2. 1-Aug
8:00
10:00
13:00
15:00
17:00
Schedule of 2weeks
2-Aug 3-Aug 4-Aug 5-Aug 8-Aug 9-Aug 10-Aug 11-Aug
Opening
Meeting
Hull 1
new design
practice
session
Closing
Summary&Meeting
withinateam
Progress
check
GENBA
report
Remind
of
plan
Hull 1
new design
practice
session
PreparationProcess
&
Operation
current
Assy 2 line
Visualize
merit
Process
design
Process
integration
of
detail
design
Discussion
of
after design
Design
of
Kit supply
Wear house : Inventory reduction
Work
design
of
after
process
design
Streaming
&
Process
design
Target
share
Process
&
Operation
current
Assy ２line
Visualize
merit
Process
design
Process
integration
of
detail
design
3. AMAKUSA YMC/support
P/J Leader
Gurudatt Sanil
P/J Support
AMAKUSA Mr. Kayama
Key Word ： ALL YJBM Member Join！！
Div. Manager Roy Reneau
M.E. Mng. Stefan Broeker
Asst. Div. Mng. Fred Muramatsu
Gen. Manager Mike Fishback
YMC
ＹＰＭＴ TVP Activity organization
Production QC,QA MAINTENANCEPC
YJBM TVP Member
Branden
Spicer
David
Glover
Christi
Hambrick
Roy
Reneau
M.E.ENGINEER
Bharadwaj
Venkatesan
TVP Activity Organization YJBM
YMC Boat ManufacturingMember
Shannon Fisher
PURCHASING
Richard
Kirkland
Monthly update
to Gen Manager
from PJ Manager
4. Cost structure(By Product)
Product name : 24ft : F3F 242Ltd Se
$42,636
$720
Material
$31,552
Manufacturing
$8,713
Depreciation
74％
20.5％
8,221
17,209
3,963
Direct Labor 2,799
Non-PROD. 5,822
CKD CIF
Local Parts Cost
Raw Material
Item FY16 FY17 FY18
Production Number 4461 3109 3169
Direct number 315 220 220
Labor Efficiency $65K $50K $125K $240K
（生産性向上） 84%-->85%
85%-->86%
Accumulation from FY16
86%-->87%
Accumulation from FY16
Manufacturing Improvement $220K $150K $150K $520K
(製造改革） ($50/unit) ($50/unit) ($50/unit)
US Parts CD & VA/VE $350K $250K $250K $850K
(購入品CD & VA/VE推進) ($80/unit) ($80/unit) ($80/unit)
Purchasing --> In-house $0K $50K $200K $250K
（部品の内製化） 準備期間 From MY18 model
Accumulation
from FY17
$635K $500K $725K $1860K
3
2
4
1
No. Total
CIP target
Kaizen
Necessity
Kaizen
Orientation
Necessity summary
・ Investment minimum
・ Build up cost competitiveness
Productivity up ×1.44 (2018)
Labor expenses
Expenses
Material
Manufacturing
CKD CIF
Local Parts Cost
Raw Material
Shortening of cycle time
OEE up
Process design
・Process integration
Purchase method
Localize
Material yield
Quality yield
Stock reduction
・Improvement of material flow
（Streaming）
Work space out
15
By Configuration to order
By Lean-manufacturing / SCM
By 3D-Development & BOM management
By Employee’s Culture
Way
YJBM Product Innovation
In the small boat world
No.1 Quality & reasonable value
supported by the customer
Goal
Together we build our future
YJBM slogan
Investment minimum ⇒ Productivity up
Build up cost competitiveness （Including Investment ）
