WORLD CLASS MANAGEMENT

ZULKIFLI BIN ZAKARIA

2015830026
 Shojinka

A flexible manufacturing or flexible staffing.

Attaining flexibility in the number of workers at a workshop to adapt to demand changes

Alter the number of workers at a shop when the production demand has changed

Equivalent to increasing productivity by the adjustment and rescheduling of human resources.

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Shojinka concept, three factors are prerequisite :

Proper design of machinery layout.

A versatile and well-trained worker.

Continuous evaluation and periodic revisions of the

standard operations routine.
Ideal Layout design :
the U-turn layout
-entrance and exit of a line are at the same position.
-flexible to increase or decrease the necessary number of workers when adapting to changes in
demand.
-range of jobs for each responsible workers can be widened or narrowed easily

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Improper layout-avoided by Toyota
Bird cage layouts :
-usually triangular, rectangular or rhombic in shape.
-The simplest form of machine layout : one worker assigned to one type of machine.
-disadvantage : the worker has waiting time after he has loaded the work piece into the machine and the
part is in process.
-To avoid such waiting times, two or more stands containing the same type of machine can be laid out
around the worker

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 Isolated Island layouts :
-To avoid excessive inventories from each station and decrease the conveyance time.
-Layout of machines should be improved in accordance with the sequential order of processing a
part
-This layout assumes the existence if a multi-function worker, and enables a continuous smooth
flow of products among different types of machines.
-It also ensures a continuous walking route with the least distance for each worker.

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 Linear layouts :
-overcome demerit of an isolated island layout, different types of machines can be laid in a linear form.
-Under this layout, workers must walk between machines.
-This linear layout, allowed products to flow smoothly and quickly among machines resulting to the
elimination of the major advantage of isolated layout.
-One problem : the inability of reallocating operations among workers to adapt in changes in demand

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Attaining Shojinka through multi-function workers

Shojinka demands that the worker must be able to respond to changes in cycle time, operations routines,
and in many cases, the contents of individual jobs.
worker must be multi-functioned

Cultivating multi-function workers through job rotation

each manager and supervisor must prove their own abilities. *rotate through every job
each worker within the shop is rotated through and trained to perform each job in the shop.
scheduling the workers through job rotation at a frequency of several times each day.

*Shojinka = ability to quickly alter the number of workers at each shop to adapt to changes in demand.

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advantages of job rotation

o The workers attitudes are refreshed and muscular fatigue can be prevented.

o The feeling of unfairness that veterans must have heavy works will disappear.

o The human relationship between workers improves

o the skills and know-how are dispersed throughout the shops and kept on standard operations sheets.

o create a responsible workers

o ideas and suggestions to improve the process will increase remarkably.

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Continuous evaluation and periodic revisions of the standard operations routine

-The purpose is to reduce the necessary number of workers even in the period of increased
demand

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