Design of working procedure for handling the breakdown machine in parameter of reaction time based on Jidoka system approach in cement company

Packaging is not a complementary of the product. Packaging is an interface between producer and consumer in a supply chain. Portland cement is one of the products which is usually distributed in unit packed with bags made of kraft paper. Cement production that done with large capacity machines requires the amount of bag in quantity that much anyway. The production of bag factory in Cement company line 4 ideally could reach 9-10 million bags per month. In fact, the average production of cement bag from January to June 2012 is 6.5 million bags per month. In addition, the average defects of work in process in the range of the same month reached 56,000 tubes per month. This indicates that engine breakdown is happen frequently and there is a lack of good performance in term of production process quality control. Long reaction time of operator against the possible breakdown and the breakdown that occur is the cause of the length of time handling problems on the machine, so much going on a lot of waste in time and there are work in process defects that pass to the next process. Minimizing the reaction time to the breakdown of machine can be done with the implementation of jidoka system on the production floor. Andon which is the tool of jidoka will ensure operator and other parties (operators, technicians, foreman) gather to repair the machine effectively and also efficient in term of time. The lights that flashing and the sound of alarm that raised by andon will ensure this happen. Working procedures with the jidoka system approach is proven can minimize the reaction time to the breakdown of machine. Based on calculations, minimizing of time can reach up to 93.66%. The mathematical model for the jidoka system approach that has been valid then converted to a standard operating procedure in handling the breakdown of machine in bag factory. The standard operating procedure that proposed will be technically efficient and effective in terms of time and method to handle the breakdown of machine. * Corresponding author: nilda@ft.unand.ac.id © The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons Attribution License 4.0 (http://creativecommons.org/licenses/by/4.0/). MATEC Web of Conferences 204, 03008 (2018) https://doi.org/10.1051/matecconf/201820403008 IMIEC 2018


Introduction
Cement company in West Sumatra, Indonesia, also known as Padang Cement Company, has its own bag factory consists of 4 line.Line 1 and 2 are produce the sewing bag (using suture thread), while line 3 and 4 are the pasted (using glue as an adhesive).Currently, the production lines running 24 hours in line 4, while the 1, 2, 3 rarely operated.Line 4 has a length of 72 meters and 24 machines.The bags are produced by using the principle of one-piece-flow that produces it from one line arrangement machine.There are two groups of machines in the manufacturing of pasted cement bag: Tuber machines and Bottomer machines.The problem in one machine in tuber will make all of tuber machines stop operating, as well as the Bottomer machines.Operator of the machine is not adopted the full concept of autonomous when abnormal condition is detected on the machine, even though each operator has a good ability to analyze the condition of the machine.Operators sometimes have to ask to the others or the head shift about the problem encountered.This is ensued the longtime of reaction time.
Automation or the Japanese language called jidoka is the second pillar of the Toyota Production System.The term "autonomation" is a combination of autonomy and automation or allowing a process to be able to make its own decisions, thereby giving it a human touch [1].Jidoka means automation with a human touch or equipment/machining with the help of human intelligence [2]; [3].In the implementation, when the equipment shut down, then there will be a flag or light usually together with the music or an alarm which used as a sign to ask for the help from the others to handle the problem.This marking system called andon.
There were some previous studies related to implementation of Jidoka system approach in manufacturing industries and service industries as well.Baduka, Veza, and Bilic [4] conducted study about application of lean in automotive industry by integrated lean approach (tools and principles) in Process Failure Mode and Effect Analysis (PFMEA).Some of those lean tools and techniques integrated in PFMEA are Genchi Genbutsu, Kaizen, standardized work, Jidoka, and 5 why.
Jidoka system approach or error proofing devices can also applied in service processes which are not physically observable [5]; [6].Lopez et al. [5] suggested that Jidoka's application to service environments should entail alert systems which detect failures in service and stop its supply whenever its occur.

Research Methodology
The bag factory currently has implemented two working procedures to handle the breakdown of machine.This study will look at the ability of the jidoka system approach to minimize the reaction time on the machine breakdown handling procedures.The parameter of measurement is personnel reaction time.Valid model will be transformed into the proposal of work procedures to handling the breakdown of machine in the bag factory, Padang Cement Company.

Working Procedure
There were four working procedure has been designed in this study i.e.: 1. Handling the breakdown of machine (Auto-Off) based on work procedure in Line 4, cement bag factory (Working Procedure 1) a.The personnel finds out which machine is involve with the breakdown b.Personnel who close with the broken machine have to fix it together c.If the personnel could not fix the broken machine, the personnel have to call the others for the help 2. Handling the breakdown of machine (Auto-Off) based on jidoka system approach (Working Procedure 2) a.All personnel see andon board to find out what machine is involved with the breakdown b.Personnel who have the responsibility to fix the certain machine have to do it together 3. Handling the breakdown machine that turned off by the personnel (autonomous) based on working procedure of Cement Company (without andon) (Working Procedure 3) a.Operator of Machine (Personnel 1) have to turn off the machine when the abnormal condition is detected b.Other personnel have to find out what machine is involved with the breakdown c.Personnel who close with the broken machine have to fix it together d.If the Personnel could not fix the broken machine, the personnel have to call the others for the help 4. Handling the breakdown of machine based on Jidoka principles (Working Procedure 4) a.Operator of machine (personnel 1) have to turn off the machine when the abnormal condition is detected b.All personnel see andon board to find out what machine is involved with the breakdown.c.Personnel who have the responsibility to fix the certain machine have to do it together

Model Formulation
Deficiencies in the work procedure 1 (number of uncontrollable inputs) will be anticipated by the work procedure 2, as well as work procedure 3 against 4. Work procedure 2 and 4 are not implemented in the factory, so the mathematical models required in this case in order comparing the performance of work procedure 1 against 2 and 3 against 4 in parameter of reaction time.

