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TIME   -   TWO HOURS                       TVS-Mysore
ABOUT HIRANO SANFull name       - Mr HIROYUKI HIRANOAuthor of       - JUST IN TIME - FACTORY REVOLUTIONConsultant on   - J...
JIT FACTORY REVOLTUION         BY  Mr HIROYUKI HIRANO                         TVS-Mysore
JIT FACTORY REVOLUTION                               STEPS IN IMPLEMENTING JIT PRODUCTION                                 ...
JIT FACTORY REVOLUTION          TOPICS1    INTRODUCTION2    AWARENESS REVOLUTION3    5S4    FLOW MANUFACTURING5    STANDAR...
JIT FACTORY REVOLUTION                           1       INTRODUCTIONCELL SHOULD BE FLEXIBLEFLEXIBILITY TO ADAPT TO CHANGE...
JIT FACTORY REVOLUTION    2        AWARENESS REVOLUTIONASSUME CURRENT PRODUCTION SYSTEM IS THE WORST          CHANGE IN TH...
JIT FACTORY REVOLUTION TEN COMMANDMENTS OF INNOVATION1 - DISCARD FIXED IDEAS2 - THINK HOW IT CAN BE DONE THAN, HOW IT WON’...
JIT FACTORY REVOLUTION                    INNOVATION CYCLE                                  ACT     PLANIMPROVEMENT CYCLEK...
JIT FACTORY REVOLUTION                   3       5S        SEIRI          -        PROPER ARRANGEMENT        SEITON       ...
JIT FACTORY REVOLUTION                     4        FLOW MANUFACTURING                           PRODUCING ONE PIECE AT A ...
JIT FACTORY REVOLUTION          5      STANDARD OPERATIONS      RULES & METHODS TO PRODUCE QUALITY PRODUCTS,              ...
JIT FACTORY REVOLUTION     6        MULTI PROCESS HANDLING ONE OPERATOR HANDLES SEVERAL PROCESS IN A CELLDE-LINEATE JOBS P...
JIT FACTORY REVOLUTION       7      REDUCING OPERATOR HOURS  TO PRODUCE GOODS WITH MINIMUM NUMBER OF OPERATORS      ADJUST...
JIT FACTORY REVOLUTION             8       LEVELLING PRODUCTION       TO PRODUCE THE SAME QUANTITY OF AN ITEM EVERY DAY   ...
JIT FACTORY REVOLUTION                    LINE CYCLE TIME =       4.8 min / UNIT                    WORK TIME       =     ...
JIT FACTORY REVOLUTION                          SEQUENCING OF PARTS FOR LEVELLED PRODUCTION      X - ONE IN 9.6 MINUTES   ...
JIT FACTORY REVOLUTION                     9       JIDOKA             AUTOMATION WITH A HUMAN TOUCH     AUTONOMATION - AUT...
JIT FACTORY REVOLUTION                         10       CHANGEOVERTHE TIME BETWEEN THE LAST GOOD PRODUCT OF ONE TYPE TO TH...
JIT FACTORY REVOLUTION                 11       QUALITY ASSURANCEMAINTAINING QUALITY USING OPERATORS, MANUFACTURING SYSTEM...
JIT FACTORY REVOLUTION                            12      KANBAN    A TOOL THAT CARRIES INFORMATION TO FACILITATE PRODUCTI...
JIT FACTORY REVOLUTION13     MAINTENANCE & SAFETY      3 RULES OF MAINTENANCE             CLEAN UP          OIL APPLICATIO...
HIRANO SANGUIDELINES             TVS-Mysore
HIRANOSAN GUIDELINES          DREAMCURRENT                       TVS-Mysore
HIRANOSAN GUIDELINES             Use KAIKAKU in place of KAIZEN    KAIZEN                                    KAIKAKU(Conti...
HIRANOSAN GUIDELINES         Use JIT improvement in place of IE improvement      IE improvement                          J...
HIRANOSAN GUIDELINES           STEPS FOR KAIKAKU                                  FOREST                                  ...
HIRANOSAN GUIDELINES                   STEPS FOR KAIKAKU                                SUPPLIER               D    C   B ...
