lean manufacturing system

NAZA AUTOMOTIVE MANUFACTURING SDN BHD[Company No.: 591026-M]

Lean Manufacturi

ngSystem

Kamarulzaman Darus PJNDirector of Manufacturing NAM

[email protected]+6012-277-2059

Graduated in B.Sc. Mechanical Engineering from Graduated in B.Sc. Mechanical Engineering from Leeds University, UK. Leeds University, UK.

Had been in the Automotive Manufacturing Had been in the Automotive Manufacturing Business for more than 25 years.Business for more than 25 years.

Had been responsible in key areas of Production Had been responsible in key areas of Production and Planning, Manufacturing Engineering, Plant and Planning, Manufacturing Engineering, Plant Engineering, Product Research and Development.Engineering, Product Research and Development.

Currently, the Director of Manufacturing – Currently, the Director of Manufacturing – responsible in all aspects of Manufacturing for responsible in all aspects of Manufacturing for Naza Automotive Manufacturing.Naza Automotive Manufacturing.


Basic Philosophy Of Lean Production System

1.Quality guaranteed in process1) In production line, only 100% quality guaranteed parts can be transferred

to the subsequent process.

2.Cost reduction activities1) Elimination of overload, waste and

unevenness

(Defect parts will not go to the next process) Common Basic Philosophy

Lean Production System

Consistent basic philosophy for company management

Manager

Staff

Worker

Top Management

Lean Production System is a measure to realize the basic Philosophy


How to Operate A Factory Base On Lean Production System


Why Quality To Be Guaranteed In Process?


Just in Time


Leveled Production System


Leveled Production System (Manpower Allocation)


Leveled Production System (Logistics)


Leveled Production System (Averaging Calculating Conditions)


Leveled Production System (Process Arrangement)


Leveled Production System (Establish Standard Working Time)


Leveled Production System (Process Arrangement – Grouping Method)


Leveled Production System (Process Arrangement – Short Line Management)


Leveled Production System (Process Arrangement – A-B Control System)


Leveled Production System (Process Arrangement – Fixed-Stop Position)


Leveled Production System (Process Arrangement On-Line Inspection and Repair)


Leveled Production System (Process Arrangement – ANDON)


Leveled Production System (Process Arrangement – Parts Request ANDON)


Leveled Production System (Process Arrangement – Buffer)


Leveled Production System (Process Arrangement – Scratch Prevention Cover)


Leveled Production System (Process Arrangement – ALC – Automated Line Controller Concept)


Leveled Production System (Process Arrangement – ALC System)


Leveled Production System (Process Arrangement – ALC Production Order System)


Leveled Production System (Process Arrangement – ALC - Body Shop Pokayoke)


Leveled Production System (Process Arrangement – ALC - TF Shop Pokayoke for Torque)


Leveled Production System (Process Arrangement – ALC - TF Shop Pokayoke for Parts Selection)


Leveled Production System (Process Arrangement – ALC - KAIZEN)


Leveled Production System (Process Arrangement – ALC – Synchronized Process Layout)


Leveled Production System (Process Arrangement – ALC – Sequenced Supply System)


Leveled Production System (Process Arrangement – ALC – Eliminate MUDA (Waste) Thoroughly)


Leveled Production System (Process Arrangement – Wide Dolly Friction Conveyor)


Leveled Production System (Process Arrangement – Assessment Method for Workload Hardship Level)


Leveled Production System (Process Arrangement – Assessment Method to determine Quantity of Working Hardship Level TVAL


Leveled Production System (Process Arrangement – Door-less System – Reduce Hardship Level)


Leveled Production System (Process Arrangement – Working Posture Improvement – Reduce Hardship Level)


Leveled Production System (Process Arrangement – Labor Saving Equipment – Reduce Hardship Level)


Leveled Production System (Process Arrangement – Robot System – Reduce Hardship Level)


Leveled Production System (Process Arrangement – Intelligent Pre-set Automation – Reduce Hardship Level)


Leveled Production System (Process Arrangement – Synchronized Wagon Dolly – Reduce Hardship Level)