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You MUST know that You can WIN.
You MUST think that You can WIN,
and You MUST feel that You can WIN.
-Sugar Ray Leonard-

Manufacturing Strategy Development

Manufacturing strategy is the root of success and failure of current industries, espescially for manufacturing business so far. Strategy must be developed to increase power and competitiveness of the industry. A company should develop business strategy not only for maintaining the costumers but also strengthening whole business core.

Flexible Manufacturing
Manufacturing strategy that develops manufacturing process that's easy to costumize in order to fits rapid growing market changes. This system needs ability to modify current system to meet product changes. Production line changes developed should allow small-run batches but also consider production cost according to planning market strategy.

Lean manufacturing
Lean manufacturing strategy, or also known as just-in-time manufacturing, aims to develop efficient manufacturing process bu reducing wasted labor and material costs. The stratgey needs multi skill labor and high percentage quality control process production.

Service Based Manufacturing
The strategy focuses on continued aftermarket purchases by selling goods with low profit margin. Selling premium goods is just side of the strategy, but with aftermarket sales and service estabilishes costumer bases.

10 Tips & Tricks for Effective Presentation

  1. Know your audience! Make sure the presentation style suits the audience.
  2. Know the goals of your presentation.
  3. Show interest and enthusiasm.
  4. Always have at max 3-4 points on a slide. Simplify your slide.
  5. The slides are just a tool, the presentation is how you talk, move your body and interpret the audiences.
  6. The best presentations are those that are interactive.
  7. Images are worth 1000 words, use illustration.
  8. Demonstrations are always better than slides if possible.
  9. Respond to questions, comments and concerns.
  10. Follow up your slides.

Motivational Quote

Our duties are not to be success.
Our duties are trying, because when we are trying, we will find and learn to build the opportunities to be success.

7 Principles of Toyota Production System (TPS)

  1. Reduced Setup Times
  2. All setup practices are wasteful because they add no value and they tie up labor and equipment. By organizing procedures, using carts, and training workers to do their own setups, Toyota managed to slash setup times from months to hours and sometimes even minutes.
  3. Small-Lot Production
  4. Producing things in large batches results in huge setup costs, high capital cost of high-speed dedicated machinery, larger inventories, extended lead times, and larger defect costs. Because Toyota has found the way to make setups short and inexpensive, it became possible for them to economically produce a variety of things in small quantities.
  5. Employee Involvement and Empowerment
  6. Toyota organized their workers by forming team and gave them the responsibility and training to do many specialized tasks. Teams are also given responsibility for housekeeping and minor equipment repair. Each team has a leader who also works as one of them on the line.
  7. Quality at the Source
  8. To eliminate product defects, they must be discovered and corrected as soon as possible. Since workers are at the best position to discover a defect and to immediately fix it, they are assigned this responsibility. If a defect cannot be readily fixed, any worker can halt the entire line by pulling a cord (called Jidoka).
  9. Equipment Maintenance
  10. Toyota operators are assigned primary responsibility for basic maintenance since they are in the best position to defect signs of malfunctions. Maintenance specialists diagnose and fix only complex problems, improve the performance of equipment, and train workers in maintenance.
  11. Pull Production
  12. To reduce inventory holding costs and lead times, Toyota developed the pull production method wherein the quantity of work performed at each stage of the process is dictated solely by demand for materials from the immediate next stage. The Kamban scheme coordinates the flow of small containers of materials between stages. This is where the term Just-in-Time(JIT) originated.
  13. Supplier Involvement
  14. Toyota treats its suppliers as partners, as integral elements of Toyota Production System (TPS). Suppliers are trained in ways to reduce setup times, inventories, defects, machine breakdowns etc., and take responsibility to deliver their best possible parts.

Toyota Production System (TPS) Goals

The right process will produce the right results
1. Create continuous process flow to bring problems to the surface
2. Use the "pull" system to avoid overproduction
3. Level out the workload (heijunka). (Work like the tortoise, not the hare.)
4. Build a culture of stopping to fix problems, to get quality right from the first
5. Standardized tasks are the foundation for continuous improvement and employee empowerment
6. Use visual control so no problems are hidden
7. Use only reliable, thoroughly tested technology that serves your people and processes.

Add value to the organization by developing your people and partners
1. Grow leaders who thoroughly understand the work, live the philosophy, and teach it to others.
2. Develop exceptional people and teams who follow your company's philosophy.
3. Respect your extended network of partners and suppliers by challenging them and helping them improve.

Continuously solving root problems drives organizational learning
1. Go and see for yourself to thoroughly understand the situation (Genchi Genbutsu);
2. Make decisions slowly by consensus, thoroughly considering all options (Nemawashi); implement decisions rapidly;
3. Become a learning organization through relentless reflection (Hansei) and continuous improvement (Kaizen).

Toyota Production System

The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota, that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for the automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic "Lean manufacturing." Taiichi Ohno, Shigeo Shingo and Eiji Toyoda developed the system between 1948 and 1975.

Originally called "Just In Time Production," it builds on the approach created by the founder of Toyota, Sakichi Toyoda, his son Kiichiro Toyoda, and the engineer Taiichi Ohno. The founders of Toyota drew heavily on the work of W. Edwards Deming and the writings of Henry Ford. When these men came to the United States to observe the assembly line and mass production that had made Ford rich, they were unimpressed. While shopping in a supermarket they observed the simple idea of an automatic drink resupplier; when the customer wants a drink, he takes one, and another replaces it. The principles underlying the TPS are embodied in The Toyota Way.

Source: Wikipedia

5 Principle of ACE Cell Line Design

ACE Cell Line Design for manufacturing production system is based on five principles:
  1. Cell work table maximum height is 160cm (Visual Management)
  2. Material arrangement height between navel to chest (Moving Loss) is 120 degree from front side
  3. Movable distance during Cell operation (Moving Loss) is one step
  4. Equipment and tools are easy to convert or changeable (Direct Improvement)
  5. Line construction type is one person completion to reach Line of Balance or LoB 100% (Composition Loss)

ACE Cell Line Manufacturing Production System

ACE or Advanced Creative Environment is a name of DMC Biz Cell Line that contains the meaning of 'Creativity' and 'Development'.

ACE Cell Line is developed and applied considering to culture, customs, environment and so on of each nations of subsidiaries.

Cell Line Manufacturing Production System

Cell Production System is production system that a single human worker assembles each product from start to finish almost manually. Cell Production System is more flexible than conveyor system.

Kind of Cell Production System:
  1. Single Worker Completion Cell or One Person Completion.
  2. Circulation Completion Cell or Rotation Syste.
  3. Separation Completion Cell.
  4. Block Synchronized Cell.