Lean -

Improving the borrow-return book process with Lean technique

Chutima Ketsa

2553
 Lean -

5217670026


.. 2553
..

(Lean) -
, ,

(Minimum Waste)
(Final
Products)
(Non-value added)

-

..

II


I
II
III
V
VI
1
1.1 1
1.2 1
1.3 2
1.4 2
1.5 2
1.6 2
1.7 3
1.8
3
2
2.1 6
2.2 6
2.3 8
2.4 Lean Operation 12
2.5 ECRS 19
2.6 (Barcode) 22
2.7 (Microsoft SQL Server 2000) 24
2.8 28
3
3.1 29
3.2 29
3.3 33
3.4 Context Diagram 34
3.5 Data Flow Diagram 35
3.6 Data Dictionary of Data Store 43
3.7 Entity Relationship Diagram 45

III
 ()

3.8 Mapping Entity-Relationship Diagram 46

3.9 Database Schema 47
3.10 52
4
4.1 53
4.2 53
4.3 53
4.4 53
4.5 54
4.6 54
5
5.1 55
5.2 56
5.3 56
5.4 57
5.5 68
6
6.1 71
6.2 71
6.3 71
73
75
78

IV


1.1 5
2.1 Toolkit (Greene, 2002) 17
2.1 Toolkit (Greene, 2002)() 18
2.2 5W1H 21
2.2 5W1H () 22
3.1 Book_Category 47
3.2 Provide_Type 47
3.3 Publishers 48
3.4 Book 48
3.5 Book_Copy 49
3.6 Book_Status 49
3.7 Main_Group 49
3.8 Main_Type 50
3.9 Borrow_Type_Permission 50
3.10 Borrow_Permission 50
3.11 Borrow 50
3.12 Borrow_Status 51
3.13 Fine 51
3.14 Fine_Status 51
5.1 67

V


2.1 11
2.2 ECRS
20
2.3 24
2.4 26
2.5 2 Tier 27
2.6 Microsoft 27
3.1
30
3.2
- 30
3.3 31
3.4 32
3.5 33
3.6 Context Diagram 34
3.7 Data Flow Diagram Level 1 35
3.8 Data Flow Diagram Level 1 () 36
3.9 Data Flow Diagram Level 2 Process 1 37
3.10 Data Flow Diagram Level 2 Process 2 38
3.11 Data Flow Diagram Level 2 Process 3 38
3.12 Data Flow Diagram Level 2 Process 4 39
3.13 Data Flow Diagram Level 2 Process 5 40
3.14 Entity-Relationship Diagram 46
5.1 Login ( ) 55
5.2 56
5.3 57
5.4 57
5.6 ( -> ) 58
5.6 59
5.7 ( -> ) 60
5.8 61
5.9 63

VI


5.10 64
5.11 Barcode 64
5.12 66
5.13 67
5.14 67

VII
 1

1.1

1.2
60
1,080

1
1.3

1.4
1.3
(Lean)
Lean () , ,

(Minimum Waste)
(Final
Products)
(Non-value added)

-

1.5

1.5.1
1.5.2
1.5.3

1.6

2

1.6.1

2
 -

-
-
1.6.2
.
-
-
.
-

1.7

1.7.1

1.7.2

1.7.3

1.8



1.8.1
-
-
-
-
-
-
-
1.8.2
- VB.NET
-

3
 -

1.8.3
-

4
 1.1

5
 2

2.1

(Automatic Identification) Auto ID

(Barcode System)

2.2

2.2.1 [1]
Plastic(2540)



70 Gram


2.2.2 [2]
.. 2546 :

6



12


2

2.2.3 [3]
.. 2546 :

2.2.4 [4] "()

. .. 2546 :
()
() 20 26
60
10 %
3.3 271,875
2.2.5 [5] (2546)

3



3 14.8 %
14.8 % 70.4 %
2.2.6 [6] ( 2549)

7


ECRS (Eliminate, Combine, Re-arrange ,Simplify 5W1H
21 14.5
14 212.11 /4 13
8 8 141.01 /4
2.2.7 [7] (2534)



37 33
11
22

2.2.8 [8] (2538)
36
3
(Intergrated System)
Mini/Micro CDS/ISIS

dBase , FoxPro , HyPlus , FoxBase Paradox 3
Dynix Innopac VTLS



(2534)

2.3


,
ECRS

8
 (Business Process Reengineering)
(Core
business process)


-
- IT /
- (cross-functional team)

-
-

(Lean Operations)

(waste)


Lean Operations get the right things to the right place, at the right
time, in the right quantities, while minimizing waste






5
(Process Flow)
1)

9
 2)

3)
4)
5)

ECRS

ECRS








2
1.
2.

