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1 LI E BALA CI G AT A PACKI G PROCESS OF MEDICAL PRODUCTS By BOO CHEE KEE SUPERVISOR: MR. MOHD FATHULLAH BI GHAZALI Report submitted in partial fulfillment of the requirements for the Degree of Bachelor of Engineering (Manufacturing Engineering) APRIL 2010

2 ACK OWLEDGEME TS First of all, I would like to take this opportunity to express my greatest thank to my project supervisor, Mr. Mohd Fathullah bin Ghazali who guided me, giving me full support and helping me while doing my Final Year Project. I also would like to express my gratitude Lecture Nor Zaiazmin bin Yahaya for his invaluable guidance and support me while learning Witness software and allow me to use all the equipment provided at the laboratory. My appreciation also goes to all the Manufacturing Laboratory staff for their encouragement and constructive comments. Special thanks go to my friends, staff and lectures in University Malaysia Perlis (UniMAP) for their kind support and invaluable co-operation during my final year project. I am very grateful for their comments and suggestions about my logbook and final report. I also wish to recognize the determined efforts and patience of my beloved family especially to my mum and dad for their encouragement and understanding. During my study in UniMAP for almost four years, I become to appreciate the vital nature of manufacturing engineering, design engineering and technology as an academic subject that is exciting, challenging and important as any other discipline. Finally, it is hoped that this final report will assist others to understand the concepts of final year project and thus make the learning process both effective and enjoyable. At last, I would like to highlight my apology for any mistake I had made. Thank you very much. I

3 APPROVAL A D DECLARATIO SHEET This project report titled Line Balancing at A Packing Process Of Medical Products was prepared and submitted by Boon Chee Keen (Matrix umber: ) and has been found satisfactory in terms of scope, quality and presentation as partial fulfillment of the requirement for the Bachelor of Engineering ( Manufacturing Engineering ) in Universiti Malaysia Perlis (UniMAP). Checked and Approved by ( Mr. Mohd Fathullah bin Ghazali) Project Supervisor School of Manufacturing Engineering Universiti Malaysia Perlis APRIL 2010 II

4 GARIS PERIMBA GA DI PROSES PEMBU GKUSA DALAM PRODUK PERUBATA ABSTRAK Tujuan utama untuk menyiapkan laporan ini adalah untuk merekod semua kemajuan dan keputusan yang diperolehi ketika dalam tempoh yang ditetapkan untuk menyiapkan tugasan ini. Projek yang dikendalikan untuk kedua dua semester, semester 1 dan /2010 ini ialah untuk Garis Perimbangan di proses Pembungkusan dalam produk perubatan dan mengkaji pengendalian dan menyokong susun system pembuatan. Projek ini diselia oleh Mr. Mohd Fathullah bin Ghazali, selaku penyelia projek. Laporan ini menerangkan perkembangan keseluruhan projek dan informasi seperti kaedah Yamazumi Board yang digunakan selain menggunakan perisian Witness 2003 untuk tujuan simulasi proses. Tujuan projek ini adalah menyesuaikan pembuatan lean teknik untuk dapat menyimbangan process secara teknologi memajukan. III

5 LI E BALA CI G AT A PACKI G PROCESS OF MEDICAL PRODUCTS ABSTRACT The main purpose for preparing this report is to record all the progress and results obtained during the period required to complete this task. Project conducted for the two semester, semester 1 and 2 for 2009/2010 is in the Line Balancing at a Packing process of Medical Product and review the operation and support of the manufacturing system layout. The project is supervised by Mr.. Fathullah Mohd Ghazali bin as the project supervisor. This report describes the development of the whole project, and information such as methods used Yamazumi Board other than using Witness in 2003 for the purpose of the simulation process. The purpose of this project is adjusting manufacturing 'Lean' techniques in order to develop the balance technological process. IV

