LEANaero Workshop 2022

Agenda for LEANaero Workshop for M&E Sdn Bhd + UIRDC Team
Date: 15 June 2022 (Wednesday)

Time Agenda
8:30 am – 9:00 am Breakfast

9:00 am – 11:00 am SGIA Foundation
• Basic 7 WASTE
• Problem Solving Methodology (Step 1 - Step 10)
• Share BEST Practice SGIA

11:00 pm – 1:00 pm Group Exercise
• Mapping Current Process
• Use MIFC/Process Flow/SOP
• Identify WASTE

1:00 pm – 2:00 pm Lunch break

2:30 pm – 4:00 pm Group Presentation
• Each team to present (Step 1 & Step 2)
• Mapping Outcomes
• Identify WASTE
• Project proposal

4:30 pm – 5:00 pm Project Listing

5:00 pm Workshop end

*Note: Review Progress - after 2 weeks team to present following Step
STEP 3, STEP 4 and STEP 5

PROBLEM SOLVING METHODOLOGY (A3 REPORT) STANDARD

KAIZEN / CONTINUAL IMPROVEMENT (CI) / COST SAVING ACTIVITIES R
DEPARTMENT :
TITLE :

STEP 1: THEME SELECTION AND EXPLANATION STEP 5: DEVELOP IMPL
1. Dig the countermeasu
Problem statement in one Theme may comes from potential areas from many resources.
sentence (Refer Continual Improvement (CI) procedure) a) List up countermea

What is the issues; cause Example : 2. Evaluate countermea
Project Theme: The prolonged WEEKLY SGIA FACILITATION a) Evaluate from vari
INTERRUPTION due to the enforcement of Act 342 Movement Control countermeasures
Order from 18/03/20 to 28/04/20 had resulted in the delay of M&E SGIA practicability, cos
project roll out.
3. Determine 5W2H- Wh
STEP 2: GRASPING CURRENT SITUATION and How Much
a) Clarify order of cou
1. Collect and record data reflected to STEP 1 Example of Pareto Chart b) Clarify function all
a) Current information c) Review & buy-off p
b) Past information
c) Numerical data 4. Solution technique SC
Adapt, Modify, Put to
2. Determine the gap to be solved.
a) Analyze degree of scale, importance Effective Tools
and emergency of the gap.
b) Narrow down the gap areas to be STEP 6: RESULT AND A
adopted (priority conciousness)

3. Go to the source ask 4W1H during data collection 1. Track the counterm
4. Convert data to visual (Graph, Chart or etc) 2. Report and record
3. Check the effect of
4. Verify the effect of t
5. Show result achiev

Effective Tools Checksheet, Line graph Bar chart Pareto MIFC, VSM
Affinity diagram chart or Flow chart

STEP 3: TARGET SETTING AND EXPLANATION Effective Tools
1. Clarify the target by "how much","what" and "until when"
2. Express the target quantitative and practically (RM, Qty, %, Hour, etc) STEP 7: EVALUATE AND

- Before implementation 50
- After implementation
3. Use RICE (Reduce, Increase, Create, Eliminate) Tangible benefits
4. State the reason the target choosen (Industry std, policy,
top management needs, KPI, pareto) 1. Validate the result
5. Use element SMART (Specific, Measurable, Achievable, Realistic 2. Identify benefits
Time oriented) 3. Benefits that can be

Effective Tools Graph Pareto Histogram calculated and oth
chart 4. Example : Time, Qu

others

STEP 4: ROOT CAUSE ANALYSIS Man STEP 8: SAVING
1. Calculate project sa
1. Dig out as many factors as possible 2. Verify by accountan
( Repeat "why" until end of cause )
Sa
2. Evaluate the root causes from many causes = RM10,
3. Verify the root causes is facts, not estimation
4. 50%-60% problem solved by doing right RCA
5. MUST involve subject expert for brainstorming

