The Failure Mode and Effect

Lean behavior is an essential element to create a culture of continuous improvement culture in a service organization. Continuous improvement is defined as the never-ending efforts for improvement involving everyone in an organization. The purpose of this study is to evaluate the changes of behavioral practices after the introduction of lean tools and discuss the effects of lean behavior in developing a culture of continuous improvement in an office environment. This study adopted a self-administered questionnaire method to obtain real time data for the analysis of behavioral practices. Ford Questionnaire was used and distributed to employees of different management levels in the Business Development and IT Department. The obtained results were analyzed using the Statistical Package for the Social Sciences (SPSS) software. The same questionnaire survey was distributed after the introduction of lean tools. The expected outcomes of this study were to determine the level of lean behavioral practices in the office department and to provide a clear understanding of some lean behavioral practices that need to be nurtured among the employees in order to produce a healthy work environment.

Abstract.Respond time in manufacturing give the major impact that able to contribute too many manufacturing issues. Based on two worst case scenario occurred where Toyota in 2009 made a massive vehicles call due to car complexity of 11 major models and over 9 million vehicles. The recalls cost at least $2 billion in cost of repair, lost deals and result in lost 5% of its market share in United State of America, while A380 was reported on missing target in new production and leads to delayed market entry due to their weak product life cycle management (PLM). These cases give a sign to all industries to possess and optimize the facilities for better traceability in shortest time period. In Industry 4.0, the traceability and time respond become the factors for high performance manufacturing and rapid time respond able to expedite the traceability process and strengthen the communication level between man, machine and management. The round trip time (RTT) experiment gives variant time respond between two difference operating system for intra and inter-platform signal. If this rapid time respond is adopted in any manufacturing process, the delay in traceability on every issue that lead to losses can be successfully avoided.

The evolvement of Internet of thing (IoT) is undeniable by making the management process become more ease at lowest cost as possible. Product lifecycle management (PLM) is a best approach to be embedded the IoT for the entire manufacturing processes. Real cases reported for weak PLM implemented like late market entry faced by A380 while Toyota faced cost loses in repair, deals and market share from massive called made which effect on company reputations. In this paper, traceability becomes a factor among man, machine and management in order to make fast respond on the data retrieved. The term traceability is measured based on response time in real time system to track the information in just in time for one-to-one communication through JAVA programming and two different operating systems as an approach. The communication can be occurred in less than 20seconds within two different machines. The traceability time is a performance measure for just in time data process which the human behavior factor is neglected for this study. The fastest time response have a potential to optimize the manufacturing management, make more efficient and offer the traceability on product/project status beside improve the flexibility, maintainability, reusability as well as extensibility.

This paper highlights a methodology to implement Lean-EMS integration system in the case study company. Lean manufacturing is a concept widely applied in industries to eliminate wastes and achieve high business efficiency. The concept implemented through five principles which is called a self-sustaining cycle. EMS on the other side is an international standard for environmental management. It guides organizations through compliance requirements to reduce environmental impacts from business activities and boost up operating efficiency. Researches on EMS implementation have revealed that the system has similarity with Lean Principles. Hence, researchers had integrated both systems to attain both lean and EMS goals. This integration required a management system for continuous improvement. This paper focuses on design, and development of database system to manage the integration of Lean Principles and Environmental Management System (EMS) to aid employees in problem solving through visual indicators for continuous improvement and sustain the certification. The methodology adapted for the study is using the database development steps with Microsoft Access 2010 software. The database which is comprised of five performance measures (each reflects a lean principle and selected EMS clause) from integration framework specially designed and developed for the case study company. The results of the study validated the use of developed database system for continuous improvement. The study is indeed very useful to the company because the developed system is a comprehensive tool, where it can visualize problems in operations that might affect the production flow and EMS compliance. As the problem visualized, immediate problem solving can be done to continuously improve the conditions and sustain EMS certification.