10


2.1

- ECRS

ECRS

ECRS

-
-
-

-

11
2.4 (Lean Operation)
2.4.1
1 Henry Ford Alfred Sloan General
Motors (Craft
Production) ()
(Economies of Scale)


2 Eiji Toyada Taiichi Ohno
(Toyota Production
System)

(Pull System)


Just In
Time

(Lean
Manufacturing, Lean Production Lean Thinking)

Craft Production




20

12


(Standard Designs)

/





Lean Producer

(Manufacturing Enterprise)

13


(Agility)


.. 1990 Jim Womack Machine that
Changed the World 5
(Value)

(Waste-free)


Muda




(Value Steam Mapping)


(VSM)
Value Steam ( )


(Flow)

(Lead Time)

14
 (Pull)



3


Task Time

(Perfection)
(Continuous Improvement)
3
1.

2.

3.
Kaizen

(Benchmarking) Balance Scorecard

5


7
1. (Overproduction)


2. (Waiting)


3. (Transportation)

15


4. (Inappropriate Processing)

5. (Unnecessary Inventory)

6. (Unnecessary Motions)

7. ( Defects)

7
2 4 2 4
(Waiting) -
-
(Inappropriate Processing)

2.4.2

(Lean Tool) Greene (2002)
Toolkit 26

16
 2.1 Toolkit (Greene, 2002)

1 5s Flow : Housekeeping
Standardize
2 Set-up Reduction Flexibility Single Minute Exchange
ofDies,SMED
3 Production to takt time Flow Line arity
4 Standard Work Flow : Standard Operation Routine
Standardize
5 Method Sheets Flow : Graphical Work Instructions ,
Standardize Standard
Wprl Omstrictons
6 Flow Cells Throughput Cell Layout, Cellular
Manufacturing, Continuous Flow
cells, U-shaped Cells
7 Visual Controls Flow : Visual Factory , Management by
Standardize Sight , Visual Production Controls ,
Visual Material controls , Visual
Work Controls
8 One-Piece Flow Flow Continuous flow
9 Mixed-Model Flexibility Mixed-model , Mixed Model
Production Scheduling
10 Point-of-Use Material Throughput Vendor Managed Inventory,
Storage Supermarkets
11 Smoothed Production Flexibility Level-loading, Production
Scheduling Smoothing
12 Pull Production Flow : Material Kanban, Pull, Replenishment
Scheduling
13 Cross-Trained Flexibility Flexible work force,Rotating Jobs,
Workforce Muliskilled workforce
14 Lean Kaizen Events Continuous Kaizen Baitz,Accelerated
Improvement

17
 2.1 Toolkit (Greene, 2002) ()

15 Total Productive Flow Autonomous Maintenance
Maintenance Maintenance
16 Reliability-Centered Flow
Maintenance Maintenance
17 Preventive Flow
Maintenance Maintenance
18 Predictive Flow
Maintenance Maintenance
19 Autonomation Throughput : Jidoka, source inspection
Quality
20 Mistake-Proofing Throughput : Pokayoke,Error-proofing
Quality
21 Self-Check Inspection Throughput :
Quality
22 Successive Check Throughput :
Inspection Quality
23 Line Stop Throughput : Jidoka
Quality
24 Design-of- Continuous
Experiments Improvement
25 Root Cause Analysis Continuous 5 whys
Improvement
26 Statistical Process Continuous
Control Improvement

(Mistake-Proofing)
-

Dr.Shingo 10

18


(Continuous Improvement)