Effective Tools Cause + effect, Fishbone, 5-Why Fault tree Decision Scatter
Ishikawa diagram analysis matrix table diagram

NO. KAIZEN / CI : TEAM MEMBERS : PREPARED CHECKED APPROVED

REPORT DATE:
TEAM NAME:
TEAM LEADER:

LEMENTATION PLAN Example : Systematic / Tree diagram

ures against respectives root causes LEGENDS
asures widely before checking
X
END WHY
asures to be executed PROBLEM
ious view points to select
(view points: effect, DEGREE OF EFFECT
st,etc) PRODUCTIVITY
COST

OVERALL EVALUATION
CAUSE 1 PROPOSED SOLUTION XX 6
CAUSE 2 X 6
X 2
Example of Gantt Chart X X
3
6
2
4

ho, What,Where, When,Why,How 0

Legends: Plan start Plan Finish Actual start Actual Finish

untermeasures to be executed
located to each member
proposal with top management

CAMPER (Substitute, Combine,
o other use, Eliminate, Rearrange)

Systematic / Gantt
Tree diagram chart

ACHIEVEMENT

measure progress

the countermeasures against the target setting at STEP 3
the countermeasures execution
vement (Before, Target, After)

s Graph Pareto Histogram
diagram

D REFLECTION Before & After results Example : Spider Web Chart

s Intangible benefits Item Before After
Teamwork 3 4
e assessed, measured, Involving 3 4
hers 2 4
uantity, Productivity and Interest 2 4
Confident 2 5
Knowledge 3 5
Responsibilities

STEP 9: STANDARDIZATION / CONCEPT DUPLICATION STEP 10: NEXT PROJECT

aving 1. Manage actions for the continuation of the effect 1. Should take level-2 from PARETO
nt or Head of Department a) Establishment standard / new job procedure chart, tree diagram or relevant chart
b) Training, coaching and evaluate respective PIC
aving c) Monitor standard effectiveness 2. Propose timeline for next project
,000 / Year d) Register in doc. control ISO/TS/QS/AS; etc

2. Horizontal deployment across the organization
a) Pattern process / design / prototype
b) Opportunity for communication (software, apps)

LA-001-G01-Rev03

0 PROBLEM SOLVING METHODOLOGY (A3 REPORT) STANDARD

UMW M&I KAIZEN / CONTINUAL IMPROVEMENT (CI) / COST SAVING ACTIVITIES R
DIVISION DEPARTMENT :
TITLE :

STEP 1: THEME SELECTION AND EXPLANATION STEP 5: DEVELOP IMPL

STEP 2: GRASPING CURRENT SITUATION

STEP 6: RESULT AND A

STEP 3: TARGET SETTING AND EXPLANATION

STEP 7: EVALUATE AND

STEP 4: ROOT CAUSE ANALYSIS STEP 8: SAVING

NO. KAIZEN / CI : TEAM MEMBERS : PREPARED CHECKED APPROVED

REPORT DATE:
TEAM NAME:
TEAM LEADER:

LEMENTATION PLAN

ACHIEVEMENT
D REFLECTION

STEP 9: STANDARDIZATION / CONCEPT DUPLICATION STEP 10: NEXT PROJECT
LA-001-G01-Rev03

WELCOM

3rd LEA
SGIA CON

202

TITLE : O

ME TO

AN aero
NVENTION

21

OIL LEAK

MOHD HUSSAIN B RAMLI

INTRO THEME PROBLEM TARGET ANAL

TERMIN

OUTER SHELL • MAIN MATERIAL USED TO
PRODUCE A SHOCK
ABSORBER

CLAMP • WORKPIECE HOLDER

MISS CHECK • BYPASS OF CERTAIN
SPEC PROCEDURE

VACUUM • SPECIFICATION OR
STOW STANDARD

• CLEANNING PROCESS FROM
CONTAMINATION, CHIP
AND DUST

• WELDING PROCESS
PRODUCE OUTERSHELL
ASSY (CASING)

