Reduction of delivery delay in a jewelry factory : a case study

Abstract

This thesis concerns with reduce delivery delay problem in a jewelry factory caused by process flow. A jewelry factory faces with delivery delay problem is used as a case study. Process flow with in production is scoped to concentrate on. Analysing existing system is the first stage. Factors related with process flow are determined. The related factors consist of internal and external factor. The internal factors are the process flow itself, document How, and material handling. For the external factor, production planning is considered. After analysing, many improvements are introduced and have been implemented. The process flow is shorten by cutting some non-value added job regarding with maintain providing high quality product. Once the process flow changes, developed document system is introduced to serve the changed process flow. Some unimportant roles eliminated from the flow are replace within this document system. Basket system is implemented as new tool of material handling. Counting and checking size is reduced. Furthermore, the increase efficiency of responding to rework is achieved from the basket system. Monthly pre-production plan is developed. The introduced plan does not aim at advance stage of conformance the plan. It purposes to be as reminder for each shop. The production dates for each shop that still allows the final shop to finish its work are informed in the plan. Pull system is employed in parallel with the information received from the plan. Pulling job from the previous process is attempted when the informed date reaches. For the improvement result, It is provided in two forms: objective and subjective result. In objective aspect, the process flow is shorter. In quantitative result, process flow improvement has been proved by the manufacturing flow efficiency and rework rate. 14.4% and 47.4% of manufacturing flow efficiency and rework rate improvement is gained. When consider delivery performance, delivery satisfaction has been increased. From partial measurement, delay of delivery decreases around 66.6% . However, result evaluation of meeting thesis objective can not be directly proved. Therefore, subject result is generated in order to support objective fulfillment. By interviewing related staffs, the result comes out in the same positive direction. Finally, it could be concluded that the objective of this study to reduce delivery delay is fulfilled partially.