1. Lean Kaizen Events (Kaizen Blitz, Accelerated Improvement Workshop
(AIW)) Kaizen (Improvement)


(Continuous
Improvement)
Kaizen

Innovation

Kaizen
2. (Design-of-Experiments)

3. (Root Cause Analysis) (5 Whys)

4. (Statistical Process Control)
(Control Charts) Out
of Control
5. (Team-Based Problem Solving) (Quality
Circles, Self-Direct Work Teams)

2.5 ECRS

19


ECRS

4. Simplify

3. Re-arrange

2. Combine

1. Eliminate

2.2 ECRS

1. (E: Eliminate)

2. (C: Combine)



3. (R: Re-arrange)

4. (S : Simplify)

20







5W1H
2
1. What, Where, When, Who, and How (5W 1H)
-
-
-
-

-
2. Why

2.2 5W1H

? : ? Eliminate
?:
? : ? Combine + Re-arrange
? : ?
21
 2.2 5W1H ()

? : ? Simplify

2.6 (Barcode)
(Barcode)
(Bar) (Code)

(Bar) (Space)
(Symbology)

2.6.1
.. 1970

.. 1973 UPC
(Uniform Product Code)

.. 1975
EAN (European Article Number) .. 1977 EAN

IANA (International Article Numbering Association) EAN
UPC
UPC
EAN .. 2530 Thai Product
Numbering Association TPNA
EAN

.. 2536 TPNA
885 EAN EAN International
22
 EAN Thailand 885

885

91
EAN 2 3
EAN




2.6.2

1.

2.
3.

2.6.3



1. Quiet Zone

2. Start/ Stop Character

3. Data
4. Check Digit
Data
2.6.4
3
1. ()

23
 2.

3.
(
)

1
() 0

1. (Wide Bar)
(Narrow Bar)
2. (Wide
Space) (Narrow Space)

2.3

(Infrared)

24
2.6.5
2
1. Laser




(Analog)
(Digital)


2. CCD
LED
CCD Image

2 Single Scan
1
Picket Fence Direction Raster Scan


Ladder Direction
2.6.7

1. Moving Beam Scanner

2. Fixed Beam Scanner

3. Hand Held Scanner


4. Wand Scanner

5. Hand Held Laser Scanner Moving
Beam Scanner

25
 2.4

2.7 (Microsoft SQL Server 2005)

SQL Server 2005 Enterprise Edition SQL Server
2005 Client/Server
2
2.7.1 2 (2-Tier Architecture Model)
/ (Client/Server)
(Task)
(Network System)
Tier
/ 2
1.
2.

26
 Server Data Tier

Data Tier

Business Rules

Client Presentation Tier

2.5 2 Tier

2
2 Tier

(Web Browser) (Host)

2

Web Server

ASP

Web Browser

HTTP

HTML
Server Data Tier

2.6 Microsoft
27
 2
IE (Internet Explorer)

IIS

HTTP
Business Rules
2 VB.NET
Microsoft SQL Server 2000 Enterprise Edition

2.8

28
 3

3.1
12,000
1,140
(Manual)

3.2










2
25 1
10
20

29

25

15 10

3.1

- 20

7 3 5 5

3.2
-

1.
25
-
20 -

2. -

3.

30
 3.3

3.3 (1)

(2)