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

NOLOGY

MATERIAL • OUTERSHELL CYLINDER

CUTTING • OUTERSHELL CUTTING
CNC PROCESS
ASSY
• OUTERSHELL MACHINING
PROCESS

• ASSEMBLY SHOCK
ABSORBER PROCESS

SUMMARY REJECT • ANALYSE IN HOUSE REJECTS

STRUT • FRONT SHOCK ABSORBER

INTRO THEME PROBLEM TARGET ANAL

ORGAN

TEAM LE

ASSIST LEADER
HUSSA

AIRIL

SHARIN JAFIRUL NAZAM HAMIZAN

“QUALITY & QUANT

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

NIZATION FACILITATOR

EADER

RAMAN MUSA LATIF
ADVISOR
AIN
SECRETARY BOB

SAIFUL

HISYAM HADI JULIYANA MAFAZAH

TITY OUR PRIORITY”

INTRO THEME PROBLEM TARGET ANAL

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

INTRO THEME PROBLEM TARGET ANAL

OUR OB
REDUCE COST OF RE

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

BJECTIVE
EJECT TO ZERO DEFECT

INTRO THEME PROBLEM TARGET ANAL

KYB-UMW MALAYSIA SDN BHD

TEAM SEPAKAT
HISTORIC STRUT ASSY. LINE 2
4 OCT 2011
L
11 MEMBERS

12TH PROJECTS

Roll

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

OUR RESPONSIBILITY

PRODUCE SHOCK
ABSORBER STRUT TYPE

NORMAL STRUT TYPE PROCESS FLOW

LOGISTIC CYLINDER STOW ROBOT ED STRUT MODULE
WASHING ASSY.
WELDING COATING

l Closure type

INTRO THEME PROBLEM TARGET ANAL

TEAM ACTIVITY &

1 TEAM 3

•Set team & theme selection. PROBL
•Analyz
Root &

SEP W1 – W2 SEP W3 – W4
SEP W3
START

ATTANDANCE

2 DEFINE PROPLEMS & TAR
SETTING
•Target setting (SMART), M
Schedule & Work delegati

ESTABLISHED NORM
• DAY – EVERY WEDNESDAY
• TIME – 7.45am - 8.15am
• DURATION – 30 MINUTES

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

& PROJECT TIMELINE

5 PROJECT EVALUATION, REFLECTION

LEM ANALYSIS & STANDARDIZATION
ze Data (7 QC tools), Solution, •Record & Review result
& cause, Recommendations (successful/unsuccessful)

NOV W1 – FEB W2

END

SEP W4 – DEC W2 FEB W2

4 6

RGET NEXT ACTION
•New project
Master
ion. IMPROVEMENT ACTION
•Corrective action, Executes

