PRODUCTION SMALL TOOL KIT FOR MANUFACTURING.

SHARING MY EXPERTISE IN RELATING TO PRODUCTION FOR MANUFACTURING SECTORS CAN ACHIEVE THEIR FEAT BY FOLLOWING WITH FOCUSING ON THESE IMPORTANT VITAL SMALL TOOL KIT "TO MAKE IT HAPPEN"

1. PLANNING

OBJECTIVES

ANALYZE

FORECAST

SCHEDULE

DAILY

2 DAYS

3 DAYS

PLANNING FOR NEXT DAY

2. ORGANIZING PRODUCTION.

OBJECTIVES

JUST IN TIME (J I T)

VISUAL DISPLAY

MATERIAL

MANPOWER

MACHINES

EQUIPEMENT

METHOD

WORK PLACE

LOT PRODUCTION

QUANTITY

QUALITY

STORAGE AREA

CRITICAL AREA

 3. TIME STUDY

OBJECTIVES

TIME STUDY FOR THE STYLE

TIME STUDY FOR THE INDIVIDUAL

   PROCESS

TARGET PER HOUR

TARGET PER DAY

WASTES IDENTITY

 4. LAYOUT SETTING

OBJECTIVES

SEQUENCE OF OPERATION

CONTINUOUS FLOW

MATERIAL FLOW

WORK STATION SETTING

MANPOWER SETTING

MACHINE SETTING

EQUIPMENT SETTING

ELIMINATE CURVE FLOW

5. EMPLOYEE ALLOCATION AS REQUIRED

OBJECTIVES

SKILLED

SEMI SKILLED

UNSKILLED

TABLE OPERATOR

STITCHER

GLUE SPRAY

EDGE INKING

FITTING

EMBOSSING

TRIMMING

HAMMERING

IRONING

THREAD BURNING

CLEANING

INSPECTION

6. MACHINE AVAILABILITY

OBJECTIVES

SEWING M/C FLATBED

SEWING M/C CY.BED SMALL ARM

SEWING M/C CY.BED BIG ARM

SEWING M/C POST BED

AUTOMATIC SEWING M/C

SEWING SLIM POST BED

PUNCHING M/C

RIVETING M/C

EMBOSSING M/C

HAMMERING M/C

IRONING M/C

SPRAYING M/C

COLORING M/C

THREAD BURNER

GLUE CLEANER

7. TOOLS AVAILABILITY

OBJECTIVES

WORKING PATTERNS

JIGS & FIXTURES

HAMMERS & TRIMMERS

SCALES, INCH TAPES & MEASURING

    GAUGES

SEWING M/C GUIDES

KADAPPA STONES

KNIVES WITH HANDLE

GLUE CANS

CREPE RUBBER

SCREW DRIVERS

CLEANING BRUSHES

8. ASSIGNING WORK

OBJECTIVES

WORK ALLOTMENT AS PER SKILL LEVEL

MULTI USAGE OF WORKMEN

ONE JOB ONE PERSON

9. WORK AS PER SOP (STANDARDIZATION OF OPERATION)

OBJECTIVES

WORK PROCESS DESIGNING

VISUAL SYSTEM

10. PRODUCTION FLOW PROCESS

OBJECTIVES

CONTINUOUS SEQUENCE

CONTROL RE-WORK

CONTROL RE-PRODUCTION

 PRODUCTIVITY & QUALITY

CONTROL ZIGZAG PROCESS

CONTROLS MAN-MOVEMENT

RIGHT METHOD

11. LINE BALANCING

OBJECTIVES

MULTI JOB USAGE OF SKILL LEVEL

UTILIZATION OF MANPOWER

UTILIZATION OF M/C

CONTROL BOTTLE NECKS

ELIMINATES REPEATED WORKS

PRODUCTION & QUALITY BALANCED

12. HOURLY MONITORING

OBJECTIVES

PROPER ALLOCATION OF MANPOWER

PROPER ASSIGNMENT OF JOB

DAILY HOURLY MONITORING MANDATORY

CHECK TARGET/HOUR

IF NOT ADJUSTED IN NEXT HOUR

IF NOT CHANGE MANPOWER

OUTPUT TO BE BALANCED

TRAIN & EDUCATE MANPOWER

TARGET SHOULD BE ACHIEVED

AT THE END OF THE DAY AT ANY COST

13. TRACKING OF MATERIALS

OBJECTIVES

MATERIALS FOR THE DAY AS PER PLAN

