Develop standardization work of coil setup at pressing machine : a case study

Che Ab. Hamid, Mohamad Nor Hafiz (2016) Develop standardization work of coil setup at pressing machine : a case study. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Standardize work (SW) is a detailed and documented of routine procedures where it enable managers and employees to follow the task completely, while maintaining the productivity and efficiency by ensuring the uniformity so that the rate of production are consistent. This study is carried out on a pressing section in a semiconductor company that produce a chip resistor. The purpose of this study is to develop and standardize the method of coil setup on the pressing machine by focusing on standardization work and cycle time of the process with the most efficient method to setup a coil at pressing machine by developing the new SOP due to the inconsistent setup time. In this study the variation method that exists in coil setup process has been identified by creating the process flow for each method. Each cycle time of sequence or activity in the setup operation has been recorded from the beginning until the end of the coil setup by using a stop watch. The time was documented using the Time Measurement Sheet and the data is transferred into standardize work combination table (SWCT) to demonstrate the time relationship and precisely describe the element of the process (Walk, Automatic, Manual) and analyzed using single minutes die exchange (SMED). Finally, the Standard Operating Procedure has been developed based on the documentation and analyzation that have been done. Therefore, It has been identified that there are four different methods that the machine operators usually perform which lead to the inconsistent and vary in coil setup operation. Through, SMED technique a new method has been developed, where the coil setup time is 345 seconds, which is lower compared to the other method and it’s able to reduce the non-added value by 6.37%. Thus, the SOP have been developed though the new method that have been identified. As a conclusion, all the objective in this study has been achieved.

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