Current condition is good ⇒ Continue the present activity
Top management interview
Necessity summary
Investment minimum
Cost competitiveness up
Labor efficiency
Productivity up
Work space out
FY15 FY16 FY17 FY18 FY19 FY20
Transfer Value $132.4 $147.3 $168.4 $187.0 $205.6 $212.5
Units 4,266 4,461 5,201 6,124 6,783 6,827
$132.4
$147.3
$168.4
$187.0
$205.6
$212.5
4,266 4,461
5,201
6,124
6,783 6,827
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
$0
$50
$100
$150
$200
$250
(M) (ships)
MTP vs Capacity
YJBM MTP
×1.46
Investment plan
24Boats/day 26
(Aug)
28 35
Lamina
tion
GC
20
30
40 FY18
35units/day
(Units)
17ft 80%
F4A 20%
1Shift 6:00-16:30 555min
Pulling Hole
cut
Assy Pinning Assy FinishingLake
test
foamingMold
preparation
PI Final
insp
Liner
set
$12.７M
$3.0M
Production volume ×1.46
End of 2017
5. Current
Expansion Plan
Overall factory (Target figure)
Target (Dec,2017)
Wear
house
outside
Current
Process flow (Current condition)
GC
(吹付)
Lamination
(積層)
Pulling
(離型)
Hole cut
(ｻﾝﾄﾘ)
assembly
(前艤装)
Pinning
(接着)
assembly
(後艤装)
Finishing
(仕上げ)
Shipment
(出荷)
Lake test
(浸水検査)
成形
Lamination area
組立
Assembly area
Liner
set
(接着)
foaming
(発泡)
Mold
prep
(型準備)
PI
(前仕上)
Final
insp
TT 25min
600min(10h)/24ships/day
PT21min
24ft
21ft
19ft
HULL(ﾊﾙ)
DECK(ﾃﾞｯｷ)
GC lamination
liner
set
foaming pulling
hole
cut
PI assembly pinning assembly lake tast finishing final
Liner ○ ○ - - ○ ○ - - - - - -
deck ○ ○ - - ○ ○ ○ - - - - -
Hull ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Process
○
Liner(ﾗｲﾅｰ)
Current condition (Mar,2016)
Target (Oct, 2017)
GC
(吹付)
Lamination
(積層)
Pulling
(離型)
Hole cut
(ｻﾝﾄﾘ)
assembly
(前艤装)
Pinning
(接着)
assembly
(後艤装)
Finishing
(仕上げ)
Shipment
(出荷)
Lake test
(浸水検査)
成形
Lamination area
組立
Assembly area
Liner
set
(接着)
foaming
(発泡)
Mold
prep
(型準備)
PI
(前仕上)
Final
insp
LargerboatsSmallerboats
24ft
21ft
19ft
17ft
Liner
(ﾗｲﾅｰ)
HULL
(ﾊﾙ)
DECK
(ﾃﾞｯｷ)
18boats/day
TT 30.8min
T-OEE 90%
T-CT 27.7min
17boats/day
TT 32.6min
T-OEE 90%
T-CT 29.3min
Process Optimum Production
◆Common Production Line
◆No Standard Manpower per each model
◆Multiple Pitch Process（each Process has own speed ）
◆In-house Equalization Production
Model TVP
◆Production Line per model(Streaming)
◆Standard Manpower・Operation per model
◆Uniform pitch Production
◆Production Flexibility per Market Request
6. Overall STEP
Current condition Step① Target Ideal
Mar.2016 20XX
34boats/day
(Jan 2018)
Dec.2017
1.?? times1.17times
Nov.2016
Space
BPD 24boats/day 28boats/day
Productivity
Streaming
Process design
Productivity up
Productivity up
Process design
Standardization
New design of the assembly line
Big
boats
Small
boats
Process
integration
Productivity up
Productivity
up
Boats/day
/Parson
0.072 0.084 ???
Direct 333 333 333(+ ??)
