecek posisi
rotari & hook dengan posisi jarum
20
135 0
Waktu perbaikan >
waktu standar
perbaikan
Mesin
Manusia
Setting ulang tinggi
tiang jarum
Hasil jahitan ada lobang
jarum Line 7 01oct
Setting otomatis
singkron mesin
Pisau tidak fungsi /
tidak bisa motong
Singkron otomatis eror L.6
01oct
Setting rotari dan hook
Posisi rotari & hook jauh dengan jarum
Mekanik hanya mengencangkan baut rotari
yang kendor tidak cek posisi rotari & hook
L.6 29 september
Metode
Mesin
Ganti baut dudukan pisau
Baut dudukan pisau hilang
Posisi baut
diluar
mesin L.6
Baut
dudukan
pisau kendor
& lepas
Terkena getaran mesin

21. ADD A FOOTER 21

22. General Information
AKAR MASALAH PERBAIKAN
MESIN KASUS JAHITAN
LONCAT
Looper Seting
Sparepart
Pasang
Jarum
Jarum
Tumpul
Tension
Benang
Rotary
Kasar

25. Train for mechanic
development
Test Skill

26. Visual Control Mechanic
Development Skill
No NAME Machine
Problem
Focus
Analyze Std
Total
Time
Setting
+ repair
(Minute
)
Education Skill
Update:
19 Feb
Update:
26 Mar
Update:
16 Apr
Update:
11 Mei
Update:
3 Jun
Update:
15 Jun
Update:
07 Jul
Update:
10
August
Update:
19 Feb
Update:
26 Mar
Update:
16 Apr
Update:
11 Mei
Update:
3 Jun
Update:
15 Jun
Update:
07 Jul
Update:
10
August
1 Dendi
Overdeck
( 3
Neddle,
Cutt )
Jumping
Stitch
3,7 3,8 3,9 3,6 3,7 3,9
20
2 Tatang 3,7 3,7 3,8 3,8 3,4 3,6 3,6 3,7
3 Aji 2,0 2,6 3,6 3,0 2,9 3,3
4 Jenal 3,3 3,7 3,7 3,3 3,4 3,7
5 Andre 3,1 3,3 3,7 3,3 3,3 3,4
6 Hari 4,0 4,0 3,9 3,9
7 Willy 2,8 3,1 3,2 2,7 2,7 3,0
NOTE
SCORE REMARKS
0 Can not repairing machine
1 Can carry out basic repairing machine
2 Can carry out basic repairing machine + requires intermediate supervision
3 Can carry out basic repairing machine + requires advance supervision
4 Can carry out basic repairing machine , propose improvement ideas, be able to work with
other Dept. & can train other mechanics to make repairs

27. Score Mechanic skill before & after
project
2.8
2.0
3.1
3.3
3.7 3.7
4.0
3.2
3.6 3.7 3.7 3.8 3.9 4.0
WILLY AJI ANDRE JENAL TATANG DENDI HARI
SKILL MATRIX MECHANIC
BEFORE AFTER
3.

28. Result on machine breakdown

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30. General Information
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33. General Information

34. General Information
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35. General Information
35
Perawatan Mandiri Operator Sewing – Mesin SN

36. General Information
36
Perawatan Mandiri Operator Sewing – Mesin Obras

37. General Information
37
Perawatan Mandiri Operator Sewing – Mesin Overdeck

38. General Information
General Information
QUALITY
IMPROVEMENT
QC focus on garment quality
improvement by hourly review
endline Defect with IE &
Production Team with Goal Target
Defect : 4%
Hourly review Defect
Impact from Self
Trimming and Self Checking by Operator
Regularly Machine Cleaning by 2
times a day to minimize the defect
& machine downtime
Needle changing schedule for
special machines / process
such as Overdeck , overlock
machine
Posted cleaning instruction in
each special machines
Intense communication between
Production Team SPV, QC and IE to
make improvements related to
Quality.

39. General Information
• The work area looks very dirty
• Sticker thrown on the floor
• The machine looks dirty filled with scraps
• No trash can
• Daily Cleaning Activity 2 times a day
• including the cleanliness of the machine
and the work place area.
From the small things can have a Big Impact

40. General Information
60%
PENURUNAN
DARI INI
KE
WAKTU PERBAIKAN MESIN

41. General Information
Graphic Defect Trimming & Broken
33.9% 34.2%
24.0%
16.1%
23.1%
16.1%
18.2%
21.3%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
JAN FEB MAR APR MAY JUN JUL AUG
Untrimming Thread
16.2%
17.9%
5.9%
7.8%
3.4%
8.9%
10.7%
0.9%
0.0%
2.0%
4.0%
6.0%
8.0%
10.0%
12.0%
14.0%
16.0%
18.0%
20.0%
JAN FEB MAR APR MAY JUN JUL AUG
Broken Stitched
62%
Average : 30.7% Average : 13.3%
Average : 18.9% Average : 6.3%
47%

42. Neal Creative ©
FINISH
IMPROVEMENTS!
THANK YOU