Fundamental TPS kaizen view point

(Issue on Aug 2'13 / Revise 02)

Category No. View point Illustration Possible Cause Standard Condition Countermeasure
LIMIT of
OPT work
actual takt average
Weight Cycle time - Work load not match to production - Rearrange work. ( Balance process )
more than Takt time ratio. Weight average cycle time = 95% - Keep heijunka condition.( Model ratio )
1 actual takt-5% - Many model variation. ( Some model ~ 100 % of Takt time. - By pass process
has many option work )
Over Work load effect to Waight
A B C D E

delay / line stop average

Conveyor line Fixed station

1 Pitch If delay can't cover
with in Takt time - Long cycle time job with Pokayoke.
NG Pokayoke job Cycle time - Add / Modify machine / tools to
T.T. (Machine Pokayoke)
setting 100% support.
Muri of 70% - NG Pokayoke sequence setting. Pokayoke setting area within
2 start Finish - Rearrange work. (Pokayoke in begining
Workload 70% - Pokayoke set at the end of process 70% of Takt time
If delay can't sequence)
cover with in Pokayoke due to Kanketsu condition.
Pokayoke job setting Takt time job NG OK - Set specific Pokayoke stop position
Pokayoke job
effect to delay / line stop

Poor Ergonomics Part weight not over 20 Kg. - Apply equipment / tools to support.
- Area limitation.
3 Tool weight not over 2 Kg. (Manipulator, Hoist, Hanger,dolly,
- No have equipment to support.
Pull/Push force not over 5 Kg. shooter, etc.)
Push / Pull / Lift heavy
weight.(Tool & part )

LI M I T o f
a c t ua l t a k t +10 %
aver ag e OPT - Option work suffix.
Difference cycle time a c t ua l t a k t - Incident work (Changing
in difference model - Rearrange work. ( Balance process )
Mura of dolly/tools/dies, empty box) Fluctuation of cycle time not
4 a c t ua l t a k t - 10 % - Apply equipment / tools to support.
Fluctuation - Difference part / tools picking point. over ± 5% of Takt time (karakuri,pneumatic,hydraulic…)
- Part assy need setting or adjusting.
option work, incident work, W ai g ht A B C D E - Many model variation.
change over time aver ag e

Repair / Rework - Machine error. - Keep good machine condition & PM

- NG material - Keep good part quality
Muda of process - No repair / rework process (in
5 - NG skill - Develop & refresh operation skill
repair production line)
- NG standard - Improve key point identification
Have to repair / rework
- NG working environment - keep good environment
before send the next
process
Many Stock

Standard of work in process relate with - Implement Kanban System

Muda of Advance operation - No Pull system
production require. - Update standard stock.
- Unsuitable of line speed
over 6 - Max-min stock control.
S/A
Table - Operation speed don’t relate with Heijunka production: WIP=1
production Ｓ F part supply cycle.
- Control ine speed.
Over sub assy / Stock buffer
Lot production: WIP= lot size
more than requirement

Production QG QC
Double job / Over - NG process flow
- No repeat job / operation - Rearrange process flow
Muda of inspection - Not self completed process. (assure
7 - Keep standard judgment. - Kanketsu activity
processing major part done in process and can
- Self completed part in process - Grouping process (part in process)
Repeat / double job / over confirm quality condition)
Inspection / Work
unnecessarily
- Shortest conveyance time
- NG layout - Simple supply route
Long distance Main line - NG route setting - Re-layout to direct supply.
8 - Many variation of supply quantity. Assembly process - Compact line / area
- Area limitation - Combine process for short distance.
Long conveyance time / S/A - Part size / lot size supply control S/A process
Complicate supply route Process
Muda of
Conveyance Hand
lif t
1 method for 1 route
2 nd
Many conveyance Li ne

- Area limitation E-Car

methods per route - Different line design
9 E- car
- Automatic tool ( Shooter, hoist ,etc.)
1st (Trim-->Chassis)
- Need special equipment.
Long conveyance time /
E- car จอด Hand Li ne
Complicate supply route 1 1

