The 4th FAGAT / 1999 in Beijing
Information Echange Meeting
The way to increase the printing productivity and to decrease the cost
April 3, 2000
The Thai Printing Association
Advisor / Mr. Suwat Charungsaksakul
Fax:662-749-1053
CASE STUDY : Coating Paper Industry Co., Ltd.(CPI)
Due to economic recession in 1997 coupled with the coming free trade zone in
2000, competition will become dynamic,borderless and fiercer. Everyone in busine
s arena has to be prepared to cope with global competition. One of the criterias is to increase printing productivity and to reduce cost which has to be carried out as soon as possible on proactive and consistent basis. what is productvity?
Productivity can be classified into 2 ways of perception namely
1) Social & economic perception
2) Scientific perception
1) Social & Economic Perception
It concerns with attitude to always seek better development
Believing that we can do today better than yesterday and tomorrow shall be better than today
It is an endless effort to improve environment and economy
It believes in progress and human capability
2) Scientific perception
It concerns with full utilization of resources
| |
| Case 1:input(equal)/output(increase) | Case2:input(decrease)/output(increase) |
| Case 3:input(equal)/output(decrease) | Case4:input(increase)/output(furthermore increase) |
| Case 5:input(devrease)/output(futhermore decrease) | |
Sales Revenue = Quanity of sales x Selling Price Per unit
Profitability = Productivity x Price Proportion
Total Cost = Value of resources usedb x cost pet unit
Basic tools
5S / suggestions / safety / small group activity / inustrial engineering(IE)
Quality control(QC) / Valueengineering(VE) / Productive Maintenance(PM)
How can staff help to improve productivity
by cooperation with productivity plan of the board of directors
by having good attitude towards working atmosphere
by aiming at company's excellence
by learning new things and always develop themselves
by working as a team
by having mutual responsibility
by feeling free to exchange information
by sacrificing willingly
by keeping work place and office clean
by producing high quality products and services
by planning in advance
by managing time effectively
by giving good suggestions
by preparing jobs for each shift in advance
How can foreman helps to improve productivity
by giving good advice when necessary
by having themselves trained on supervisory capability
by giving advice to form up discipline
by using machine properly
by keeping machine clean and in proper condition
by understanding company's objective and policy and convey the message through
workers
by doing every activity to achieve productivity
How can executives help achieve productivity?
to sell goods and services under competable prices
to increase sales value per unit of machine
to inrease sales value per head
to increase sales volume per head
to extend working hours
to purchase raw matesial at lower price (considering quantity and in time deliv
ry)
to train staff and let them have participation and give incentives
to use advanced equipment
to increase capital
to increase velocity of working capital
to apply appropriate technology
to utilize raw material to the utmost benefit
objectives of productivity
<Corporate level>
to strengthen business competitve edge to ensure company's consistent growth
<Industrial level>
aiming at industrial wealth
strengthen industrial competitive edge
upgrade standard of living of labour
<National level>
to increase income per capita
to strengthen international competitive edge
to upgrade standard of living of citizen
<Citizen level>
to develop public welfare and well being of people
<Consumer level>
to develop and stabilize quality of life
<Employee level>
to develop stability of employment both executives and labour
technical development on productivity:
| |
| 1)4M : | man /machine / material / method |
| 2)waste management : | due to over production / due to over stock / due to delivery / due to movement / due to ineffective production process / due to waiting / due to defects and correction |
| 3)P Q C D S M E E : | P=productivity / Q=quality / C=cost / D=delivery / S=safefy / M=morale / E=environment / E=ethics |
4)technical Tools
5S:
It concerns with guidelines in arranging things in order and in place so as to have a good and safe working environment,resulting in productivity.