HIRANOSAN GUIDELINES                   Guidelines* Focus on managament benefit (Watch the forest) IE benefit will not be m...
HIRANOSAN GUIDELINES                Guidelines* Introduce auto ejection of component* Introduce auto fixture cleaning* Hav...
HIRANOSAN GUIDELINES                   Guidelines* Introduce single piece work flow 1. Fix the WIP required 2. No Dango pr...
HIRANOSAN GUIDELINES                                 Guidelines* Have separate trolley for “tested ok”&“to be tested” (Tsu...
HIRANOSAN GUIDELINES                        Guidelines* Work flow line should be “straight line” (3M I - Man, Machine, Mat...
HIRANOSAN GUIDELINES               Guidelines* Implement the KAIKAKU points immediately  within one day - A rank  within t...
HIRANOSAN GUIDELINES                                MUDA TORI                           (PROCEDURE TO REMOVE WASTE)   FOR ...
HIRANOSAN GUIDELINES                            MUDA TORI - contd...                             (PROCEDURE TO REMOVE WAST...
HIRANOSAN GUIDELINES                                       TSURUBE                   (Pronounced as THU RU BE, means SUPPL...
HIRANOSAN GUIDELINES              REVERSE FLOW OPERATION OF A CELL                                    OUT                 ...
HIRANOSAN GUIDELINES                  DETAILS AT ENTRANCE OF A CELLCELL NAME BOARD                                        ...
HIRANOSAN GUIDELINES              DETAILS AT ENTRANCE OF A CELL - contd...MAN MACHINE CHART       HAND     -       MACHINE...
HIRANOSAN GUIDELINES                         CELL DESIGNOPERATOR / PARTFLOW DIRECTION TOBE ANTICLOCKWISE                  ...
HIRANOSAN GUIDELINES                        CELL DESIGN            OPERATOR HAND MOVEMENT TO BE AS A FLOW           NO BAC...
HIRANOSAN GUIDELINES                        CELL DESIGN - contd...FLOW DIRECTION TOBE MARKED ONCHUTES         DENOTE PROCE...
HIRANOSAN GUIDELINES               CELL DESIGN - contd...          MACHINES TO BE CLOSE TO EACH OTHER- BRING CHECK POINTS ...
HIRANOSAN GUIDELINES                         CELL DESIGN - contd...PROVIDE TAB SWITCH FOR CYCLE STARTPROVIDE AUTO UNCLAMP ...
HIRANOSAN GUIDELINES                        CELL DESIGN - contd...AT EACH MACHINE OPERATOR TO LOAD PART, PICK UNLOADED PAR...
HIRANOSAN GUIDELINES                 CELL DESIGN - contd...       PROVIDE WIRE IN FRONT OF MACHINES TO HANG VCS       PROV...
HIRANOSAN GUIDELINES                           TYPES OF CELLSU LINEW LINET LINEPLUS LINEFLOWER LINE    HAVE SIGNAL AT CENT...
HIRANOSAN GUIDELINES                                 ASSEMBLY                                 OPERATION TIMEBALANCING RATI...
HIRANOSAN GUIDELINES                ANDONS                             AAASDASDKRWQEOF                             EMPTY  ...
HIRANOSAN GUIDELINES                             ANDONSALL ANDONS TO BE OF          TSL                        TSL        ...
HIRANOSAN GUIDELINES             THREE REGULATION FOR KEEPING PARTS                                                       ...
HIRANOSAN GUIDELINES                        STORAGE OF PARTSDO NOT KEEP PARTS ABOVE EYE LEVELDO NOT KEEP PARTS BELOW KNEE ...
HIRANOSAN GUIDELINES                               YELLOW LINEYELLOW LINE IS A WALLCANNOT / DO NOT CROSS ITMARK TIGER LINE...
HIRANOSAN GUIDELINES                             YELLOW LINEPROVIDE CHAMFERS ATCORNERS OF GANGWAYSMARK ARROWS ON GANGWAYS ...
HIRANOSAN GUIDELINES                 KAIKAKU MEASURES* Productivity     - In terms of out/shift* Inventory        - Total ...
HIRANOSAN GUIDELINES       Implement “Self KAIKAKU”* Understand JITs 10 commandments* Understand Hiranosan’s guidelines* C...
