12 passos - exemplo tetrapak - repro_loops_jipm.pdf

8/9/2019 12 passos - Exemplo Tetrapak - Repro_loops_JIPM.pdf

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EDUCATION & TRAINING PILLAR

EDUCATION & TRAINING PILLARIntern

Basic Data


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Team Members


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Methodology


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Total number

of designs

1. Indentify/Classify Losses JAN-MAR 2011

Repro mistakes

(some of designare with more

than one mistake)

80 repro

mistakes

on the 57

designs


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2. Select Theme and Justify

Problem will be eliminate by

implementing new PDF

scope format in W42, 2011.


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3. Understand

1. Difference between AW file

and Repro file

ArtWork Repro file


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Intern

3. UnderstandProcess

New – mod design flow chart



Adobe Illustrator CS5

Adobe Photoshop CS5

FreeHand 10

Esko PackEdge 7.6

Esko BackStage Pilot 7.0

Intern

3. Understand

Agency Repro In House

Equipment



Intern

4. Grasp the Actual Situation

5W1H


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EDUCATION & TRAINING PILLAR / EDUCATION & TRAINING PILLAR / Intern

5. Establish Objectives

29

0

Week 22

Team goal is to eliminate repro loops due

to difference between AW and repro file


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6. Master plan

7 C A l i 4M


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7. Cause Analysis 4M

4M

7 C A l i 5 Wh


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7. Cause Analysis 5 Why

3.1

3.2

8 Propose Co ntermeas re


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8. Propose Countermeasure

T l t KEYLINE fil N t OK


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Template KEYLINE file – Not OK

1.1

Template KEYLINE file OK


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Template KEYLINE file - OK

1.1

9 Implement Countermeasure


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9. Implement Countermeasure

OPL 1


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Old Design Manual


New Design Manual plus Design preparation (shorten manual

with frequent examples of mistakes)

1.2

1.4


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Example from Design preparation

1.2

1.4


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Frequent design seminars during the year


In 2011 we held 12 design seminars for 14 customers, 32 design agencies and CSR’s

1.3


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Old DT procedure


New - revised DT procedure

2


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New - revised Instruction for layer structure

3

3.1

New DesignJob Folder&

Repro fileLayout

Tetra Pak * Repro in house * june 2011



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Comparing raw AW file with Repro file in BS Viewer ( side by side )

Comparing raw AW file with Repro file in BS Viewer

( highlight difference )


SOP 4


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Comparing raw AW file with Repro file in BS Viewer ( side by side )

4

AW file

Repro file


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Comparing raw AW file with Repro file in BS Viewer( highlight difference )

4

AW file

over

Repro file

9 I l t C t


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Old check list


New - refreshed check list

7

10 Check Results


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Results before improvement

10. Check Results

Results after improvement

10. Check Results


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Team

Start

-New keyline set up

-Refreshed instruction for layers

-Trening for layer structure

-Refreshed check list

Countermeasures

Losses Impact

Trigger point

-Design preparation

-Refreshed DTs procedure

-SOP: comparing AW with GRS

4 months without

Repro loops!

4M and 5Why for Trigger Point


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4M and 5Why for Trigger Point

Mistake example


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Mistake example

ArtWork – instructions for typing, send by e-mail

After every typing, it’s

necessary to read text for

several times, to check and

be sure there’s not possibletyping mistake

Countermeasures

Missing part of latter ( mistake by typing) Corrected file


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11. Standardization


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EDUCATION & TRAINING PILLAR / Intern

All training material

Updated into

Loss Prevention System

All Procedures and instructions

are updated in our

Loss Prevention System

12 Future Plans


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12. Future Plans

Eliminate by TEAM 382 actions

(new keyline set-up)

Problem eliminate

implementing new PDF

scope format W42, 2011.

Eliminate by TEAM 382

countermeasures Problem eliminateimplementing new PDF

scope format W42, 2011.

12 Future Plans


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12. Future Plans

1. Distribute our new template to all agencies and trained them

2. Share our new template at cluster level

3. Suggest our template to become official template for ORBIS and eD

All Agencies Cluster level

ORBIS and eD

12 passos - exemplo tetrapak - repro_loops_jipm.pdf

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