Leadtime Calculation

Lot Making Kanban Heijunka Post

Waiting Post
Chuter Administration
Process
p e c
o d a
f b
n

r s m i j k l
q h
INJECTION ASSEMBLY Customer

Shipping Preparation Area Loading Area

Store Store
PRODUCTION LEADTIME DELIVERY LEADTIME

LeadTime Informasi n+o+p LeadTime Informasi a+b+c+d+e+f

LeadTime Proses s LeadTime Proses Not Available

LeadTime Stagnasi r + m LeadTime Stagnasi i

LeadTime Conveyance q LeadTime Conveyance h+j+l

 LEADTIME CALCULATION
Kind of Lead
Time
How to get data How to Calculate
Conveyance - Observe the operator handling during 1 cycle
deliver the parts to fill each store/stagnation area
- Measure with stop watch the time needed to deliver - Record the data of time by
stopwatch/Actual
the parts during 1 cycle.
Stagnation
- Genba to the plant side for each stagnation/store area
- Q'ty of parts x TT Part
- Calculate the quantity of stock at each stagnation/store

Process - Observe the job of operator, process/machine

- Separate the regular job & irregular job
- Decide the start & stop point for 1 cycle job
- Sigma C/T
- Measure with stopwatch for 1 cycle job, repeat it 10 times
- Take the data of Cycle Time by the minimum data
which tend to occurrs

Information - Decide the information point in & out

1. (When kind of information used) - (When kind of information received)

- Record when the information delivered, received and used 2. (When kind of information delivered) - (When kind of information received)
- Calculate how long the information waiting to become
production instruction at each process area (Q'ty of parts written at kbn.) X (Number of kbn.) X
LineT/T or CT
- Calculate how long the information waiting to become
production instruction at each process area (Q'ty of parts written at kbn.) X (Number of kbn.) X CT
 Part And Information Flow Chart

Simbol-simbol yang digunakan pada PIFC

PART FLOW SIGNAL KANBAN PROCESS

INFORMATION FLOW DOCUMENT

(Schedule, DN, etc) QUALITY INSPECTION

PART SEQUENCE
HEIJUNKA POST LOT KANBAN CHUTE

PART SEQUENCE BETWEEN

PROCESS LOT MAKING
KANBAN CHUTE

KANBAN WAITING POST

TEI-TEI PATERN
CUSTOMER / SUPPLIER
KANBAN COLLECTING POST (FACTORY)

P STORE
PRODUCTION INSTRUCTION KANBAN DELIVERY TRUCK
I

PW PART WITHDRAWAL KANBAN

STAGNATION TROLLEY
SPECIAL KANBAN

e - KANBAN FORKLIFT

A）Sequence
A.1 A.2
Sequence Flow based on
Production arrangement
Point Penting
A.1 1 . Part no/index no harus ditampilkan
1 . One piece Flow
pcs by pcs production
2 . Standard in proces stock 1 pcs
3 . Menunggu antrian dalam proses
A.2
1 . Kanban by kanban flow
2 . Standard in process 1 kanban
3 . Tempat menunggu
sementara berdasarkan
urutan produksi
Part Flow Chart
Term and Condition for Store
B） Store/storage（toko) Ｃ） Stagnation
Point Penting
di line store
2. Tampilkan Identifikasi/address yang jelas
(Qty/box/kbn,Box Tipe)
Tidak memenuhi
salah satu point
3. Mudah untuk diletakkan dan
diambil (FIFO) penting/syarat-
4 . Kapasitas Rak/Store harus cukup syarat dari store
menampung kapasitas max yang
akan disimpan
5 . Ada Standar Min dan Max yang harus dijaga
6 . Tempat sementara OK Parts (WIP or
Finished Good condition)
7. Tampilkan Control point dan SOP
yang jelas (termasuk bila terjadi
kondisi abnormal )