31


-
-

3.4

32
 3.4

3.3
2

Database

Internet

Web Bases

Web sever
server `

Internet User
Offline Application

`
Barcode

3.5

33
3.4 Context Diagram

3.6 Context Diagram

34
3.5 Data Flow Diagram

41 D1

D2

D5

D3

2 D2

D6

D2

3.7 Data Flow Diagram Level 1

35
 3 D1

D3

D4 -

D2

D4 -

4 D7
D4 -

D2

D3

D7

D1
D4 -

5
D1

D5

D5

- -
D7

D1

3.8 Data Flow Diagram Level 1 ()

36
 1.1
D1

1.2

1.3
D2

1.4

1.5
D5

1.6

1.7

D3

1.8

3.9 Data Flow Diagram Level 2 Process 1

37
 D2

2.1
D6

2.2 D2

2.3

3.10 Data Flow Diagram Level 2 Process 2

3.1
D1

D3

D4 -

3.2
D2

3.3
D4 -

3.11 Data Flow Diagram Level 2 Process 3

38
 4.1 D7
D4 -

4.2

D2

D3

4.3
D7

4.4

4.5

4.6
D1
D4 -

3.12 Data Flow Diagram Level 2 Process 4

39
 5.1
D7

5.2
D6

5.3 D2

- -
D4

D1

3.13 Data Flow Diagram Level 2 Process 5

3.6 Data Dictionary of Data Flow Diagram

3.6.1 Data Dictionary of Data Flow Diagram level 2 of process 1
= + + + +
+
= + + +
+
= + + +
+
= + + +
+
= + +

= + +

= +
= +

40
 = +
= + +

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+
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+
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=
= + +

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= + +
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+
= + + + +
+
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= +
= + +

= + +

= + +

3.6.2 Data Dictionary of Data Flow Diagram level 2 of process 2

= + +

41
 = + +

=
= + +

= + +

= + +

= +
= +

3.6.3 Data Dictionary of Data Flow Diagram level 2 of process 3

=
= + +
=
= +
= +
= +
= +
=
= +
=
= + +
+
=

3.6.4 Data Dictionary of Data Flow Diagram level 2 of process 4

=
= + +
+
=
= + + +

42
 = +
= +
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= + +
= + +
=
=
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=

3.6.5 Data Dictionary of Data Flow Diagram level 2 of process 5

= + +
+ +
= + + +

= + + +

= + +
+ +
= + + +

= + +
+
- = + + +

= + + + +
+

3.7 Data Dictionary Of Data Store

D1: = + + + +
+
D2: = + + +
+ ISBN +

43
D3: = + +

D4: - = + + +

D5: = +
D6: = + +
+

D7: = + + +
+ +

44
3.7 Entity-Relationship Diagram

3.14 Entity-Relationship Diagram

45
3.8 Mapping Entity-Relationship Diagram

Book_Category (book_category_id , book_category_fine ,

book_category_name)
Provide_Type (provide_type_id , provide_type_name)
Publishers (publisher_id , publisher_name , publisher_address ,
publisher_road , publisher_district , publisher_province ,
publisher_postcode , publisher_telephone ,
publisher_fax , publisher_website )
Book (book_id , book_ISBN , book_author , book_edition ,
book_month , book_year , book_heading ,
book_keyword , book_attribute , book_pagination ,
book_issue , book_page_number , book_department ,
book_abstarct , book_user_created ,
book_created_date , book_series , book_translator ,
book_note , book_category_id(fk) , provide_type_id(fk) ,
publisher_id(fk) , main_type_id(fk))
Book_Copy (book_copy_id , book_copy_code ,
book_copy_code_key , book_copy_bookcase ,
book_copy_date_in , book_copy_cancel_date ,
book_copy_cancel_reason , book_provider ,
book_call_number , created_date , created_by ,
book_status_id(fk) , book_id(fk))
Book_Status (book_status_id , book_status_name)
Main_Status (main_status_id , main_status_name)
Main_Type (main_type_id , main_type_name ,main_type_code ,
main_group_id(fk))
Borrow_Type_Permission (borrow_type_permission(fk) , main_type_id(fk) ,
comment )
Borrow_Permission (borrow_type_permission , borrow_permission_name ,
borrow_permission_period ,
borrow_permission_amount)
Borrow (borrow_id , media_code , book_name ,

46
 borrow_user_created , borrow_return_date ,
return_date , return_period , return_staff_by ,
borrow_status_id(fk))
Borrow_Status (borrow_status_id , borrow_status_name)
Fine (fine_id , cal_amount , created_date , created_by ,
pay_date , pay_staff_by , comment , fine_status_id(fk) ,
borrow_id(fk) )
Fine_Status (fine_status_id , fine_status_name)

3.9 Database Schema

3.1 Book_Category

Field Type Size KEY Comment

book_category_id Int 10 PK
book_category_fine int 10
book_category_name VarChar 50

3.2 Provide_Type

Field Type Size KEY Comment

provide_type_id int 10 PK
provide_type_name VarChar 50

3.3 Publishers

Field Type Size KEY Comment

publisher_id Int 10 PK
publisher_name Varchar 50
publisher_address VarChar 80
publisher_road VarChar 50
publisher_district VarChar 30
publisher_province VarChar 30

