12 passos - exemplo tetrapak - repro_loops_jipm.pdf
TRANSCRIPT
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EDUCATION & TRAINING PILLAR
EDUCATION & TRAINING PILLARIntern
Basic Data
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EDUCATION & TRAINING PILLAR
EDUCATION & TRAINING PILLARIntern
Team Members
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EDUCATION & TRAINING PILLAR
EDUCATION & TRAINING PILLARIntern
Methodology
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EDUCATION & TRAINING PILLAR
EDUCATION & TRAINING PILLARIntern
Total number
of designs
1. Indentify/Classify Losses JAN-MAR 2011
Repro mistakes
(some of designare with more
than one mistake)
80 repro
mistakes
on the 57
designs
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5/34EDUCATION & TRAINING PILLAREDUCATION & TRAINING PILLARIntern
2. Select Theme and Justify
Problem will be eliminate by
implementing new PDF
scope format in W42, 2011.
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6/34EDUCATION & TRAINING PILLAREDUCATION & TRAINING PILLARIntern
3. Understand
1. Difference between AW file
and Repro file
ArtWork Repro file
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Intern
3. UnderstandProcess
New – mod design flow chart
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Adobe Illustrator CS5
Adobe Photoshop CS5
FreeHand 10
Esko PackEdge 7.6
Esko BackStage Pilot 7.0
Intern
3. Understand
Agency Repro In House
Equipment
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Intern
4. Grasp the Actual Situation
5W1H
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5. Establish Objectives
29
0
Week 22
Team goal is to eliminate repro loops due
to difference between AW and repro file
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EDUCATION & TRAINING PILLAR / EDUCATION & TRAINING PILLAR / Intern
6. Master plan
7 C A l i 4M
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7. Cause Analysis 4M
4M
7 C A l i 5 Wh
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7. Cause Analysis 5 Why
3.1
3.2
8 Propose Co ntermeas re
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8. Propose Countermeasure
T l t KEYLINE fil N t OK
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Template KEYLINE file – Not OK
1.1
Template KEYLINE file OK
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EDUCATION & TRAINING PILLAR / EDUCATION & TRAINING PILLAR / Intern
Template KEYLINE file - OK
1.1
9 Implement Countermeasure
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9. Implement Countermeasure
OPL 1
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Old Design Manual
9. Implement Countermeasure
New Design Manual plus Design preparation (shorten manual
with frequent examples of mistakes)
1.2
1.4
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9. Implement Countermeasure
Example from Design preparation
1.2
1.4
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Frequent design seminars during the year
9. Implement Countermeasure
In 2011 we held 12 design seminars for 14 customers, 32 design agencies and CSR’s
1.3
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Old DT procedure
9. Implement Countermeasure
New - revised DT procedure
2
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9. Implement Countermeasure
New - revised Instruction for layer structure
3
3.1
New DesignJob Folder&
Repro fileLayout
Tetra Pak * Repro in house * june 2011
9. Implement Countermeasure
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Comparing raw AW file with Repro file in BS Viewer ( side by side )
Comparing raw AW file with Repro file in BS Viewer
( highlight difference )
9. Implement Countermeasure
SOP 4
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Comparing raw AW file with Repro file in BS Viewer ( side by side )
4
AW file
Repro file
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Comparing raw AW file with Repro file in BS Viewer( highlight difference )
4
AW file
over
Repro file
9 I l t C t
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Old check list
9. Implement Countermeasure
New - refreshed check list
7
10 Check Results
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Results before improvement
10. Check Results
Results after improvement
10. Check Results
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Team
Start
-New keyline set up
-Refreshed instruction for layers
-Trening for layer structure
-Refreshed check list
Countermeasures
Losses Impact
Trigger point
-Design preparation
-Refreshed DTs procedure
-SOP: comparing AW with GRS
4 months without
Repro loops!
4M and 5Why for Trigger Point
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4M and 5Why for Trigger Point
Mistake example
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Mistake example
ArtWork – instructions for typing, send by e-mail
After every typing, it’s
necessary to read text for
several times, to check and
be sure there’s not possibletyping mistake
Countermeasures
Missing part of latter ( mistake by typing) Corrected file
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11. Standardization
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All training material
Updated into
Loss Prevention System
All Procedures and instructions
are updated in our
Loss Prevention System
12 Future Plans
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12. Future Plans
Eliminate by TEAM 382 actions
(new keyline set-up)
Problem eliminate
implementing new PDF
scope format W42, 2011.
Eliminate by TEAM 382
countermeasures Problem eliminateimplementing new PDF
scope format W42, 2011.
12 Future Plans
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12. Future Plans
1. Distribute our new template to all agencies and trained them
2. Share our new template at cluster level
3. Suggest our template to become official template for ORBIS and eD
All Agencies Cluster level
ORBIS and eD