Time and motion distance study using VSM was incorporated into the ICC project to identify the non-value added activities causing time wastages. Out of 21 steps, three were identified as non-value added steps; four were value added steps while the remaining 14 steps required improvement. The total number of steps involved in the mark-cut to class/tape process was reduced to 18 steps as compared to 21 steps before the implementation of the ICC project. The introduction of FIFO trolley, reduction of recording items, fast quantity confirmation and incorporating Flow 3 into Flow 1 and Flow 2 have resulted a decrease in TAT at transistors EoL from 119 hours to 70 hours, amounting to a 40 percent improvement in time.

Sun Edison (SE) is among the world top solar wafer companies with a production capacity of solar wafer exceeding 800 MW annually. SE faced a problem of daily plant finished goods (FG) of solar wafer packed did not tally with the reported machine output quantity. The high variance between the reported machine output with actual packed wafer quantity was rectified by using the methods of counting good wafer, loss of wafer and review on the rework flow.

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An amount of USD1.2 million of WIP components was stored at the warehouse which would incur losses in space and inventory cost due to overabundance of HSA components. It was unnecessary to store HSA components in the warehouse as a new method was being introduced. This initiative enables HSA components to be sent straight to the next processes without having to go to the warehouse. A scanning system is also revised to ensure only good HSA components are fed into the next production line.

The Petronas Penapisan (Terengganu) had aimed to eliminate the difficulties in removing hydrocarbon at First Flush Pit. The second target was to achieve a cost reduction in time and manpower during the Oil and Gas (O&G) removal from RM1,800 per month to RM300 per month. The Innovative and Creative Circle (ICC) activities have successfully reduced the O&G in Industrial Effluent Treatment System (IETS) from 182 ppm to 98 ppm.

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Segamat Panel Borad’s (SPB) core business is to produce high quality wood based thin panels (MDF and Particleboard) with various sizes in thickness. SPB is producing an average of 6,000m3 or nearly 2.5 million square metres per month of premium grade thin panel MDF that fulfills international standards. In the past years, one of the main problems found was on chipper wood production process. After the implementation of LEAN project, SPB is able to reduce lead time by 10 minutes for the change over time.