action

INTRO THEME PROBLEM TARGET ANAL

APPROVA

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

AL LETTER

INTRO THEME PROBLEM TARGET ANAL

WORKFLOW – S

STOPPER LOAD TEST PIST
WELDING WA

O
WA

QG STICKER DA
F

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

STRUT ASSY. LINE 2

TON ROD AUTO AJ2 AUTO
ASHING CAULKING

O/SHELL OIL FILLING PRE-CAULKING
ASHING

AMPING PRESS B.STOPPER & ROLL
FORCE GAS REPULSION CLOSURE

INTRO THEME PROBLEM TARGET ANAL

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

INTRO THEME PROBLEM TARGET ANAL

WHAT IS OIL LEAKS WHY IT BECOM

DEFECT WHERE DAMPER OIL COMING OUT QUALITY •BA
FROM THE SEALING PART. PE

CUSTOMER •LI
SATISFACTION
•CU

•N
CU

OPERATION •H

•N
PR

•SH
Q

WHEN THIS PRO

•AFT
PAR
KYB

CUSTOMER •BEF
OF O

•AFT
PER

NOT IMMED

WHO FOUND T

1. CUSTOMER (CO
MANUFACTUR

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

MES A PROBLEM WHERE IT HAPPEN

AD SHOCK ABSORBER PRE CAULKING & ROLL CLOSURE MC
ERFORMANCE

INE STOP
USTOMER NOT SATISFY
NOT CONVINCING
USTOMER

HIGH REJECTION COST HOW SERIOUS THIS PROBLEM
NOT ACHIEVE DAILY
RODUCTIVITY HIGHEST REJECT IN 3 CONSECUTIVE
HORTAGE – NOT ENOUGH MONTHS WITH 22 PCS & REPEATING
QTY
CLAIM ISSUE (2019 & 2020)
OBLEM FOUND
ITEM JUNE 20 JULY 20 AUG 20 TOTAL
TER ASSEMBLY, SEALING
RT INTALLED OIL LEAKS 9 6 7 22

FORE ASSEMBLY, PRESENT PART DAMAGE 4 3 4 11
OIL ON THE SURFACE GAS OUT STD 3 2 1 6
TER ASSEMBLY, D/FORCE NG 1 2 1 4
RFORMANCE DROP 17 13 13 43
TOTAL
DIATE DETECTION.
TOTAL 10 QUALITY - LINE CLAIM 2020
THIS PROBLEM CASE / MTH
8 Oil Leaking
ONSUMER, CAR 6 8 (BZB90/BZ710) - JUN 20
RER) 4 40 0 0
2
0

Act'19 1ST HALF Jul Aug Sep

INTRO THEME PROBLEM TARGET ANAL

Specific • Eliminate O
reject

• OIL LEAKS

Measureable • Monthly in-h
(June20 – A

Achievable • LOWEST co
Realistic
Timely • Eliminate no
• Improve Qu
• Unsafe to u

• Sept 2020 –

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

OIL LEAKS to 0 in St assy line 2 In house
was the HIGHEST reject type

house reject recorded 51.6% reject
Aug20)

ost can be implemented

on-added value job
uality & Productivity
use

– Feb 2021

INTRO THEME PROBLEM TARGET ANAL

IN HOUSE REJEC

ITEM JUNE 20 JULY 20 AUG
OIL LEAKS 9 6 7
PART DAMAGE 4 3 4
GAS OUT STD 3 2 1
D/FORCE NG 1 2 1
17 13 13
TOTAL

ITEM Ø JUNE 20 JULY 20 A

48510-BZ800 Ø45 3 1
48520-BZ370
Ø45 4 3
48510-BZC20
48520-BZ710 Ø45 0 1
Ø50.8 1 0
48510-BZD90 Ø50.8 1 1
48520-BZA40

48510-ODD60

48510-BZ551
48520-BZ051

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

CT & LINE CLAIM

20 TOTAL
22
11
6
4
43

AUG 20 TOTAL REJECT BY Ø
26
3 10 Ø 50.8
12 18%
12
02 Ø 45.0
82%

INTRO THEME PROBLEM TARGET ANAL

REJECT DATA BEF
(JUNE 2

ITEM JUNE 20 JULY 20

OIL LEAKS 9 6

PART DAMAGE 4 3

GAS OUT STD 3 2

D/FORCE NG 1 2

TOTAL 17 13

OUTPUT 70,720 76,324

PARETO CHART BE
(JUNE 2

0.020% 77%
0.015%
Reject Ratio (%) 0.010% 51%

0.005% 0.010% 0.005%

0.000%

OIL LEAKS PART DAMA

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

FORE IMPROVEMENT
20 - AUG 20)

AUG 20 TOTAL RATIO %
7 22 0.010% 51.16
4 11 0.005% 25.58
1 6 0.003% 13.95
1 4 0.002% 9.31
100
13 43 0.019%

76,271 223,315

EFORE IMPROVEMENT
20 ~ AUG 20)

100%

91% 100%

80% Percentage Reject (%)

