JISHUKEN STEP 2 - Theme Selection

In this step we will determine what will be the theme of jishuken. The theme is usually determined from the results analysis of past and forecasting data.
The analysis process is important so the theme determination of improvement that will effect the results.

Beside that, with theme selection step, the jishuken team will get the commitment from the top management for all the effect such as costs, supporting and implementation in production line. That's why we need to analyze accurately in this step.

Here is the step to complete the theme selection step:

1. Data Searching / Researching & Analysis (past and forecast data).
The data is used usually :
• 10 biggest customers
• 10 biggest type
• 10 biggest rejection
• 10 biggest repair
• 10 highest stock over
• 10 biggest overtime
• 10 largest customer claim
2. Clarify the Problems
   Clarify all the problem that linked with data above. Make all the problem clear and there is no hidden problem.
3. Discuss with Management
   
   • Present all the data available to management
   • Make conclusions from data - the data presented
   • Request approval from management for the selected theme based on data
   • If management agrees, use the above data to determine the theme
   • If management does not agree, determine the selected theme, but must refer to the above data, eg data in second, third
   • Create reasons why choosing themes that are not Pareto
4. Theme Selection and Decision
• Set the selected theme
• Show photo part and its position in the end product
• Determine the initial target for parts such jishuken:
  - Reduce lead times 50%
  - Reduce 30% rejection
  - Reduce 100% repair
  - Reduce 50% stock
  - Reduce 25% over time

JISHUKEN STEP 1 - STOP 6 (Safety Toyota Zero Project)

STOP is an acronym for Safety Toyota Zero Project. There are 6 types of accidents in STOP 6, mostly related with equipment / machine. They are:

1. Apparatus, accidents caused by caughted in machine
2. Big Heavy, accidents caused by heavy object hitting
3. Car, accidents caused by transportation accident
4. Drop, accidents caused by dropped from high place
5. Electric, accidents caused by electrical contact
6. Fire, accidents caused by hot object contact, or exposed to flames

Classification level based on hazard and risk ranking:

• Rank 1 (Red) ; Death , Disability ,Lost of Organ
• Rank 2 (Yellow) ; Injury ,Production shutdown/ Lost Working Day (LWD)
• Rank 3 (Green) ; Little injury (no absent) ,No production shutdown / Non Lost Working Day (NLWD)

Here 7 Steps of Safety Assurance:

1. Patrol Check base on STOP 6 by Jishuken team
2. Making rank criteria by company management
3. Confirm Actual Patrol Check by Company Management
4. Company Decision (Ranking category)
5. 4M analysis
6. Countermeasure for Safety Assurance (Permanent & temporary base on 4M)
7. Company Standardization (Discuss with Management linked to productivity & quality)

Continue...

JISHUKEN STEP 0 - Training

Training usually is held about one week. The purposes of training basically are:

1. Evaluate TPS theory understanding & skill level of all Jishuken members (before training).
2. All members join training (Stop 6 Introduction, TPS Introduction, JIT (Just In Time), 12 Steps of QAC (Quality Assurance Chain), Standardized Work, 17 Steps of Productivity).
3. Evaluate theory understanding of all Jishuken members (after training) & skill level (before Jishuken).
4. Based on evaluation result, set up target level up for each member (level up target should be step by step, do not jump to the high level).

Training will make sure all members have been ready to implement all the steps.

12 Steps of Quality Assurance Chain (QAC)

QAC (Quality Assurance Chain) is a systematic and integrated method to assure no defect outflow and no defect making. Consist of 3 levels :

• Level 1 : Map of all processes in the supply chain
  
• Level 2 : Focus on no defect outflow
  
• Level 3 : Focus on no defect making
  

There are 12 steps of Quality Assurance Chain (QAC):

• Step 1 : Theme Selection
  
• Step 2 : Set up Target
  
• Step 3 : Set Activity Plan
  
• Step 4 : Process Mapping & Problem Investigation
  
• Step 5 : Grasp the Confirm Item and Confirm Point to prevent defect outflow (level 2)
  
• Step 6 : Trial & Kaizen Activity
  
• Step 7 : Monitoring & Evaluation of Result and Process
  
• Step 8 : Standardized and Yokoten (copy paste)
  
• Step 9 : Grasp the Confirm Item and Confirm Point to prevent defect making (level 3)
  
• Step 10 : Trial & Kaizen Activity
  
• Step 11 : Monitoring & Evaluation of Result and Process
  
• Step 12 : Standardized and Yokoten (copy paste)

17 Steps of Productivity (Jishuken)

17 Steps of Productivity (Jishuken)

• Step 0 : Training
  
• Step 1 : Safety Mapping
  
• Step 2 : Theme Selection
  
• Step 3 : Make PFC (Part Flow Chart) Before
  
• Step 4 : Arrange Smooth Flow (Seiryuka)
  
• Step 5 : Make PIFC (Part & Information Flow Chart) Before
  
• Step 6 : Make PIFC (Part & Information Flow Chart) Ideal
  
• Step 7 : Make Gap/Problem Analysis
  
• Step 8 : Set Temporary Standard
  
• Step 9 : Confirmation and Trial
  
• Step 10 : Make PIFC (Part & Information Flow Chart) Target
  
• Step 11 : Set up Target
  
• Step 12 : Set Groups and Schedule
  
• Step 13 : Kaizen Activity
  
• Step 14 : Training and Trial
  
• Step 15 : Trial and Result Evaluation
  
• Step 16 : Make Standardized Work
  
• Step 17 : Set Next Step Kaizen Target