FOLLOW UP OF MATERIAL MOVEMENT

EXTRA MATERIAL CONTROLLED

EXCESS INVENTORY ELIMINATED

MATERIALS AS PER PLAN FOR THE NEXT DAY

14. ACHIEVING TARGET

OBJECTIVES

PROPER PLANNING

FULL MATERIALS

REQUIRED. MANPOWER

REQUIRED. MACHINES

METHODS

REQUIRED EQUIPMENT

TARGET SHOULD BE ACHIEVED, IS A MUST

 15.PRODUCTION DATA CAPTURING

OBJECTIVES

ATTENDANCE REGISTER

DAILY DOCUMENTATION MANDATORY

PRODUCTION REGISTER MANDATORY

RE-WORK REGISTER

RE-PRODUCTION REGISTER

16. ON TIME DELIVERY (O T D)

OBJECTIVES

AS PER CUSTOMER REQUIREMENT

PLAN AS PER DELIVERY

IN TIME MATERIAL

PROPER ALLOCATION OF JOB

 ALLOCATION OF MANPOWER

ALLOCATION OF MACHINES

ALLOCATION OF EQUIPEMENT

RIGHT METHOD

CONTINUAL IMPROVEMENTS

INSTANT PROBLEM SOLVING

 17. EXECUTION (PDCA)

OBJECTIVES/DOCUMENTATION

PLAN

DO

CHECK

ACTION

18. REVIEW YESTERDAY'S PROBLEM

OBJECTIVES

PROBLEM SOLVING

CORRECTIVE ACTION (CA)

PREVENTIVE ACTION (PA)

CROSS FUNCTIONAL TEAM (CFT)

REVIEW WITH TEAM

DOCUMENTATION

19. YESTERDAY'S LINE PERFORMANCE

OBJECTIVES

MEETING WITH LINE EVERYDAY FOR

 5 MINUTES BEFORE THE WORK STARTS, MUST

ACHIEVED TARGET OR NOT

ANALYSIS

ACTION PLAN

CORRECTIVE ACTION (CA)

PREVENTIVE ACTION (PA)

DOCUMENTATION

20. APPROVALS

OBJECTIVES

SET OF SAMPLES - 5 NOS

SHOULD BE APPROVED FOR EVERY PROCESS

CHECK WITH TECH PACK &

CUSTOMER APPROVED SAMPLES

CHECK WITH CUSTOMER FEEDBACK

DOCUMENTATION

VISUAL DISPLAY

 21. CONTROLLING MAN MOVEMENT

OBJECTIVES

PROPER PLANNING

PROPER ALLOCATION OF JOB

ACHIEVING TARGET HOURLY

ZIGZAG PROCESS SHOULD NOT

VIGILANCE

22. EMPLOYEES EVALUATION

OBJECTIVES

PERIODICAL REVIEW

 ONCE IN 2 MONTHS

INDIVIDUAL EMPLOYEE REVIEWS

 DOCUMENTATION

SKILL SET IDENTIFICATION

23. WORK IN PROGRESS(WIP) IN CONTROL

OBJECTIVES

MATERIALS/JOBS FOR 3 DAYS PLAN

CONTINUOUS FLOW IN PRODUCTION

NO BACKLOGS ACCUMULATION

AVOID EXCESS INVENTORY

DOCUMENTATION MANDATORY

24. EFFECTIVE COST CONTROL

OBJECTIVES

PROPER UTILIZATION OF

a. material/job

b. manpower

c. machines & equipments

d. effective methods for yielding

     good productivity/quality

e. control re-work

f. control re-production

g. repeated work process

h. target achieved as per plan with

    quality/production

i. taking care of style change over

25. PLANNING FOR THE NEXT DAY

   BEFORE 4 PM AT THE END OF THE DAY

OBJECTIVES

     a. materials/job

     b. manpower

     c. machines

     d. methods

     e. style focus & change over

SUNDARAMURTHY VELMURUGAN, LEATHER PROFESSIONAL CONSULTANT from PONDICHERRY, a2z Leather Professional Consultancy; [email protected] & [email protected] WHATSAPP: +91 8973231705