Thinking People System (TPS) Implementation Program

1. Thinking People System (TPS) Implementation Program BY: Vendor Improvement Section, Vendor Development Dept, Group Procurement

2. Program Objective • Implementation of TPS Element - Standardized Work • Takt Time • Work Sequence • ≥ 85% Manpower Efficiency • Implementation of Jishuken • Quality related Jishuken • Delivery related Jishuken

3. Jishuken Requirement • Two week’s cycle per project. At each end of project, present to Proton GP • Judging criteria as per Attachment • As a handout, • 8D reporting will be required (refer to Attachment for sample of 8D report) • QAF

4. Sample of Jishuken Schedule • 1st Day = Data Analysis & Identify problem/process • 2nd Day = Training operator & line leader on how and what to do • 3rd Day = Map out current process condition (VSM or Fish bone diagram-why why analysis • 4th 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 improvement • 8th Day = • 9th Day = Documentation preparation -8D and Presentation slide • 10th Day = Present to PROTON

5. Three Level of Kaizen • Kaizen of Method • Improve working sequence/process or operator movement • Kaizen of Tool • Replace, improve or implement new tool • Kaizen of environment/surrounding • Base on 5S and placement of material.

6. Standard Work Requirement • All 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: • QAF • Time Measurement Check Sheet • Standard Work Combination Table (SWCT) • Calculation Required: • Manpower Efficiency • Manpower Requirement

7. Recap Time Measurement Check Sheet • Identify standard time allowed for every process, for each operator • Take 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)

8. How to Fill Up Time Measurement 1. DETAIL CHECK SHEET 2. WORK SEQUENCES & PROBLEM 7. RANK – HIGHEST RANK GOES TO HIGHEST RANGE VALUE 5. ‘X MIN’-MINIMUM TIME FOR EACH PROSESS. 5. ‘X MIN’-MINIMUM TIME FOR EACH PROSESS. 5. ‘X MIN’-MINIMUM TIME FOR EACH PROSESS. 5. ‘X MIN’-MINIMUM TIME FOR EACH PROSESS. 6. RANGE = MAX TIME – MIN TIME (for each process) 6. RANGE = MAX TIME – MIN TIME (for each process) 6. RANGE = MAX TIME – MIN TIME (for each process) 8. ALLOWANCE - SET BY EACH COMPANY BUT MUST BE JUSTIFIED 8. ALLOWANCE - SET BY EACH COMPANY BUT MUST BE JUSTIFIED 3. CYCLE TIME READINGS (in this example, 15 readings) 3. CYCLE TIME READINGS (in this example, 15 readings) 3. CYCLE TIME READINGS (in this example, 15 readings) 3. CYCLE TIME READINGS (in this example, 15 readings) 9. STANDARD TIME = Xmin + ALLOWANCE

9. Example of Standard Work Combination Table 1. DETAIL CHECK SHEET 5. This is a standard Legend 4. PLOT TAKT TIME 2. WORK SEQUENCES 3. FILL UP CYCLE TIME ACCORDING TO CATEGORY 5. LINE FOR EVERY PROCESS (remember to use appropriate lines as per legend!) 6. IDENTIFY WAITING TIME (MUDA)

10. Sample Calculation of Manpower Efficiency Efficiency = Total cycle time Takt time x No Of Workers x 100 (4+4+12+4+16+4+4+4 ) ( 15 x 8 ) x 100 = 52 120 = x 100 = 43 %

11. Manpower Requirement = Total cycle time Takt Time Sample Calculation of Manpower Requirement = [(11X4) + 4 + 4]/ 15 = 3.47 people

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