LBP Theme : Reduce Overtime (O.T.

) due to high expenses results ( A3 Report Form ) Supervisor Advisor Responsible

Final Objective > To make efforts to attend Plant Hoshin and to achieve cost reduction targets > Focus : Overtime Cost <
:Initials :Initials :Initials

/ / : Date / / : Date / / : Date

Clarification of the problem .1 Root Cause Analysis .4
Monthly O.T. Results (Apr,´08 ~ Oct,´08) 1 Why
st
2 Why
nd
3rd Why 4thWhy 5th Why
Ideal Situation Actual Situation
Lack of trainining and
6,000 Exclusive staff to analyze Lack of skilled staff and
No skill to make this job man power to train about
4,963 Budget : Max 29hs/month/worker Real O.T. results order, to study the
by other staffs
no back-up for heavy job
order job. Lack of
Mis/SFX variation during order timing
5,000 4,292 4,348 4,330 ] Total = 3.219hs/month [ ] Total = 4.059 hs/month [ rotation and back-up
A A1
3,853 Man
Max R$ 21.855 in FY08/09 = R$ 27.558 > 26,1% =

B = SMU jobs forced to be done at weekends especially by leaders

4,000 Power
3,270 3,355 over budget There are no Utility
GAP

A = Excess O.T. to put order of Imported parts in order systems

Cannot make all There are not rotation of There are no job rotation
3,000 "Target : 0 "zero maintenance when
workers in determined
members to cover all program as procedure
time enough to make
equipments are stopped week days (overlap time) for man power
2,000 Results 2.008 maintenance B1
B
Budget=3.219hs/month
1,000
Detected Problem Cannot conclude order Current procedures for Lack of time to analyze Lack of P/N master to Lack of P/N master to
0 job and plan on time to order have specific time Mix/SFX received from analyze Mix/SFX and analyze Mix/SFX and
Did not achieve monthly budget / Over budget 26,1% .1 put orders in normal time control (Short time) PCL&Sales negotiate with production negotiate with production
Apr May Jun Jul Aug Sep Oct
Did not achieve company target 0 (zero) overtime .2 A
A2
: O.T. Results considering the group staffs Method
PC (57) , GP1(29) and GP2(25) There is no procedure to
Accumulate SMU to Receive SMU everyday,
ask to each shop to
analyze in one shot how even corrective or
deliver SMU in time to
Grasping the Current Situation (Breakdown) .2 to do (basically in OT) planned maintenance
make plan
B B2

Monthly O.T. Results all area (Apr,'08 ~ Oct,'08) .2.1 PC O.T. cause (Apr,'08 ~ Oct,'08) .2.3 : Explanation .2.4
Lack of enough Lack of check list to
Need to make Cannot check in SMU the
information for grasp necessary
6,000 Material preparation in advance of necessary materials and
4,963
25,000 ①case of GP1 group we had
In resources
preparation issued by
parts preparation of materials
only O.T. to support Production shops and parts
5,000 4,292 4,348 4,330 Job Details O.T. B B3
3,853
20,000
15.471 .O.T. in week or weekends
Planning 970 In case of GP2 group, also to
4,000 3,355
3,270
15,000 Local parts 1.470 ②
support production O.T. in week
Boiler, Substation, Air
compressor, Water Cannot stop equipments
All equipments are used
Machine to supply utilities for
3,000 and weekends, but also planned supply system cannot in normal production time
Imported parts 2.794 production

GP2
stop
.O.T. for Equip. Maintenance

PC
10,000 B
2,000 Order system 4.310 In case of PC group we can
1,000 5,000 Prod.OT follow 5.928 see
③ details ofWorst
each O.T. on right
graph. causes are Countermeasures Development & Implementation Plan .5
0 0 Order System + Parts Control job Risk Management
Apr May Jun Jul Aug Sep Oct PPCL Comments
PC

Quality Concern
Countermeasures description

Final Evaluation
Techn. Concern

Safety Concern
General Schedule Activities Implementation
to achieve the targets and

Environment
Item

Man Power
to avoid any reoccurence

Workbility
of problems
2.008 2.009
: Pointed out issues .2.5

Cost
Total O.T. by Cost Center (Apr,'08 ~ Oct,'08) .2.2 Nov Dec Jan Feb Mar Apr
Man Power rotation / Organization review / Back up setting / Training
25,000 A1
Man power rotation and order training oriented by

③ ) Total = 28.411 hs ( Not consider O.T. for production O.T. support ( Neccessary O.T. ) >
staff leader/Create backup

20,000 Must attack O.T. : (1) PC Order System & Parts Control job > Mix/SFX variation list / Negotaition
Create Mix/SFX variation list / To issue to PROD MH
15,471 GP2 planned maintenance ( 55% of O.T.) )2( A2 for previous check and to confirm the production
15,000 plan to put order on time
① ② Job rotation program / Training / Test / Skill up
10,000 Create Job rotation program with overlap working
6,983 5,956 B1 time to cover almost 24 hours (3 & 4 shifts). Train
for skill up before rotation
5,000
Create procedure as attachment of SMU sheet and Procedure / Implementation / Test

0 Job Process Analysis : ( PC Group & GP2 Group Jobs ) .2.6 B2 ask to PROD shop to send it in advance or make
plan to avoid job accumulation
PC
PPCL GP1
GPS GP2
Utility
A Check sheet / Implementation / Test
Create check sheet and check list to prepare
Analyze Occurence Point Make B3
Volume material, spare parts and parts for maintenance in
Mix/SFX Production advance of maintenance execution
Prod. Plan
variation
Negotiate Put Imported
Mix/SFX Excess O.T. to put order of
PC Group received from with Parts data in Imported & Local parts
.D-12 Heijunka
Sales Production system D-3 to
negotiated with
Make
Prod.Plan D-
Shop in D-8 D-1
adjust
order if
in systems Countermeasures Confirmation 7. Evaluation of Results & Processes .6
Sales
10 necessary
Prepare
Job support for ,material Force job Use SMU jobs forced to be done 6,000
Receive job
GP2 Group
water spare parts, execution in Outsourced at weekends and week days 4,963
electric,
Request Sheet
weekend by service during 5,000 4,348
from Shops Man .by O.T 4,292 3,853 4,330
steamand air power leaders weekends Achieved more than expected
3,270 3,355
4,000 but not still Company Target
Occurence Point B
3,000
2,000
Target Setting .3 1,076
1,000
150 30 68
0
Monthly O.T. Area Target = Budget .1 Company (Co.) Target = 0 (Zero) .2
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb
6,000 6,000
: .Achieve Budget O.T .1 Standardize the Processes, Future Actions .8
4,059 4,059
4,000 3,219 4,000 Max. 3.219 hs / Month
8.1. Created new standardized work of new process to assure the correct job (See attach. 1)
2,000 2,000 : .Achieve Company O.T .2 8.2. Implemented a standard training plan scheduled with staffs development and skill level up plan (See attach.2)
0 ) Zero ( 0
0 0 Future action : Implement new countermeasures based on next neck point visible in pareto graph and so on
Actual Budget Actual Co.Target