BIG ISLAND -         WHEEL HUB & PANELOUTPUT (Scooty & Spectra)      -    600 / day in 2 shifts                           ...
TVS-Mysore
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  1. 1. TIME - TWO HOURS TVS-Mysore
  2. 2. ABOUT HIRANO SANFull name - Mr HIROYUKI HIRANOAuthor of - JUST IN TIME - FACTORY REVOLUTIONConsultant on - JIT PREACHES & PRACTICES INNOVATION TVS-Mysore
  3. 3. JIT FACTORY REVOLTUION BY Mr HIROYUKI HIRANO TVS-Mysore
  4. 4. JIT FACTORY REVOLUTION STEPS IN IMPLEMENTING JIT PRODUCTION JUST IN TIME STEP 5MANPOWER REDUCTION JIDOKA-HUMAN AUTOMATION MAINTENANCE & SAFETY STANDARDISED OPERATIONS VISUAL CONTROL STEP 4 CHANGEOVER QUALITY ASSURANCE LEVELLING STEP 3 MULTI -PROCESS OPERATIONS KANBAN FLOW MANUFACTURING STEP 2 5S STEP 1 AWARENESS REVOLUTION TVS-Mysore
  5. 5. JIT FACTORY REVOLUTION TOPICS1 INTRODUCTION2 AWARENESS REVOLUTION3 5S4 FLOW MANUFACTURING5 STANDARD OPERATIONS6 MULTI PROCESS HANDLING7 REDUCING WORKER HOURS8 LEVELLING PRODUCTION9 JIDOKA10 CHANGEOVER11 QUALITY ASSURANCE12 KANBAN13 MAINTENANCE & SAFETY TVS-Mysore
  6. 6. JIT FACTORY REVOLUTION 1 INTRODUCTIONCELL SHOULD BE FLEXIBLEFLEXIBILITY TO ADAPT TO CHANGES IN DEMAND, PRODUCT MIX & PRODUCT DESIGNWITHIN CELL - ONE PIECE FLOW - REDUCED SETUP TIME - IMPROVED M/Cs TO INFORM OPERATORS ABOUT PROBLEMS - MEASURES TO PREVENT DEFECTS & BREAKDOWNSBETWEEN CELLS - SMALL LOTS - UNIFORM SIZE - KANBAN - PULL CONTROL “JIT MEANS TRIMMING LOSSES - AN ORDEAL FOR SURVIVAL” TVS-Mysore
  7. 7. JIT FACTORY REVOLUTION 2 AWARENESS REVOLUTIONASSUME CURRENT PRODUCTION SYSTEM IS THE WORST CHANGE IN THE WAY OF THINKING INSTALL NEW CORPORATE CULTURE OPERATORS TO LEARN NEW METHODS - TRAINING HAVE CLEAR POLICIES FOR RESISITANCE TVS-Mysore
  8. 8. JIT FACTORY REVOLUTION TEN COMMANDMENTS OF INNOVATION1 - DISCARD FIXED IDEAS2 - THINK HOW IT CAN BE DONE THAN, HOW IT WON’T3 - DENY STATUS QUO4 - DON’T SEEK PERFECTION5 - CORRECT MISTAKES AS SOON AS THEY ARE FOUND6 - INNOVATION NEEDS NO MONEY7 - PROBLEMS ARE OPPORTUNITIES TO USE OUR BRAINS8 - ASK WHY 5 TIMES9 - IDEAS OF 10 ARE BETTER THAN KNOWLEDGE OF 110 - INNOVATION NEVER ENDS TVS-Mysore
  9. 9. JIT FACTORY REVOLUTION INNOVATION CYCLE ACT PLANIMPROVEMENT CYCLEKAIZEN CHECK DO AC T T RGE TAINNOVATION CYCLE VISION / CHECK IMAGE PICTURE /KAIKAKU DREAM PL DO AN TVS-Mysore
  10. 10. JIT FACTORY REVOLUTION 3 5S SEIRI - PROPER ARRANGEMENT SEITON - ORDERLINESS SEISO - CLEANLINESS SEIKITSU - CLEANUP SHITSUKE - DISCIPLINEWE ARE BEHIND TIMES IF WE STILL SWEEP THE FLOORS TVS-Mysore
