Công Ty Bunge Việt Nam
Bunge Vietnam has commenced construction within the Phu My Port complex of a $100 million integrated soybean processing plant, the first of its kind in Vietnam. The facility will have soybean crushing and multi-oil refining/bottling capabilities with 3000-tons-per-day crushing line with related flat and vertical storage for raw materials and end products.
CiCC Consult Bunge implement as: BUNGE VN CI MASTER PLAN
I | Step I: CI assessment (diagnosis) |
1.1 | Interview all Department |
1.2 | Review history data |
1.3 | Factory onsite and on the job assessment |
1.4 | Assessment report and presentation to board of director |
II | Step II: Preparation and Awareness Training |
2.1 | Identify CI training room (NOTE: CI-Continuous Improvement) |
2.2 | Visual display assessment result |
2.3 | Design CI poster and print out CI process |
2.4 | Visual display CI poster and CI process |
2.5 | Establish organizational chart for CI and continuous improvement |
2.6 | Identify 4-6 key weakness topics need to improvement (Kaizen project) |
2.7 | Team leader and team members selection |
2.8 | CI Team organizational chart |
2.9 | Detail implement plan for each group |
2.10 | Support team finish “Statement of problem – SOW) |
2.11 | Support team make the data collection plan |
2.12 | Visual display project and team activities |
2.13 | CI awareness training for leaders (Kaizen, Lean, Six Sigma Foundation) |
2.14 | CI Awareness Training for Employees (Kaizen, Lean, Six Sigma Foundation) |
2.15 | CI Awareness Training for operator shift 1 (Kaizen) |
2.16 | CI Awareness Training for operator shift 1 (Kaizen) |
III | Step III: Onsite and on the Job support for deployment (5S, TPM-AM, KAIZEN EVENT) |
3.1 | Joined CI day every month |
3.2 | 5S Plan (Appendix A) |
3.3 | TPM – AM Plan (Appendix B) (Taskforce for each area) |
3.4 | TWO KAIZEN EVENT Plan (Appendix C) (Using DMAIC Methodology)(Around 8 Kaizen project) |
IV | Step IV: Expansion with LEAN SIX SIGMA GREEN BELT Plan (Appendix D) (Around 3 Green Belt project) |
V | Step V: Standardization- “Validation” |
5.1 | Support measurement and report after improvement |
5.2 | Support standardization of improvement activities |
5.3 | Continuous improvement recognizing the contribution system |
5.4 | Next plan |
5.5 | Awarded and Certificate |
5.6 | Year 1 report and presentation – Finish |
A. 5S Plan
Steps | Activities | ||
1 | SEIRI – Separate | 1.1 | Identify waste through an initial inspection |
1.2 | Place a 5S tag on fixtures, tools and materials | ||
1.3 | Eliminate unnecessary items | ||
2 | SEITON – Simplify management | 2.1 | Classify items by frequency of use |
2.2 | Find suitable locations for tools, equipment and material | ||
2.3 | Clearly identify each location and support compliance with new order | ||
3 | SEISO – Find out problems through cleaning | 3.1 | Clean and check if the order set in the previous step is maintained |
3.2 | Tag all the deviations from the desired situation | ||
3.3 | Analyse all the repetitive tags in order to find out the root causes of the deviations | ||
3.4 | Define and carry out the countermeasures | ||
3.5 | Make a list of the required standards | ||
4 | SEIKETSU – Standardise | 4.1 | Define cleaning and order standards |
4.2 | Define the check list to verify that standards are respected | ||
4.3 | Visual management improvement | ||
5 | SHITSUKE – Sustain continuous improvement | 5.1 | Plan audits to verify standard observance |
5.2 | Make problem continuous analysis and identify countermeasures | ||
5.3 | Monitor Audit scores | ||
5.4 | Set new improvement targets |
B. TPM-AM Plan
Steps | Activities | Expected Outputs | ||
1 | AM Targets, organisation & Planning | 1 | Link Losses to AM contribution & establish targets | Loss Model realting to AM. Loss Deployment for AM in shopp floor level by area, by machine |
2 | Define AM pillar KPI’s & targets (loss reduction and people empowerment) | KPI trees of AM responsibility | ||
3 | Plan of AM Roll out (by machines and steps) | Detail AM Plan rol out of the factory | ||
4 | Define the organisation to support AM Roll out (e.g. Maintenance Support ) | |||
2 | Standards & Roll out of Step 1- Initial cleaning | 1 | Initial Cleaning and regular cleaning according to a cleaning schedule | Cleaning Standards in place |
2 | Tagging, visualise and eliminate lacks | What is tag, tag format, how to tag, tag KPIs | ||
3 | Working place organization, AM activity Board | AM activitis Board for each machine | ||
4 | Make sure continuous tagging process is permanent | Counter measures for de-tagging | ||
5 | De-tagging activities and promotion for continous tagging | analysis detagging – action plan | ||
6 | Define initial cleaning standards | |||
3 | Standards & Roll out of Step 2- Eliminate sources of dirt and hard to clean & inspection areas | 1 | Identify sources of dirt and difficult to access areas | List of area sour of dirts, anlysing source of dirt, action to termination, isolat the dirt sources. |
2 | Comparision with cleaning time | cleaning time monitoring, reducing cleaning time | ||
3 | Analyse the causes and define countermeasures | ideas for detagging – difficults to access areas | ||
