Download - Galih Aprianto 55115110113
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ANTI CHIP APPLICATION :
WASTE REDUCTIONcontent :
prepared by :
BACKGROUND
IMPROVEMENT RESULT
ATTACHMENT
January, 16 th 2015PT General Motors Indonesia Manufacturing
Bekasi Plant
-behalf of Primer Coat Team-
Galih Aprianto
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BACKGROUND
Anti Chip Coatings are applied to protect vulnerable part (which is Rocker Panel) from stone chipping that
can penetrate and damage existing paint and may go all the way to the bare metal panels
Definition
Left Side Right Side
Spec :
Thickness : min 300 mAppearance : Material Applied as Designated in the MPD
Anti Chip
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BACKGROUND(cont’d)
Old Condition
Many Over Spray of Anti Chip left on the cover and floor.It is WASTE
Need to action for eliminating Anti Chip waste
( waste 461 gr/ unit)
over spray (waste)
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IMPROVEMENT
No ItemPicture
RemarkBefore After
1 Reduce GunQuantity
1. Reducing Gun Q’ty / side :2 pcs 1 pcs
2. Make new setting position &adjustment Gun for keepingcoverage coated Anti Chip areaas specification3. This improvement can reducea . over spray/ wasteb . our spare part consumptionof Gun Anti Chip
2 Simplify Anti-Chipcover
Before : Cover must be large, tocover unit from over spray. Needmore effort also for cleaningactivity After : Simple cover because ofminimum over spray. And moreeasy to be cleaned.
#1
#2
#1
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RESULT
No Item Illustration Remark
1 Before(2pcs Gun/ side)
- Placing Gun to new position- Modify guidance tube/bar of handle-arm Gun- Re-setting Gun to keep area coverage
Result :*) Thickness = 300 ~ 400 mm*) Appearance = OK
Note :-- PTR process had been followed-- SOS/JES had been revised & JIT had been completed
2 After(1 pc Gun/ side)
Conclusion : 1 pc Gun Anti Chip per side can give result that meet PCP requirement
judgment : OK
Product requirement
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RESULT (cont’d )
Conclusion : Cost Saving that can be reached about IDR 5,5 million /month
as per unit IDR
1 Anti Chip Material Waste 461 gr/ unit 82 gr/ unit Rp.24,219 /kg 379 gram 5,140,241 Reducing over spray waste
2Gun Anti Chip
(Left & Right)
4 pcs 2 pcs Rp.400,000 /pc 2 pcs 133,333 Reducing RAC tip part change
3 Cleaning time 2.9 min/unit 1.3 min/unit Rp.307.71 /min 1.6 min 275,708 Reducing Non Value Added job
5,549,282
RemarkNo. Item Before AfterSaving / month
Cost (IDR)
Cost Saving
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ATTACHMENT
Confirmation about the spec./ requirement
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Main Role and Executor
1. Udjang Andi Primer Coat Team Leader
2. Wisnu Yugo F Primer Coat Team Leader
3. Andri Saputra Primer Coat Team Member
4. Komarudin Primer Coat Team Member
5. Bayu Kurniawan Primer Coat Team Member
ATTACHMENT