  11. 11. JIT FACTORY REVOLUTION 4 FLOW MANUFACTURING PRODUCING ONE PIECE AT A TIMECYCLE TIME IS THE TIME IT TAKES TO CARRY ONE PART ALL THE WAY THROUGH THE CELL WORKING HOURS / DAY TAKT TIME = DAILY RATE MONTHLY QUANTITY REQUIRED DAILY RATE = WORKING DAYS PER MONTH MULTI PROCESS HANDLING & SMALL INLINE MACHINES TVS-Mysore
  12. 12. JIT FACTORY REVOLUTION 5 STANDARD OPERATIONS RULES & METHODS TO PRODUCE QUALITY PRODUCTS, SAFELY & INEXPENSIVELY BY EFFICIENT ARRANGEMENT OF PEOPLE, PRODUCT & MACHINESSTANDARD OPERATIONS BULLETINS & MANUALS ON WORK METHODS TVS-Mysore
  13. 13. JIT FACTORY REVOLUTION 6 MULTI PROCESS HANDLING ONE OPERATOR HANDLES SEVERAL PROCESS IN A CELLDE-LINEATE JOBS PERFORMED BY MACHINE & OPERATORS (MACHINES CAN WORK INDEPENDENTLY)MAKE CELLS U SHAPED & GIVE MACHINES JIDOKA FUNCTION OPERATORS TO STAND WHILE WORKING TRAIN OPERATORS TO BE MULTI SKILLED FOLLOW RABBIT CHASE - PRODUCTIVITY MAY GO UP TVS-Mysore
  14. 14. JIT FACTORY REVOLUTION 7 REDUCING OPERATOR HOURS TO PRODUCE GOODS WITH MINIMUM NUMBER OF OPERATORS ADJUSTING TO CHANGING MARKET REQUIREMENTS MAKE MACHINES EASY TO MOVE BY ATTACHING CASTORSSTANDARDISE OPERATIONS SO EVERYONE CAN PERFORM THE JOBTRAIN OPERATORS THROUGH JOB ROTATION TO BE MULTI SKILLEDDO NOT ASSIGN FIXED NUMBER OF OPERATORS TO ANY PROCESS IT SHOULD VARY ACCORDING TO PRODUCTION QUANTITY TVS-Mysore
  15. 15. JIT FACTORY REVOLUTION 8 LEVELLING PRODUCTION TO PRODUCE THE SAME QUANTITY OF AN ITEM EVERY DAY CALCULATE CYCLE TIMES BASED ON MONTHLY VOLUMES MAKE CYCLE LIST BASED ON CYCLE TIME SHORTEN CHANGEOVER TIMES CREATE SMOOTH FLOWINFORMATION & PARTS ARE DELIVERED TO THE LINE SEVERAL TIMES DAILY TVS-Mysore
  16. 16. JIT FACTORY REVOLUTION LINE CYCLE TIME = 4.8 min / UNIT WORK TIME = 480 min / DAYMONTHLY REQUIRED - X = 1000 Y = 600 Z = 400 2000MONTHLY PRODUCTION SCHEDULE X = 50 / DAY(20 WORKING DAYS) Y = 30 / DAY Z = 20 / DAYDAILY PRODUCTION SCHEDULE X = 50 - 08:00 - 12:00 Y = 30 - 12:30 - 15:00 Z = 20 - 15:00 - 16:30LEVELLED PRODUCTION X = 50 - ONE IN 9.6 min Y = 30 - ONE IN 16 min Z = 20 - ONE IN 24 min TVS-Mysore
  17. 17. JIT FACTORY REVOLUTION SEQUENCING OF PARTS FOR LEVELLED PRODUCTION X - ONE IN 9.6 MINUTES Y - ONE IN 16 MINUTES Z - ONE IN 24 MINUTESZ X Y X Y X Z X Y X Y X Z X Y X Y X Z X Y X Y X Z4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.8 4.84.8 9.6 14.4 19.2 24.0 28.8 33.6 38.4 43.2 48.0 52.8 57.6 62.4 67.2 72.0 76.8 81.6 86.4 91.2 96.0 100.8 105.6 110.4 115.2 120.0 At the end of 480 minutes X 50 Y 33 Z 17 TVS-Mysore
  18. 18. JIT FACTORY REVOLUTION 9 JIDOKA AUTOMATION WITH A HUMAN TOUCH AUTONOMATION - AUTOMATIC CONTROL OF DEFECTS INSTALL A MECHANISM ( SENSOR) IN THE MACHINE THAT PERMITS THEM TO DETECT DEFECTS & STOPS THE MACHINE WHEN DEFECTS OCCUR POKA YOKEMANUAL ----- MECHANISATION ---- AUTOMATION ---- AUTONOMATION TVS-Mysore