4 | Improve difficult to inspect areas | Hidden inspection points are visible | ||
4 | Standards & Roll out of Step 3- Create and maintain Cleaning, Inspection, Lubrication Standards (CIL Stds) | 1 | Definition of the necessary CIL maintaining measures | Cleaning, Inspection, Lubrication standards (CIL STDs) developed and applicable |
2 | Study the lubrication system | Operator trained about how to do CIL themselves. | ||
3 | Simplify the lubrication system | How to reduce the lubrication time | ||
4 | Introduce lubrication schedule | How to reduce the lubricant | ||
5 | Training opertors | How to set up cleaning , lubrication stations | ||
6 | Standardised measures with equipment layout and CIL maintenance plan | CIL time monitoring and redution | ||
7 | Visual management of CIL standards in shop floor environment | Visualise the CILs points | ||
8 | Auditing | How to audit the AM step 1,2,3 |
C. KAIZEN EVENT Plan
No. | Task Name |
1 | KAIZEN – LEAN tools Training and Coaching (Just using DMAIC Methodology for Kaizen) |
2 | Onsite support “Define Phase” KAIZEN Project |
I.Project Mission | |
1.1. Strategy map and drill down tree | |
1.2. Statement of problem | |
1.3. Project objective | |
II.Project saving $ and expectation | |
2.1. Project saving $ and expectation | |
2.2. Saving explanation and caculation | |
2.3. Main strategy for implement | |
III.Project scope and boundary | |
IV.Project organizational chart and role – responsibility of member | |
V.Define phase summary | |
5.1. Detail project plan | |
5.2. Statement of problem sheet and signature of approval | |
5.3. Update Project schedule | |
VI. Edit Define phase presentation and approval | |
3 | Onsite support “Measure Phare) KAIZEN Project |
I.Current state map by VSM, SIPOC, IPO | |
1.1. VSM or IPO or SIPOC | |
II.Current process performance (using Cp, Cpk) | |
III.Data collection plan (using 7QC tools) | |
IV.Current process capability | |
V.Measure phase summary | |
Joined CI day every month | |
5.2. Update project progess | |
VII. Edit Measure Phase presentation and approval | |
4 | Onsite support “Analyze Phase” KAIZEN Project |
I.Detail VSM, SIPOC, IPO | |
II.Cause and Effect Diagram | |
III.List of potential cause | |
IV.Analyze Phase summary | |
V. Edit Analyze Phase presentation and approval | |
5 | Onsite support “Improve Phase” KAIZEN Project |
I. Improvement strategy (Pilot) | |
II.Improvement using Lean tools for causes | |
III.Improvement taken summary and update new process | |
IV.Remain Improvement | |
V.Improvement trend and compare before and after improvement | |
VI.Expand to plant wide and summary of Improvement phase | |
VII. Edit Improve phase presentation and approval | |
6 | Onsite support “Control Phase” KAIZEN Project |
I.Update improvement and next deployment plan | |
II.Control plan | |
III.Update result of project | |
IV.Conclusion and caculate the project realy saving $ | |
V.Lessons learned and standardization | |
VI.Update project progress and suggest next project need to do | |
VII. Edit Control phase presentation and approval | |
7 | Step IV: Standardization- “Validation” KAIZEN Project |
Support measurement and report after improvement | |
Support standardization of improvement activities | |
Continuous improvement recognizing the contribution system | |
Awarded and Certificate |
D. LSS GREEN BELT Plan
No. | Task Name | Actions |
Training | GREEN BELT Training and Coaching | |
Define | Entered Into Opportunities | Onsite asessment |
Previous Project ? | Review Kaizen project, OPL | |
Determine Core Team | Brainstomming with manager | |
Kick Off meeting | Present the roadmap | |
Project Timeline / Plan | Brainstomming and asign | |
Measure | Process Map / IPO / Map verified | High Level SIPOC, Detail SIPOC, Actual activities and Documents |
MSA | Data Collect Plan, Gage R&R | |
Baseline Sigma, capability Yp & Yc | Collect Data, and Analyse | |
Graph performance over time Yp & Yc | Collect Data, and Analyse | |
Review target & objectives | Meeting and Discustion | |
Phase Exit Review | Presentation | |
Analyze | C&E X’s | Brainstomming, FDM, FMEA |
Hypo tests | Data Collect Plan, Gage R&R | |
Correlation / regression | Collect Data, and Analyse | |
Hypothesis test sheet complete | Summary | |
Improvement commitment | Meeting and Discustion | |
Phase Exit Review | Presentation | |
Improve | Counteractions Identified | Team work, Brainstomming, and Idea, |
Select Optimal Counteractions | Meeting and Discustion | |
Verify Counteractions | Implement Idea Improrvement | |
Full Implementation / Action Plan | Expant Improvement to another | |
Collateral Y assessment | Assessment and measure Y | |
New process map | Release New Process map | |
Joined CI day every month | Presentation | |
Control | Control plan | Make control plan |
New Sigma level / capability | Collect Data, and Analyse | |
Controls in place – Poka Yoke | Visual Desplay | |
Monitor results / tracking set up | Data Collect Plan, Gage R&R | |
Before and after graphs | Data Collect Plan, Gage R&R | |
Phase Exit Review | Presentation | |
Validation | Graph results | Collect Data, and Analyse |
Calculate dollars | Collect Data, and Analyse | |
Final report | Presentation | |
Project close out | Presentation | |
Awarded and Certificate |