5S come from 5 japanese words,namely:
1) seiri(separate)
to separate things into desired and undesired and get rid of the undesired
2) seiton (convenience)
to set things in good order for safety and convenience purpose
3) seiso(clean up)
to clean up machine and work place
4) seiketsu (hygiene)
to always keep everything clean
5) shitsuke
to train so as to form habits in following discipline and regulation strictly
suggestions:
new ideas which are applicable and beneficial to company
new methods of work proposed to improve process of work
saefty:
it concerns with management which contributes to safety in the work place so as to achieve:
good quality of life
good physical and mental state of mind
utmost working capability
good working spirit
small group activity:
it's a group of staff who are formed up either officially or unofficially to find out problems and ways of remedy in order to improve work procedures:
group activity on quality
group activity on total productive maintenance
group activity on jk
group activity on zd
industrial engineering:
it's technique derived from the application of scientific principle to manage f
ctory systematically. it can be applied to analyze and solve various problems byusing the principle of 5w,1H and ECRS
fundamental technique in development:
work study, group technology, value engineering/value analysis, ergonomics,
plant layout, material handling
total quality control (tqc):
it's management system which concentrates on quality that satisfy customers.it
needs cooperation from everyone in the organization under the theme of "next process is our customer. "
just in time:
it's the process that stresses on production of necessary parts in required quantity and in appropriate timing so as to eliminate waste occurred in work process.
total productive maintenance:
it concerns with maIntenance of machine and equipment in form of small group act
ivity to assure that machine and equipment are at top efficiency.
the system makes staff to always think that "the one who uses the machine is the one who does the maintenance. "
CASE STUDY
Companys name: Coating Paper Industry Co,Ltd.
Country:Thailand
Why they have to do "productivity "? - because they cannot manufacture enough goods to meet customers requirement.
Ways to remedy: 1) they have to install new machine or 2) to implement "productivity "
Firstly, they come to consult with "thailand productivity institute "
about how to do productivity and what they will get after implementation of productivity.
After the consultation they decided to join the productivity project.
The following are productivity project paper of CPI Co.,Ltd:
scope:
- Full support & commitment from top management
- Second echelon of the company to lead the implementation
- If needs full cooperation and support from every staff
Objectives:
- to improve productivity through every staff's participation
- to increase working efficiency at all level of staff and to reduce waste in production process
working team:
- board of director(1 managing director)
- working committee
- first opeator at the test machine
- 3 officers from thailand productivity institue
test machine:
"sheeter(shm)" in the converting room
duration
february 98-june 98
problems before implementation
- data for development analysis are inefficient
- low productivity in converting room
- setting time of sheeter is high
- bottle neck at sheeter in the production line
- machine are not fully utilized
directions of productivity improvement:
- improvement activities on time waste:
set working team for pi / set acion plan / set equipment & tools in order /
modify optional equipment to safe time
- trainng to increase work efficiency:
how to reduce set up time / 5s activity for pi / suggestion activity / kaizen activity / tpm / build up quality minded attitude
action plan on work procedures of sheeter (shm) by PDCA
| |
P = planning
- study work procedures
- set plan for implementation
- set objectives of implementation
|
D = doing:
- set key person in charge of machine
- set position of machine
- observe movement of all internal system
|
|
C = checking
- record frequency of test
- record amount of waste
- change of equipment
- various adjustment
- movement of all internal system
|
A = acting
- consult with project team
- give suggestions against points of observation
- planning for next test
|
Data analysis on methods of work:
total setting & adjusting time: total setting time+total adjusting time.
data analysis:
1) idle time
2) things that can be done separately
3) things that can be done by others
4) things that can be improved
5) basic setting and adjusting
production efficiency analysis in the converting room is 78%
productivity improvement achieved by
1) reduction of set up time
2) implementation of kaizen activity
result of productivity improvement in the converting room
1) increase efficiency from 78% to 90% which represent 0.8 roll per day
2) increase sales value of baht 9.2 mllion per annum
(us230,000 per annum)
the outcome dereived from the project」
1) staff realise the importance of working environment improvement.
2) staff realise the importance of data recording.
3) staff work with more care and attention.
4) staff can do maintenance of machine by themselves.
5) staff can work as a team.
6) staff understand reason why and how to do cost reduction.
7) staff understand procedures of productivity improvement.
suggestions for next productivity improvement
1) to follow up result of pi continuously.
2) to carry on tpm scheme.
3) to solve bottle neck problem in coating department.
4) to diverse pi project to cover the whole company, provided that we have to be able to do benchmarking of every process of work.
In conclusion, CPI Co., Ltd can manufacture enough goods to meet customers requiremen without having to install new machine on top. they have found out new ways of doing things to achieve better result, and they are still on the way of expansion of productivity improvement. let's join them.
(C)Japan Association of Graphic Arts Technology
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