  19. 19. JIT FACTORY REVOLUTION 10 CHANGEOVERTHE TIME BETWEEN THE LAST GOOD PRODUCT OF ONE TYPE TO THE FIRST GOOD PRODUCT OF THE NEXT TYPE CHANGEOVER TIME IS THE SUM OF INTERNAL & EXTERNAL TIMES INTERNAL - PROCESS MUST BE STOPPED TO PERFORM CHANGEOVER EXTERNAL - TIME SPENT WHILE THE PROCESS IS RUNNING STEP 1 - ANALYSE CHANGEOVER STEP 2 - IDENTIFY & ELIMINATE WASTE STEP 3 - MAKE INTERNAL CHANGEOVERS EXTERNAL STEP 4 - IMPROVE INTERNAL CHANGEOVERS (Bolts tighten with one turn, eliminate adjustment…) STEP 5 - IMPROVE EXTERNAL CHANGEOVERS (Use charts, assign workers…..) BOLTS ARE OUR ENEMIES TVS-Mysore
  20. 20. JIT FACTORY REVOLUTION 11 QUALITY ASSURANCEMAINTAINING QUALITY USING OPERATORS, MANUFACTURING SYSTEM DESIGN & PRODUCTION METHODS TO SATISFY CUSTOMER NEEDSSTEP 1 - OPERATOR - Disciplined, well trained & multi skilledSTEP 2 - MATERIALS - Source controlSTEP 3 - MACHINES - Pokayoke, TEI for safety & maintenanceSTEP 4 - METHOD - Flow manufacturing cells & standard operationsSTEP 5 - INFORMATION - Visual control TVS-Mysore
  21. 21. JIT FACTORY REVOLUTION 12 KANBAN A TOOL THAT CARRIES INFORMATION TO FACILITATE PRODUCTION CONTROLRULES- SUBSEQUENT PROCESS GOES TO FORMER PROCESS FOR PARTS- FORMER PROCESS PRODUCES QUANTITY REMOVED BY SUBSEQUENT PROCESS- QUALITY IS BUILT INTO THE PRODUCT - DEFECT NOT SENT TO NEXT PROCESS- KANBAN ALWAYS ACCOMPANY PRODUCT - VISUAL CONTROL- PRODUCTION QUANTITIES ARE LEVELLED TO AVOID FLUCTUATIONS- REDUCING KANBAN REVEALS PLACES WHERE IMPROVEMENTS ARE NEEDED PRODUCTION ORDERING KANBAN - WITHDRAWAL / CONVEYANCE KANBAN TVS-Mysore
  22. 22. JIT FACTORY REVOLUTION13 MAINTENANCE & SAFETY 3 RULES OF MAINTENANCE CLEAN UP OIL APPLICATION CHECK 4 RULES OF SAFETYSEPARATE MACHINES FROM OPERATORS FOLLOW SAFETY STANDARDS FOLLOW RULES FIND REAL CAUSES & PREVENT TVS-Mysore
  23. 23. HIRANO SANGUIDELINES TVS-Mysore
  24. 24. HIRANOSAN GUIDELINES DREAMCURRENT TVS-Mysore
  25. 25. HIRANOSAN GUIDELINES Use KAIKAKU in place of KAIZEN KAIZEN KAIKAKU(Continuos improvement) (Innovation) Small change Big change making better Revolution TVS-Mysore
  26. 26. HIRANOSAN GUIDELINES Use JIT improvement in place of IE improvement IE improvement JIT improvement (inductive approach) (deductive approach)ANALYSIS OF CURRENT CONDITIONS IDEAL SYSTEM AS GOOD INNOVATION = IN NOVA TION INTO THE NEW STAR = FUTURE TVS-Mysore
  27. 27. HIRANOSAN GUIDELINES STEPS FOR KAIKAKU FOREST (MORI)STEP : 1STEP : 2 SMALL FOREST (HASHI) SINGLE TREESTEP : 3 (KI) TVS-Mysore
  28. 28. HIRANOSAN GUIDELINES STEPS FOR KAIKAKU SUPPLIER D C B A ESTEP : 1 AS A WHOLE F G H I J CUSTOMER8 D C B A ESTEP : 2 IN A CELL F G H I J IN A MACHINESTEP : 3 TVS-Mysore
