ACTION POINTS OF BRAINSTORMING OUT

FCI GROUP
Date:19th Oct,2019
Sl No. What/Problems Who/Responsible

Sudden Plan change causes difficulties in machine preparation Planning

1
Special machine make renting cost high due to same style
Planning
2 planning in multiple lines

Preset time is not available in case of rented machines IE & Planning

3
4 Problems are more in rented machines Procurement & IE
Final layout paper is not available on time and information is
IE
5 missing which makes feeding time more
6 Idle machine keeping space is not available Management
After preset machine when it goes to line that time operator
Production
7 does not want to do work on that machine

Operator does not want to work on manual machine Production

8
Machine requirement sometimes more or less than actual
IE
requirement
9
Layout machine qty is not matched with actual layout IE
10
Layout sequence is not matched with final layout paper IE
11
Preset area is used by production purpose IE
12
13 Required preset area not available Management

Required spare parts are not available in store on time Store

14
15 Racing puller shortage.Need 5 pcs/per line Management
16 Raw edge cutter Flat lock is shortage Management
Rented machines are not coming from line due to production
IE & Production
17 end date is not matched with plan
Rented machines take few days to return back after giving mail
Commercial
18 to return
Rent cost is more due to plan change and same style plan in
Planning
19 multiple time
Most of the old model machine is not performing as per
Maintenance
20 efficiency
21 Spare parts related ERP is not updated IT

Layout plan is not planned considering critical to machine set up IE & Planning
22
 Some style suddenly stopped due to accessories shortage and
Planning
23 plan again without preparation
During preset operator training is not done properly which Technical
24 caused machine problem again during feeding
Machine breakdown is made an issue if target is not achieving
Production
25 with some other reason

Machine breakdown time is not accurately measured IE

26
27 Spare parts quality is not maintained properly Procurement

Minimum stock of spare parts is not available sometimes Store

28
29 Machine movement purpose people not available Management

Preset machine is not set properly by feeder by doing process Technical

30
Mechanic short when multiple line layout plan at same time in
same area IE & Planning
31
Preventive Maintenance requires more spare parts and space Management
32
Maintenance employee performance evaluation system is not
HR
33 available
34 Mechanic training time is not available Maintenance

Number of skilled mechanic is not enough in special machines Maintenance

35
TS OF BRAINSTORMING OUTCOMES
FCI GROUP
Date:19th Oct,2019
Why/Possible Root causes
RM Shortage/Production difficulties
Not consider machine availability
Last moment machine requirement
come
Rented machines quality is poor
Final layout paper is not correctly ready
Space shortage
Mindset problem
Mindset problem
Machine requirement is not made
considering actual scenery
Layout Paper is not made correctly
Layout Paper is not made correctly
Production plan is not accurate
Space shortage
Not consider spare parts availability
Not available
Not available
Plan vs Actual is varying
BEPZA gate problem
Production plan is not as per machine
availability
Not serviced properly
ERP is not updated
Production plan is not as per machine
availability
How/Possible Solutions
Ensure at least one month frozen plan
During planning need to consider the availability of
machines
Machine requirement has to come well in advance
Need to avaoid rented machines
Final layout paper has to be ready on time
Need to make space
Production need to take initiative to use preset
machines
Production need to take initiative to use preset
machines
Need to make machine requirement considering
actual scenery
Layout paper has to make correctly considering
actual situation
Layout paper has to make correctly considering
actual situation
Need to make layout considering available space
inside line
Need to make plan to make space
Need to identify the regular required parts and make
a list of minimum stock of spare parts
Need to purchase
Need to purchase
Actual Need to be closed with plan
Need to fix standard
During planning need to consider the availability of
machines
Need to service regular basis
ERP need to be updated
During planning need to consider the availability of
machines
RM Shortage/Production difficulties
Operator is not available
Not done root cause identifications of
production failures
Not maintained proper system of
breakdown identification
No feedback mechanism
It is not defined properly
Not available
Busy in layout line
Adjacent line loading preparation is
difficult for same mechanic
More parts are damaged
No effective system of performance
evaluation
Always busy in the line
No mechanic skill training plan
Ensure at least one month frozen plan
Ensure operators availability for training
Need actual root casue analysis of production
failures
Need to implement a system of mutual aggrement
for breakdown time
Need proper justification of materials quality
Need to standardized
Ensure availability
Ensure preset machine done properly
Need to make plan to avoid adjacent line plan same
time
Ensure parts availability
Make a effective system of performance evaluation
Identify a flexible time of training
Need to make a effective mechanic skill training plan