47
 3.3 Publishers ()
Field Type Size KEY Comment
publisher_postcode VarChar 10
publisher_telephone VarChar 50
publisher_fax VarChar 50
publisher_website VarChar 150

3.4 Book

Field Type Size KEY Comment

book_id int 5 PK
book_ISBN VarChar 20 PK
book_author VarChar 30
book_edition VarChar 2
book_month VarChar 20
book_year VarChar 4
book_heading VarChar 60
book_keyword VarChar 60
book_attribute VarChar 50
book_pagination VarChar 10
book_issue VarChar 30
book_page_number VarChar 150
book_department VarChar 80
book_abstarct VarChar 500
book_user_created VarChar 150
book_created_date date 10
book_series VarChar 150
book_translator VarChar 30
book_note VarChar 200
book_category_id(fk) int 10 FK
provide_type_id(fk) int 10 FK
publisher_id(fk) int 10 FK
main_type_id(fk)) int 10 FK

48
 3.5 Book_Copy

Field Type Size KEY Comment

book_copy_id Int 10 PK
book_copy_code VarChar 50
book_copy_code_key Int 10
book_copy_bookcase VarChar 200
book_copy_date_in date 20
book_copy_cancel_date date 20
book_copy_cancel_reason VarChar 50
book_provider VarChar 50
book_call_number VarChar 150
created_date date 10
created_by VarChar 20
book_status_id(fk) Int 10 FK
book_id(fk) int 10 FK

3.6 Book_Status

Field Type Size KEY Comment

book_status_id int 10 PK
book_status_name Varchar 50

3.7 Main_Group

Field Type Size KEY Comment

main_group_id int 3 PK
main_group_name VarChar 50

49
 3.8 Main_Type

Field Type Size KEY Comment

main_type_id int 10 PK
main_type_name VarChar 50
main_type_code int 2
main_group_id int 10 FK

3.9 Borrow_Type_Permission

Field Type Size KEY Comment

borrow_type_permission(fk) int 10 PK,FK
main_type_id(fk) int 10 PK,FK
comment VarChar 50

3.10 Borrow_Permission

Field Type Size KEY Comment

borrow_type_permission VarChar 3 PK
borrow_permission_name VarChar 10
borrow_permission_period Int 10
borrow_permission_amount int 10

3.11 Borrow

Field Type Size KEY Comment

borrow_id Int 3 PK
media_code VarChar 7
book_name VarChar 20
borrow_user_created VarChar 150
borrow_return_date date 10
return_date date 10
return_period int 10
return_staff_by VarChar 150
50
 3.11 Borrow()

Field Type Size KEY Comment

borrow_status_id(fk) int 10

3.12 Borrow_Status

Field Type Size KEY Comment

borrow_status_id int 10 PK
borrow_status_name VarChar 30

3.13 Fine

Field Type Size KEY Comment

fine_id int 3 PK
cal_amount VarChar 7
created_date date 10
created_by VarChar 20
pay_date date 10
pay_staff_by VarChar 150
comment VarChar 150
fine_status_id(fk) int 10
borrow_id(fk) int 10

3.14 Fine_Status

Field Type Size KEY Comment

fine_status_id int 10 PK
fine_status_name VarChar 50

51
3.10
(Server) (Client)
1
(Computer Network)

-

-
-

- 2000 (Windows 2000)
4 562 MB
80 G 1024x768 52 X
- (Windows XP )
4 128 MB
40 G 1024x768 pixel 52X

52
 4

4.1

4.2



1.
2. 1
3. 2
4. 1 ( )

4.3

4.4

1. /

53
 2. /
/

3. /

4.
.
.
.

5.

6.
7.
8.
9.
10.
11.
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4.5

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54
 5

5.1

4

1)
2)
3)

5.2

5.1

1.

- CPU : Quad Core Xeon Pro X3220 2.4 GHz

- Memory : 1 GB
- Hard Disk : 250 GB
2.

- OS : Windows Server 2003 R2 Enterprise Edition

3.