  29. 29. HIRANOSAN GUIDELINES Guidelines* Focus on managament benefit (Watch the forest) IE benefit will not be much visible & require money (Ki)* Introduce “Rabbit chase” (including sub assembly)* Have only one hour stock for process* Introduce Auto door open & close TVS-Mysore
  30. 30. HIRANOSAN GUIDELINES Guidelines* Introduce auto ejection of component* Introduce auto fixture cleaning* Have uniform cycle time* Have single Input / Output point in a machine* Do not have common machine for two parts in a cell* Standardize process sign board* Adhere to 3R (3-regulations) 1. Name 2. Quantity 3. Location TVS-Mysore
  31. 31. HIRANOSAN GUIDELINES Guidelines* Introduce single piece work flow 1. Fix the WIP required 2. No Dango production* Big sign board (nick name should be decided by concerned operators)* Have KAIKAKU board in cell* Empty bin should be kept on bottom rack (without reversing) TVS-Mysore
  32. 32. HIRANOSAN GUIDELINES Guidelines* Have separate trolley for “tested ok”&“to be tested” (Tsurube concept)* We must figurise operator movement - operator to be on the move (operator should stand only while working)* Use both hands wherever required* KIT implementation in engine assy (for big parts which require body twist while picking & occupying more space) TVS-Mysore
  33. 33. HIRANOSAN GUIDELINES Guidelines* Work flow line should be “straight line” (3M I - Man, Machine, Material & Information) No shoulder movement (paper kept under the arm should not fall) Loading point should be at elbow level No up&down (DEKO BOKA)or zig-zag* No back tracking* No return movement without any work (Loading & unloading should be done by the same person) TVS-Mysore
  34. 34. HIRANOSAN GUIDELINES Guidelines* Implement the KAIKAKU points immediately within one day - A rank within two days - B rank more than two days - C rank if it is required to have time more than three days, then plan today and have A rank for plan TVS-Mysore
  35. 35. HIRANOSAN GUIDELINES MUDA TORI (PROCEDURE TO REMOVE WASTE) FOR PRODUCTIVITY TO IMPROVE : NEVER SMALL ISLANDS - ONLY BIG ISLAND A B CSMALL ISLANDSBIG ISLAND ABCSTEP I - HITO ATSUMEOPERATOR GATHER TVS-Mysore
  36. 36. HIRANOSAN GUIDELINES MUDA TORI - contd... (PROCEDURE TO REMOVE WASTE) AB BCSTEP II - SHIGOTO ATSUMEVALUE GATHERSTEP III - MUDA ATSUMEWASTE GATHERSTEP IV - SHOUZINRESULT TOOLCHANGE IN A BIG ISLAND - STOP ALL MACHINES AND DO TVS-Mysore
  37. 37. HIRANOSAN GUIDELINES TSURUBE (Pronounced as THU RU BE, means SUPPLY ONE, RECEIVE ONE) 400 Years ago in JapanIF, IN A CELL, A PART HAS TO GOOUT FOR AN INTERMEDIATEOPERATION, FOLLOW TSURUBESYSTEM TVS-Mysore