6 TABLE OF CO TE TS ACK OWLEDGME T APPROVAL A D DECLARATIO SHEET ABSTRAK ABSTRACT TABLE OF CO TE TS LIST OF TABLES LIST OF FIGURES CHAPTER 1 I TRODUCTIO 1.1 Introduction to Line Balancing at a Packing Process of medical products Company Background Product Manufactured of Covidien Fabrication of Catheters Packing Station Introduction Objective Problem Statement Study Scope Project Planning 8 Page i ii iii iv v ix x V

7 CHAPTER 2 LITERATURE REVIEW 2.1 Introduction Research On Specification Implementation in manufacturing Push Stratery Pull strategy Yamazumi Flow charts Kaban Software Review 14 CHAPTER 3 METHODOLOGY 3.1 Introduction Understanding of Project Title Conduct Information Seeking Actual Production Observations Critical Factor Identification Data Collection & Analysis Data Interpretation Propose Improvement Revise Data and Simulation Documentation Presentation Step to Achieve First Objective Understand the Process 24 VI

8 Collect Data and Information on Process Analysis Simulation Step to Achieve Second Objective Understand the Process Collect Data and Information on Process Analysis Simulation Validation 27 CHAPTER 4 RESULTS A D DISCUSSIO 4.1 Introduction Result of Work Time Work Process Flow Results Current State Result Flow Chart Operator Step and Time The Bar Chart of Current State Witness Simulation Station Statistic Operator Statistic Experimentation 5 Operator Result Flow Chart Operator Step and Time 41 VII

9 4.5.3 The Bar Chart Witness Simulation Station Statistic Operator Statistic Experimentation 4 Operator Result Flow Chart Operator Step and Time The Bar Chart Witness Simulation Station Statistic Operator Statistic Experimentation Yamazumi Board Result Flow Chart Operator Step and Time The Bar Chart Witness Simulation Station Statistic Operator Statistic Validation 63 CHAPTER 5 CO CLUSIO A D RECOMME DATIO 5.1 Conclusion Recommendation 65 VIII

10 REFERE CES 66 APPE DIX 69 IX

11 LIST OF TABLES Tables o. 4.1 Flow Chart (Current State) Operator Step and Time (Current State) Station Statistic (Current state) Operator Statistic (Current state) Flow Chart (5 Operator) Operator Step and Time (5 Operator) Station Statistic (5 Operator) Operator Statistic (5 Operator) Flow Chart (4 Operator) Operator Step and Time (4 Operator) Station Statistic (4 Operator) Operator Statistic (4 Operator) Flow Chart (Yamazumi Board) Operator Step and Time (Yamazumi Board) Station Statistic (Yamazumi Board) Operator Statistic (Yamazumi Board) Compare of Experimentation 63 Page X

12 LIST OF FIGURES Figures o. 1.1 Cather Closed System Packing Station Structure Current Packing Station s layout Pull and Pull Witnesss 2003 Sofware Witness Screen and View Let Gallery Process Improvement Study in Actual Production Plant Step to Achieve Objective First Objective Second Objective Box Work Process Flow Bar Chart (Current state) Witness Simulation (Current state) Station Statistic Chart (Current state) Station Statistic Status Chart (Current state) Operator Statistic Chart (Current state) Operator Statistic Status Chart (Current state) 38 Page XI

13 4.9 Bar Chart (5 Operator) Witness Simulation (5 Operator) Station Statistic Chart (5 Operator) Station Statistic Status Chart (5 Operator) Operator Statistic Chart (5 Operator) Operator Statistic Status Chart (5 Operator) Bar Chart (4 Operator) Witness Simulation (4 Operator) Station Statistic Chart (4 Operator) Station Statistic Status chart (4 Operator) Operator Statistic Chart (4 Operator) Operator Statistic status Chart (4 Operator) Bar Chart (Yamazumi board) Witness Simulation (Yamazumi board) Station Statistic Chart (Yamazumi board) Station Statistic Status Chart (Yamazumi board) Operator Statistic Chart (Yamazumi board) Operator Statistic StatusChart (Yamazumi board) 62 XII