Model Validation
This research used the experimental validation to proving the jidoka system approach is better to implemented in bag factory.Experimental validation tested the value and accuracy of solution in answering the problem and lookout the significance of models parameter.Value of Ci (time of personnel to start handling machine) on the jidoka system approach was assumed equal with Ci on procedure.If the number of personnel required is less than the estimated number of personnel in the model, then the value of Ci at other personnel is 0,42 seconds.The model can be valid if the duration of personnel reaction time to breakdown machine can be minimized by jidoka system approach.Table 3  Based on the results obtained, the mathematical model to determine the reaction time with jidoka system could be declared as the valid model and would be good to implemented.Work procedure with jidoka system approach has many advantages because it can eliminate the ineffective elemental work on existing work procedure in bag plant.Table 5 shows the comparison between plant procedure and jidoka system approach procedure.Establishment of the procedure begin with determine the personnel who is responsible to overseeing each machine in the line 4, bag factory.It will be shown in Table 6.Tuber machine that is turned off will not affect the bottomer machine.This condition requires the instruction about personnel who will execute the breakdown.

Standard Operating Procedure to Handling The Auto-off Machine Breakdown
The procedure is as follows.
1.The personnel should be stand by and watch the machine in the predetermined location point.2. When the machine is off automatically (indicated by an alarm andon), the personnel directly have to see the andon board.Information on andon board should have been caught in 0.6146 seconds or less.3. The personnel who responsible to execute the machine, immediately go to the location of the machine breakdown with walking speed is 1.116 m/s (can cover a distance of 2 meters in 1.8 seconds).4. When the personnel has reached the location of machine breakdown, all personnel have to analyze the condition of the machine quickly (try in 0.42 second or less).5.All personnel who responsible to execute the machine should participate in the repair process.1.The personnel should be stand by and watch the machine in the predetermined location point.2. When the abnormal condition is detected, personnel 1 (personnel who watch the machine) should be able to push the off button of machine in the following time or less.After pushing the off button, personnel 1 immediately go to the location of machine breakdown with walking speed is 1.116 m / s (can cover 2 meters in 1.8 seconds).The recapitulation of duration time until the off button of machine pushed will be shown in Table 7. 3. When the machine is off (indicated by an alarm andon), the personnel directly have to see the andon board.Information on andon board should have been caught in 0.6146 seconds or less.4. The personnel who responsible to execute the machine, immediately go to the location of the machine breakdown with walking speed is 1.116 m/s (can cover a distance of 2 meters in 1.8 seconds).5.When the personnel have reached the location of machine breakdown, all personnel have to analyze the condition of the machine quickly (try in 0.42 second or less).All personnel who responsible to execute the machine should participate in the repair process.

Design of Andon Board
There are two signals that would indicate the off machine: alarm as an auditory stimulus and the light as the visual signal.Figure 1 is andon (the unit is meter) while Figure 2 describing the tool that used to sounding the alarm.855XH Hazardous Location Horns can sounding the alarm at 110 dB sound power up to 117 dB.Line 4 that has 2 groups of machines: bottomer and tuber can cause miss or error communication in calling the personnel who responsible to execute the machine.This was anticipated with the 2 types of alarms that serve each group machine.

Conclusion
Work procedure of bag factory, Padang Cement Company to handling the machine breakdown is considered less effective in term of the way and less efficient in term of time.This can be resolved by jidoka and genchi genbutsu that will ensuring shorter reaction time to handling the machine breakdown and the problem will fixed together effectively.One thing that important too is there is no problem hidden for anybody in factory.In general, the advice that can be proposed for bag factory, Padang Cement Company is applying the jidoka and genchi butsu intensively according with the emendation proposal.This will ensure the reaction time to the abnormal condition of the machine and machine breakdown could be shortened significantly.Jidoka and genchi genbutsu are also directly expected to minimize the duration of machine breakdown.Discipline and seriousness as well as the control and supervision of personnel from the related parties are the very important things needed to achieve the goals of these two principles.

Table 4 . 6 Personnel 2
Total reaction time by work procedure off the machine 3 Time of personnel 1 to start handling machine (discuss with head of production sector) 37Personnel 1 handling the machine 18 Time of personnel 2 to start handling machine (discuss with head of production sector) handling the machine 51 Personel 2 memanggil bantuan ke personel 3 3 Personnel 3 walk to machine location 7 Time of personnel 3 to start handling machine (get instruction from personnel 2 and take the tools)

Table 1 .
Duration of personnel go to the damage perforating unit machine

Table 2 .
Reaction time of personnel 1 to turn off the machine

Table 3 .
Total reaction time by work procedure 1

Table 6 .
Personnel who responsible to overseeing each machine

Table 7 .
Duration until the off button of machine is pushed