  38. 38. HIRANOSAN GUIDELINES REVERSE FLOW OPERATION OF A CELL OUT INSEIJUN - CORRECT SEQUENCING 7 6 5 4 3 2 1 MANMAN & WORK FLOW IN THE SAMEDIRECTION WORK 1 2 3 4 5 6 7 IN OUT IN OUT 1 2 3 4 5 6 7 MANGYAKUJUN - REVERSE SEQUENCING WORKMAN & WORK FLOW IN OPPOSITEDIRECTIONS 1 2 3 4 5 6 7 JAPANESE - IN RANK A LINES OUT TVS-Mysore
  39. 39. HIRANOSAN GUIDELINES DETAILS AT ENTRANCE OF A CELLCELL NAME BOARD WHEEL HUB CELL R-50 F-40 R-40 T R W AS H B RO R&F-3 0 ACH DRILL 0-F 2CELL LAYOUT T R RT NU 0 F-1 R-10 R-20 RN P TURN TURN P TU TAKT TIME = 104 SECONDSTAKT TIME / CYCLE TIME CYCLE TIME = 129 SECONDS SHOP SIGN BOARD FOR ALL AREAS - VCS ON TOP OF BOARDS TVS-Mysore
  40. 40. HIRANOSAN GUIDELINES DETAILS AT ENTRANCE OF A CELL - contd...MAN MACHINE CHART HAND - MACHINE - WALKING - WAITING - PROCESS No. - 10PROCESS DETAILS PROCESS NAME - TURNING & FACING CYCLE TIME - 108 SECONDSOPERATORS NAME &PHOTO M1033 - LOKESHA M1007 - NAGARAJA TVS-Mysore
  41. 41. HIRANOSAN GUIDELINES CELL DESIGNOPERATOR / PARTFLOW DIRECTION TOBE ANTICLOCKWISE BROAC R-40 TR DRILL R&F-30 R-50 W ASH F-40LOCATION FOR H 0-F 2TROLLIES & PALLETS RT NU TRTO BE CONVENIENTTO OPERATOR 0 F-1 R-10 R-20 RN P P TU TURN TURNOPERATOR WALKINGZONE INSIDE CELL TO BEMARKED BY WHITE LINE -FOR FREE MOVEMENT TVS-Mysore
  42. 42. HIRANOSAN GUIDELINES CELL DESIGN OPERATOR HAND MOVEMENT TO BE AS A FLOW NO BACK TRACKING / NO SHOULDER MOVEMENTOPERATOR EYE LEVEL TO BE MAINTAINED AT SAME LEVEL WITHIN THE CELL PROVIDE REMIDER TOKENS FOR OPERATORS TO USE DURING BREAKS TVS-Mysore
  43. 43. HIRANOSAN GUIDELINES CELL DESIGN - contd...FLOW DIRECTION TOBE MARKED ONCHUTES DENOTE PROCESS TIMES IN SECONDS & SETUP TIMES IN MINUTES GAUGES TO BE KEPT ON THE MACHINE - NOT ON GAUGE STANDS TVS-Mysore
  44. 44. HIRANOSAN GUIDELINES CELL DESIGN - contd... MACHINES TO BE CLOSE TO EACH OTHER- BRING CHECK POINTS TO REAR OR FRONT OF MACHINE- MAKE ACCESSORIES BEHIND THE MACHINE EASILY MOVABLE- AS A LAST OPTION MOVE MACHINES APART DO NOT HAVE SNAKES ON THE FLOOR LOOSE WIRES TVS-Mysore
  45. 45. HIRANOSAN GUIDELINES CELL DESIGN - contd...PROVIDE TAB SWITCH FOR CYCLE STARTPROVIDE AUTO UNCLAMP & AUTO UNLOADINGIT IS CHEAPER TO AUTOMATE UNLOADING THAN LOADINGeg: NET TO CATCH PART WHEN CHUCK IS OPENED / EJECTOR INTHE FIXTURE WITH CHUTE TO BRING PART OUT TVS-Mysore
  46. 46. HIRANOSAN GUIDELINES CELL DESIGN - contd...AT EACH MACHINE OPERATOR TO LOAD PART, PICK UNLOADED PART & HIT TAB SWITCH AS HE MOVES TO NEXT MACHINE OPERATOR TO OPERATE ALL MACHINES - MPO - RABBIT CHASE OPERATOR NOT TO WATCH THE MACHINE - MAN MACHINE SEPARATE TVS-Mysore