60%

40%

0.003% 0.002% 20%

0%
AGE GAS OUT STD D/FORCE NG

INTRO THEME PROBLEM TARGET ANAL

MATRIX

NAME COST PRODUCTIVITY

HUSSAIN 5 5
AIRIL 5 5
SAIFUL 5 5
5 5
SHARIN 3 4
HADI 5 4
4 4
NAZAM 4 4
JEFIRUL 4 4
HAMIZAN 4 3
HISYAM 4 3
MAFAZAH
JULIYANA 48 46

TOTAL

SCORE REDUCTION EVALUATE

0~44 0% 1-POOR

45~88 25% 2-NOT CONFIDENT

89~132 50% 3-MODERATE

133~176 75% 4-CONFIDENT

177~220 100% 5-TOO CONFIDENT

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

X TABLE

SOLVING DATA SCORE
ABBILITIES COLLECTION
20
5 5 20
5 5 20
5 5 20
5 5 17
5 5 17
3 5 16
4 4 16
4 4 14
3 3 13
3 3 13
3 3
186
45 47

TARGET
100%

INTRO THEME PROBLEM TARGET ANAL

TARGET

REJECT RATIO (%) 0.010% 0.010%
0.009% OIL LEAKS
0.008%
0.007%
0.006%
0.005%
0.004%
0.003%
0.002%
0.001%
0.000%

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

T SETTING

100%

0.000%
TARGET (FEB 2021)

INTRO THEME PROBLEM TARGET ANAL

DUST FROM A
REBOUND CUSHION
SHARP P/ROD
SURFACE P/ROD SHARP
SURFACE
DUST FROM
REBOUND DESIGN DUST
CUSHION ERROR STICKED

CLASH WITH TOO TIGHT CANT SEE
SHARP EDGE
NOT READ
MCP

MCP WAS LAZY
TOO HIGH

INSERTION IN HURRY NO
CAP DROP NO CLEANING
CAULKING JIG
SCRATCH

TOO MANY
SPATTER

CONTINUE WELDING UNSTABL
WORK SPATTER CURRENT
NO CHECK
NO JIG NG
RUSHING CLEANING

DROP TOO MANY DUST
INSERTION CAP IN HURRY AT PRE CAULKING

MC

IRON DUST

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

NO NOT NO WIPING
ASKING UNDESTAND CLOTH INCOMPLETE
CLEANING
NEW
WORKER DIRTY MC

NOT NOT

CLEANING PERFORM 3S

NOT SHY

CLEANING

DIRTY MANY OIL
DUST LEAKS

DIRTY FAN NOT DIRTY
CLEANING FLOOR
TOO
MANY DUST

IRON DUST

OT CHANGE NO SPARE

INSERTION CAP
DROP TO THE FLOOR

TOO MANY NO TABLE
DUST ASSY.

LE PART DROP
T TO THE FLOOR

G IN HURRY TO
CHASE OUTPUT

DIRTY
CAULKING DIES

NO TIME
TO CLEAN

INTRO THEME PROBLEM TARGET ANAL

ENVIRONMENT PROBLEM STD CONDITION T
N
DIRTY FLOOR THE FLOOR IS ALWAYS CLEAN

NEW EMPLOYEES SKILLED WORKERS OPERATE N
MACHINES K

MAN

DO NOT READ MCP BEFORE READ AND UNDERSTAND MCP E
BEGINNING WORK BEFORE STARTING ANY WORK U

MATERIAL SHARP P/ROD SURFACE P/ROD IS PRODUCED ACCORDING TO R

PRESCRIBED SPECIFICATIONS S

NO ASSY TABLE - P
D

MACHINE SPATTER COMES OUT OF THE NO SPATTER SPARK COMING OUT OF T

MACHINE DURING WELDING MC S

JIG PRE CAULKING SCRATCH JIG NO SCRATCHES T
L

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

ACTUAL / FINDING EVALUATE PIC

THE CONDITION OF THE FLOOR WAS DIRTY AND HADI
NOT CLEANED PROPERLY

NEW EMPLOYEES WITH LACK OF SKILLS AND FARHAN
KNOWLEDGE ABOUT CONTAMI AIRIL

EMPLOYEES DO NOT KNOW AND DO NOT HUSSAIN
UNDERSTAND WHILE DOING A JOB HUSSAIN
HISYAM
REBOUND CUSHION TORN AND LEFT ON THE NAZAM
SURFACE OF P/ROD

