Problem Statement

End Date :
Signature :
Starting Date : 30 Juli 2012
1. Problem Statement
Eliminate Pallet Reading Error Alarm
Depalletiser
Name : Chandra Pramana
Job Title : Packaging Technician I In Training
Function : Team Leader
Name : Pratondho Hany Prakoso
Job Title : Packaging Technician I In Training
Function : Team Member
Role : Execute & Update Action List
Update Team Performance Indicator
Update Minutes of Meeting & Attendance list
Standardize counter measure ( OPL, WI, SOP )
Execute 5 WHY
Role : To lead & coordinate weekly meeting
Monitor and improve team result
Update Communication Board
Update Team Master Plan
Support data collection and deployment
Execute job planned
Monitoring result & reported
3. Loss Type
Down time Waste
Breakdown Defect
Minor stop Starup
Setup Process
Rework
Safety Environment
4. Loss Deployment
Alarm Pallet Reading Error Data P1 Data Collect ( Week 29 )
Tuesday, 17 July 2012 ( PL-24 Production )
Thursday, 19 July 2012 ( PL-16 Production )
Pallet Reading
Error P1 Alarm
Shift Shift 1 Shift 2 Shift 3 Shift 1 Shift 2
Intensitas 5 7 6 7 13
Pint PL-24 ( 17 July 2012 ) Bremer PL-16 ( 19 July 2012 )
0
2
4
6
8
10
12
14
Shift 1 Shift 2 Shift 3 Shift 1 Shift 2
Pint PL-24 ( 17 July 2012 ) Bremer PL-16 ( 19 July 2012 )
Pallet Reading Error P1 Alarm Data Collect Per Shift
Shift 3
13
Bremer PL-16 ( 19 July 2012 )
Shift 2 Shift 3
Bremer PL-16 ( 19 July 2012 )
Alarm Data Collect Per Shift
5. Failure Mode
Brake
ELMOT
Roller + Sproket
Conveyor
Chain Conveyor
Unit
Proximity +
Roller Proximity
Pallet Conv. Unit
OK
OK NOK OK
Photocell
Crate Presence
Photocell
Pallet Presence
Reflector
Crate Presence
Reflector
Pallet Presence
Photocell
DEPALLETISER
Reflector
OK NOK NOK OK
6. Target
Target Alarm Pallet Reading Error After Week 30
ELIMINATE PALLET READING
ERROR ALARM
7. Master Plan
29
1 State problem
2 Team selection
3 Define loss type
4 Loss deployment
5 Describe the failure mode
6 Set target
7 Master Plan
8 Analyze the problem rootcause
9 Define countermeasure and action plan
10 Start monitor result
11 Create and train standard
12 Define future actions
Note:
No Team Activity
Week
30 31 32 33 34 35 36 37

= Plan
or = Actual
* Centang dengan menggunakan ballpoint setelah suatu step dari aktivitas selesai
Week
8. 5-Why Sheet
Why (1)
C
h
e
c
k
Pallet di P1 sering
"bablas" menyebabkan
Alarm Pallet Reading
Error
Internal Cause
Pallet berhenti tidak pada
posisinya
O
K
FIVE WHY ANALYSIS
Problem Description
Potential Causes
Why (2)
C
h
e
c
k
Why (3)
C
h
e
c
k
Why (4)
C
h
e
c
k
Pallet masih berjalan ketika
motor berhenti
O
K
Ada jarak chain masih
bergerak akibat moment
dari pallet
O
K
Chain kendor
O
K
Sensor photocell tidak
membaca dengan benar
O
K
Sensor photocell pallet
presence masih menyala
"ON" ketika pallet sudah
berhenti
O
K
Posisi reflector photocell
pallet presence terlalu
melebar dari pallet
O
K
FIVE WHY ANALYSIS
Potential Causes
Why (5)
C
h
e
c
k
PREVENTIVE ACTION CORRECTIVE ACTION
Machine,
Methode
CILT AM-3-Depall-005 Adjust chain elongation
Machine
OPL Position Reflector
Pallet Presence
Reposition reflector,
adjust posisi photocell dan
reflector dapat membaca
semua jenis pallet
FIVE WHY ANALYSIS
Potential Causes
4M
Actions
9. Corrective Action
5 Why Action # Countermeasure Owner
Chain Roller Pallet
Conveyor kendor dan
kurang pelumasan
1
Adjust kekencangan
rantai dan lakukan
pelumasan berkala
sesuai CILT AM-3-
Depall-005
Pratondho
Reposisi support
reflector, adjust posisi
photocell dan reflector
dapat membaca semua
jenis pallet
2
Reposisi reflector
photocell pallet
presence
Chandra
Failure Mode
Yes
Expected
date
Actual date
Start Q3
2012
Max
31 32 33 34 35
28-Jul-12 28-Jul-12
3-Aug-12 3-Aug-12
Reoccurrencies Weekly
0
36 37
Reoccurrencies Weekly
9. Improvement Result
Pallet Reading Error Alarm Week 31 after Trial Setting on PMD week 30
PL 16 - Bremer Production
PL 24 - Pint Production
Pint PL-24 Bremer PL-16 Pint PL-24 Bremer PL-16
Shift 1 5 7 0 0
Shift 2 7 13 0 0
Shift 3 6 13 0 0
Pallet Reading
Error P1 Alarm
Before After
0
2
4
6
8
10
12
14
Pint PL-24 Bremer PL-16 Pint PL-24 Bremer PL-16
Before After
:
31.2. Pemeriksaan ke-
Ausan Rantai
31.3. Pemeriksaan ke-
Ausan Spie & Borek
Sproket
31. Palet Conveyor
31.1. Pemeriksaan ke-
Ausan Sproket
AM - CILT STANDARD
Cleaning, Inspection, Lubrication and Tightening
Machine Section Depalletiser 31.Pallet Conveyor
Part : Sproket & Chain
Jarak Bebas
Line : Prepared by : Yoyok
Equipment : Approved by : PKM
D W
NI
1
1
1 > Adjustment
Borek / Baut
Tanam sproket
> Replace Spie
Sproket
Standard
measurement :
Jarak Bebas /
Kekencangan Rantai
max 30mm
NI I
> Adjustment
tension sproket
> Jika
adjustment
sudah maksimal
dan rantai masih
terlalu kendor,
potong rantai
Standard
measurement :
Sproket Tidak kocak
terhadap Shaft
gearbox
NI I
Action if abnormal
Standard
measurement :
Sproket tidak Runcing
& Tidak kocak
terhadap Shaft
gearbox
I
Interval
> Replace
Sproket
AM - CILT STANDARD Weekly
Bottling Date : 30 Agustus 2010
Depalletiser Date :
Depalletiser 31.Pallet Conveyor
Standard : Method Tool
M Y
10 mnt
PM Weekend
10 mnt
10 mnt
Time Remark
Interval
Ref. OPL
Weekly
Date : 30 Agustus 2010
CILT-AM-3-
Depall-005
Date :
Depalletiser 31.Pallet Conveyor