26boats/day 28boats/day
(July 2017)
7. Master Plan
20172016
April May July Aug SeptJune Oct Nov Dec Jan Feb Mar
Process design
LaminationareaAssemblyarea
April May June July
Preparation time
Move time
Shortening CT
Kit supply design
Kit supply Trial Kit supply Start
26boats
◆Foaming
◆Lamination
◆GC
◆Liner set
kaizen of Mizusumashi
Shortening CT
◆Hole cut
◆Final Assy
◆Pinning
◆Deck Line
◆Hull Line
◆Final Finish
◆PI
Preparation time
Move time
Non value KAIZEN
Non value KAIZEN Cure time reduction
Non value KAIZEN
Non value KAIZEN
Non value KAIZEN
Additional Machine
Additional Machine
Robot Machine time KAIZEN
Mizusumashi
Non value KAIZEN
Non value
KAIZEN
Non value
KAIZEN
Non value KAIZEN
Redesigned Layout/work
Non value KAIZEN
kaizen of Mizusumashi
Material
Target(Oct)
Warehouse Design Warehouse Layout
Training Cross training implementation
Current
Evaluation
Design strategy
(Micro/Macro)
Mizusumashi
28boats
34boats
Jan 2018
New Assembly line
TVP design & Try
Current
8. Material flow Target (Dec, 2017)
GC
(吹付)
Lamination
(積層)
Pulling
(離型)
Hole cut
(ｻﾝﾄﾘ)
assembly
(前艤装)
Pinning
(接着)
assembly
(後艤装)
Finishing
(仕上げ)
Shipment
(出荷)
Lake test
(浸水検査)
成形
Lamination area
組立
Assembly area
Liner
set
(接着)
foaming
(発泡)
Mold
prep
(型準備)
PI
(前仕上)
Final
insp
BigSmall
24ft
21ft
19ft
17ft
Liner
(ﾗｲﾅｰ)
HULL
(ﾊﾙ)
DECK
(ﾃﾞｯｷ)
17boats/day
TT 31.7min
T-OEE 90%
T-CT 28.0min
17boats/day
TT 31.7min
T-OEE 90%
T-CT 28.0min
This time the
main activities
Assembly area
Basic & Detail design
10. How to “PDCAS” ① (Outline)
TVP
Team
Mgmt.
Prod
T.L
Prod
Mgr.
Prod
Oper
Simulate
work
sequence
and review
Review TVP
material a
Review TVP
suggestions
and SOP
Operator
training and
changes
Mock trial,
review and
final
changes
Kaizen Kai
(Line through)
↓
Check
↓
Standardize
No Ok
Feedback
Notification
to Mgmt.
and
approval
Notification
to TVP team
and
approval
End
Selecting an operator
TVP team also join
Process
Design
&
Re-balancing
Design new
SOP and
station
layout
Start
11. Work Area Redesign Process
P
② Work design
No element time
1 ・・・ ・・・
2 ・・・ ・・・
3 ・・・ ・・・
・ ・・・ ・・・
Loss structure
Make a layout
e
current target
value
Semi-
Non-
e
Estimate
reduced time
What is changed ?
current target
Before KAIZEN-KAI
Explain the plan to operators
・the aim of KAIZEN-KAI
・Estimated result
If necessary, simulate the operations of some parts.
D
VTRExplanation board
・line balance sheet
・work sheet
・loss structure
・layout
・KAIZEN operators must
know the operation.
・Record a video
・Explain the aim of KAIZEN-
KAI to everyone.
・Managers must take part in.
C
e
Current Target
value
Semi-
Non-
Insp
e
reduced time
What is different
from estimation ?