PART AND INSERTION CAP FELL TO THE FLOOR.
DAMAGED JIG AND ATTACHED DUST

THE WELDING PROCESS PRODUCES A LOT OF
SPATTER

THE JIG SCRATCHES FRICTION AND PRODUCES A
LOT OF IRON DUST

INTRO THEME PROBLEM TARGET ANAL

ANALY

FACTOR PROBLEM STD CONDITION

ENVIRONM DIRTY FLOOR THE FLOOR IS ALWAYS
ENT CLEAN

WORKING CU
ENVIRONM

ALSO, COMP
PERFORM CLEA

&

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

YSIS 1

N ACTUAL/ EVALUATION WHO
FINDING
HADI
THE CONDITION OF
S THE FLOOR WAS DIRTY

AND NOT CLEANED
PROPERLY

ULTURE TO ENSURE WORKING
MENT ALWAYS CLEAN & TIDY.

PANY HAVE ALLOCATE TIME TO
ANING BEFORE START WORKING
& BEFORE FINISH.

INTRO THEME PROBLEM TARGET ANAL

ANALY

FACTOR PROBLEM STD CONDITION

MAN NEW EMPLOYEES SKILLED WORKERS
OPERATE MACHINES

EVERY WORKER INCLUDE
NEW WORKER WERE GIVEN
ENOUGH TRAINING & WERE

EVALUATE

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

YSIS 2

N ACTUAL/ EVALUATION WHO
FINDING
FARHAN
NEW EMPLOYEES WITH
LACK OF SKILLS AND
KNOWLEDGE ABOUT

CONTAMI

PLUS USING “KAKOTORA”AT
EACH PROCESS TO SHARE THE
PAST PROBLEM EVER HAPPEN

INTRO THEME PROBLEM TARGET ANAL

ANALY

FACTOR PROBLEM STD CONDITION

MAN DO NOT READ MCP READ AND
BEFORE BEGINNING UNDERSTAND MCP
BEFORE STARTING
WORK
ANY WORK

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

YSIS 3

N ACTUAL/ EVALUATION WHO
FINDING
AIRIL
EMPLOYEES DO NOT
KNOW AND DO NOT
UNDERSTAND WHILE

DOING A JOB

SHARING SESSION EVERYDAY BEFORE
START WORKING. WORKER WILL BE
ROTATE READING WORKING CHECK
POINT EVERYDAY.

INTRO THEME PROBLEM TARGET ANAL

ANALY

FACTOR PROBLEM STD CONDITION

MATERIAL SHARP P/ROD P/ROD IS PRODUCED
SURFACE ACCORDING TO
PRESCRIBED
SPECIFICATIONS

SUBSPRING TYPE

HOW SUBSPRING
WERE INSTALL

LYSIS ACTION RESULT STANDARD EVALUATE NEXT
PROJECT

YSIS 4

N ACTUAL/ EVALUATION WHO
FINDING
HUSSAIN
REBOUND CUSHION
TORN AND LEFT ON

THE SURFACE OF
P/ROD

PRESENCE OF PLASTIC CHIP MAY
PLASTIC CHIP AFTER INTERFERE & STUCK ON
OIL SEAL DURIN OIL SEAL
INSTALLATION OF
SUBSPRING INSTALLATION

INTRO THEME PROBLEM TARGET ANAL

ANALY

FACTOR PROBLEM STD CONDITION

MACHINE NO ASSY TABLE -