  47. 47. HIRANOSAN GUIDELINES CELL DESIGN - contd... PROVIDE WIRE IN FRONT OF MACHINES TO HANG VCS PROVIDE PROPER ILLUMINATION TO INSIDE OF CELLHAVE ALL DETAILS DISPLAYED RATHER THAN IN FILES - OPEN SYSTEM MONITOR PRODUCTIVITY OF CELL - OUTPUT / MAN TVS-Mysore
  48. 48. HIRANOSAN GUIDELINES TYPES OF CELLSU LINEW LINET LINEPLUS LINEFLOWER LINE HAVE SIGNAL AT CENTER TO INDICATE TO OPERATOR WHICH CELL TO OPERATE TVS-Mysore
  49. 49. HIRANOSAN GUIDELINES ASSEMBLY OPERATION TIMEBALANCING RATIO = x 100 TAKT TIME x TOTAL No. OF STAGESLOSS RATIO = 100 - BALANCING RATIO MARK LINE ON CONVEYOR TO INDICATE START OF WORK FOR OPERATOR TIME BETWEEN STOP OF WORK & COINCIDING OF LINE IS SLACK IN THAT STAGE WAITING MUDA WILL BE VISIBLE MARK IN & OUT ON SUPERMARKET STANDS TO INDICATE FLOW OF PARTS TVS-Mysore
  50. 50. HIRANOSAN GUIDELINES ANDONS AAASDASDKRWQEOF EMPTY FULL KJFSDKLJKFASD4TAXI ANDONSEPARATIONHIRE ANDON ROW A ROW BCONCENTRATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TVS-Mysore
  51. 51. HIRANOSAN GUIDELINES ANDONSALL ANDONS TO BE OF TSL TSL TC20 TC30 TC20 TC30THE SAME ORDERALL ANDONS TO BE OFTHE SAME HEIGHT -VISIBLE FROMGANGWAY TSL TSL TC20 TC30 TC20 TC30 PET BOTTLES - LOW COST TVS-Mysore
  52. 52. HIRANOSAN GUIDELINES THREE REGULATION FOR KEEPING PARTS Bolts1 - PROVIDE LOCATION2 - PROVIDE IDENTIFICATION / NAME BOARD Bolts 4 Pallets 1000x43 - SPECIFY QUANTITY SPECIFY INVENTORY OF MATERIAL IN DAYS - INVENTORY OF WIP IN HOURS TVS-Mysore
  53. 53. HIRANOSAN GUIDELINES STORAGE OF PARTSDO NOT KEEP PARTS ABOVE EYE LEVELDO NOT KEEP PARTS BELOW KNEE LEVEL TVS-Mysore
  54. 54. HIRANOSAN GUIDELINES YELLOW LINEYELLOW LINE IS A WALLCANNOT / DO NOT CROSS ITMARK TIGER LINE FOR CROSSINGYELLOW LINE - MEN & MATERIAL TVS-Mysore
  55. 55. HIRANOSAN GUIDELINES YELLOW LINEPROVIDE CHAMFERS ATCORNERS OF GANGWAYSMARK ARROWS ON GANGWAYS TOSHOW WALKING DIRECTION O P S T STOPMARK “STOP” SIGN ATINTERSECTIONS OF GANGWAYS AVOID PROTRUSIONS INTO THE GANGWAY - YELLOW LINE IS A WALL TVS-Mysore
  56. 56. HIRANOSAN GUIDELINES KAIKAKU MEASURES* Productivity - In terms of out/shift* Inventory - Total WIP* Lead time - Time to convert raw material to finish* Walking distance - In terms of steps/cycle* Operators - In numbers* Cycle time - Rhythm at which product comes out* Takt time - Available time in sec / (qty. to be supplied) (does not include allowance) TVS-Mysore
  57. 57. HIRANOSAN GUIDELINES Implement “Self KAIKAKU”* Understand JITs 10 commandments* Understand Hiranosan’s guidelines* Conduct audit assuming yourself as Hiranosan* Follow the KAIKAKU steps TVS-Mysore
  58. 58. BIG ISLAND - WHEEL HUB & PANELOUTPUT (Scooty & Spectra) - 600 / day in 2 shifts TVS-Mysore
  59. 59. TVS-Mysore
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