- Internet Information Services 6.0

55
 5.1
()

4.

- Microsoft SQL Server 2005

5.

-

6.

-
Windows
Appliction Web Appliction
7.

5.3


5.2
5.2

1.
2.
3.
4.

-
-
-

56
 5.2 ()

5.

-
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6.

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5.4
2 Windows
Application Web Application
Windows Application
1.
2.
3.
Web Application

1.
2.

5.3

57
 5.4.1 Login ( )

5.1 Login ( )

Login
1.

3 4
2.
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4. Enter

58
 5.4.2 ( -> )
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5.2

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3. 4
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59
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3.
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5.4.6 ( -> )
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61
 5.6

1.
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5.4.7 ( -> )

62
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65
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3.
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66
 5.10

5.4.9 Barcode ( -> Barcode)

5.11 Barcode

Barcode
1.
2. Barcode Barcode Pringting

67
 3. Barcode
4.

5.
6. 1
7. Barcode
2
8. 1 Barcode
9. Barcode Barcode
Pringting Barcode

10. 2
11. 2
12.
2

5.5

68
 5.3

5.5.1

5.12

5.12
2-3 3
83
3 96 %

69
 5.5.2

5.13

5.13 11
2
82 %

5.5.3

5.14

5.14 2

70
 6

6.1

6.2

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71


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74


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19.

77


50

.1 (IOC)

1 2 3
1.
1 1 1
2.
1 1 1
3.
ScienceDirect,
Scopus, ProQuest
1 1 1
4.
1 0 1
5.
1 1 0
6.
1 1 1
7.
1 0 1
8. 1 1 1
9. -
1 1 1
10. 1 1 1
11. 1 0 1

78



12. 1 1 0
13.
1 1 1
14. 1 0 1
15.
1 1 1
16. 1 1 1
17.
1 1 1
18. 1 1 1
19.
1 1 1

.2

1. .969
2. .970
3.
ScienceDirect, .955
Scopus, ProQuest
4. .904
5. .866
6. .928
7. .871
8. .983
9. - .886
10. .916
11. .902
12. .904

79

13. .991
14. .919
15.
.808

16. .919
17. .758
18. .916
19. .979
.987

Reliability Coefficients
N of Cases = 30.0 N of Items = 19
Alpha = .987

Reliability Statistics
Cronbach's
Alpha N of Items
.987 19

80
 Item-Total Statistics
Scale Corrected Cronbach's
Scale Mean if Variance if Item-Total Alpha if Item
Item Deleted Item Deleted Correlation Deleted
s1 66.2333 333.151 .969 .986
s2 66.2667 333.789 .970 .986
s3 65.8667 347.844 .955 .985
s4 66.1000 347.748 .904 .986
s5 65.8667 369.982 .866 .987
s6 66.0667 346.892 .928 .986
s7 66.0000 355.862 .871 .986
s8 66.0333 334.102 .983 .985
s9 66.2000 361.890 .886 .986
s10 66.3667 352.309 .916 .986
s11 66.2333 359.909 .902 .986
s12 66.2333 362.530 .904 .986
s13 65.9667 332.654 .991 .985
s14 66.2667 360.547 .919 .986
s15 65.8333 354.626 .808 .987
s16 66.2667 360.547 .919 .986
s17 66.3000 373.872 .758 .987
s18 66.3667 352.309 .916 .986
s19 66.5333 360.878 .979 .986

Case Processing Summary

N %
Cases Valid 30 100.0
Excludeda 0 .0
Total 30 100.0

81


3

-
=

5 1
=
3

= 1.33

3.67 - 5.00
2.34 3.66
1.00 2.33

Frequency Percent Valid Percent

44 88 % 88 %
6 12 % 12 %
0 0% 0%
50 100 % 100 %

Frequency Percent Valid Percent

45 90 % 90 %
5 10 % 10 %
0 0% 0%
50 100 % 100 %

82


Frequency Percent Valid Percent

47 94 % 94 %
3 6% 6%
0 0% 0%
50 100 % 100 %

Frequency Percent Valid Percent

47 94 % 94 %
3 6% 6%
0 0% 0%
50 100 % 100 %

83