- Keep control standard stock

Over stock -Control Max-Min stock concern
Over necessary Transportation time
Stock = Transportation time Takt time
Muda of stock - Un-control area of stock. Takt time
10
Stock - Supply don't match line require. - Control stock area
Over stock work in process, Stock part in process not over 1 Pcs. (Big
part) or 1 box (Small part) for next
large stock area, over S/A Process
round supply part
supply

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Fundamental TPS kaizen view point
(Issue on Aug 2'13 / Revise 02)
Category No. View point Illustration Possible Cause Standard Condition Countermeasure
1 Pitch 1 pitch 1 return
Many times of - Big part picking
- Using synchronize dolly
returning - Relocate flow-rack to match with work
- Many part assy. 6 7 8 9 1
11 4 5 8 9 1 sequence.
- Flow-rack location not match with Wagon
1 return 5 4 3 2 - SPS supply
work sequence.
Frequency of walk between 7 6 3 2 Flow rack - Shooter supply
work position and flow-rack Flow rack

3 Conveyer Line

L4
4
L3 L2
1
L1
0 ~ 1 working position change
Many working LR C9 C3 C3 LE LF
2 L4 L3 L2 L1
1 Conveyer Line

CR C5 CE CF
position change RR
C8 C2
RF - Long cycle time work LR C9 C3 C3 LE LF - Grouping job for working position
12 C7 C4 C1 L1
3 2
R4 R3 R2 R1 - Many model variation CR C8 C5 C2 CE CF - Auto jig return (spot / spray)
Jig RR C7 C4 C1 L1 RF
Number of movement for 4 working position R4 R3 R2 R1
4 1 Jig
change working position transfer Fix Station
Fix Station
(Buishuyaku)
1 Pitch
Part area within the length of
Part area over the pitch - SPS supply
working area - Long cycle time work (part quantity) 1 pit ch
Muda of - Sequence part supply
13 - Many part variation
Motion - Slim flow-rack
- Big size part
- Improve flow rack efficiency
work area Flow rack
Part area over working area
part area
/ 1 pitch (Pa rt a rea ）
work area

- Temotoka (STD. work posture)

- Area limitation (Movement within 1 reach)
- Apply equipment / tool to support
NG work posture - NG production line design
(Sliding seat, Stand, balancer, flow-rack
(overhead assy)
14 level, shooter, Auto turning)
- Part/tool direction not match with
- Lamp,light (DPS), voice signal. (for
Reach, bend (body), twist,
assy condition. - Body bend 45 degree
judgement)
turning (body,face), looking - Big size part - Body turning 90 degree
for - No have judgement by eye.

- Cannot keep same part in same

- Same part same process
Double handling 3 2
1
process.
- Rearrange work sequence
15 - NG work sequence (pick & assy) Single handling part / tool
- Direct supply
- 1 side supply condition.
- Grouping process
Many handling job for parts - Many tools in process
/ tools

A
Right process
- Rearrange working position (Bui) &
Interfere process - Different working position in
- Working in same position-same time suitable density.
same working time.
16 - Area limitation - Design suitable working area
Interference - High density process - Keep standard density process. ( Machine operation route, swing arm of
! ( Ex. Conveyor : 2 processes in 1 pitch) wagon dolly)
Interfere of Man-Man, Man-
Left process
Part/Tool, Man-Machine B

Multi processes - Rearrange work

work together - Apply automation to support one
- Together work start different time.
17 Together work start same time process operating.
- Safety condition (Clamp - Unclamp)
( Manipulator, Hoist, Hanger, Auto spot,
Dual process, Continuous Auto spray )
Muda of process

Waiting
０ Waiting TT.
M/C operate
NG time matching of - Machine work & hand work unrelated.
man & machine - Rearrange work.
- Low machine speed. Must have hand work while
18 - Modify machine to speed up.
- Keep safety condition while machine machine operating.
- Add hand work while machine operate.
operating.
Waiting machine operate /
home position
LIMIT of
average
actual takt

Weight average cycle

actual takt-5%
time lower than Takt - Work load unmatch to production Weight average cycle time = 95%
19 - Rearrange work. (Balance process)
ratio. ~ 100 % of Takt time.
Waiting before start next A B C D E
vehicle assembly Weight
average

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