e
decrease
increase
A Modification or an addition
KAIZEN-KAI
VTR analysis
KAIZEN-KAI
How to “PDCAS” ② (After process design)
S
Make new process sheet and worksheet
New layout also
① Line re-balancing
Value
Semi
value
●
●
Non
value
●
●
St.1 St.2 St.3 St.4 St.1&4
14. Hull line new design(Basic)
0
5
10
15
20
25
30
35
Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8
Time(Min)
Hull Stations
Hull Line- Current Time Analysis (242 ltd S)
Operator 1 Operator 2 Operator 3
21 min
27.1
30.2 30.4
27.226.5
25.5
26.4
26.0
9.8
4.2
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
Station 1 Station 2 Station 3 Station 4
Time(Min)
Hull Stations
Hull Line-LARGE: Future Analysis
Operator 1 Operator 2 Operator 3
27.5 min
CURRENT MIX LINE
24.5
7.6
24.7
21.1
25.8
26.6
16.6
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
Station 1 Station 2 Station 3 Station 4
Time(Min)
Hull Stations
Hull Line-Small With Floating Operator (6 Operators)
Operator 1 Operator 2 Floating Operator
27.5 min
SPLIT LINE
24
Boats
34
Boats
KAIZEN NEEDED
Total Operators 16
Mizusumashi 0
Total Stations (floor space) 8
Total Operators 15
Mizusumashi 1
Total Stations (floor space) 4
Number of operators
same in split line with
higher productivity &
less stations
Big Line
9 operators
Small Line
6 operators
+0.5min
+0.5min
15. 1, Standard Work Combination Worksheet
2, Required parts list
New Hull 1 New design(Detail) Big line
16. New Hull 1 New design(Detail) Big line
# Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Parts # Qty Parts name Part #
G-D-00 1 MOTOR MOUNTS 68N-44517-00 8 INTAKE SCREEN F2J-U72B7-00 1 JOINT HOSE ASSY 6AP-Y125J02 2
9 BOLTS M8-1.25X40MM 90119-08857 16 INTAKE SCREEN F2J-U72B7-10 1 GROMMETS F1C-U136D-10 4
9C-00 2 SPACER F1C-U72C0-01 8 DIE CAST PLATE F3F-U273B-01 2 DRAIN PLUG ASSY BLACK F2J-U2280-00 1
52-33 2 SHIMS 10MM GDO-U7249-00-10 BOLT 90101-06SA2 6 WASHER 90201-06809 6
6D-00 1 SHIMS 5MM GDO-U7249-00-5 SCREW 90111-08832 14 WASHER 90201-15SA1 4
41-00 2 BOSTIC BLACK 10212 SCREW 90111-08833 8 WASHER 90209-12SB6 10
3B-01 2 ACTIVATOR 10167 1 SCREW 90149-12SD1 10 CLAMP HOSE 90450-27801 2
33-00 2 MIXING TUBE SMP-SM 1 SCREW 90167-08S10 2 CABLE TIE 90464-44801 10
64-00 2 SCREW 90167-08S12 4 WASHER LOCK 92990-06100 6
80-00 2 SCREW 90167-10S12 8 NYLON NUT LOCK 95780-08300 4
42-00 1 SCREW 90169-10SA1 12 BULKHEAD 3 CARPETED F3F-BHD3-00 1
90-00 1 SCREW 90169-12SA8 4 BULKHEAD 4 CARPETED W/SHOWER PUMP F3F-BHD4-10 1
PACKING 7 F2D-U266F-10 1 BULKHEAD 5 CARPETED F3F-BHD5-10 1
BOSTIC 10212 1.75 BULKHEAD 6 CARPETED F3F-BHD6-10 1
ACTIVATOR 10167 1 BULKHEAD COMP VINYL F3F-BHDCOMP-10 1
STEERING CABLE ASSY F3F-U1470-00 1 BILGE PUMP ASSY F3F-BPASY-00 1
DUCT INTAKE F3F-U72B6-00 1 WATER TANK ASSY F3F-WTASY-00 1
DUCT INTAKE F3F-U72B6-10 1
MIXING TUBE SMP-SM 1
SEAL PIPE 30/CABLE CONN ASSY EU0-61435-00 2
BODY/CH PT OF EU0-6727-00 EU0-61436-00 2
PACKING C/CH PT OF EU0-67267-00 EU0-61438-00 2
WASHER 30/CH PT OF EU0-61446-00 EU0-61446-00 2
STOPPER EU0-61486-00 2
St.2
Hull
OP1OP3-1 OP1 OP2
St.3
OP1 OP2
2 4 6 8 10 12 14 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50
1 Move Boat 16 16
2 Apply silicone to drain plug assy 46 46
3 Install water pilots 31 31
4 lay carpet out for installation 56 56
5 Retrieve ladder 19 19
6 Wipe down sides with alcohol 40 40
7 Drill plug hole-If nessessary 36 36
8 Install floor drain 22 22
9 Remove yellow plug tops 87 87
10 Wipe down hull 58 58
11 Install anchor stopper 47 47
12 Clean trash out of hull 37 37
13 Vacuum out hull 121 121
14 Install carpet/glue 673 673
15 Cut excess edges of carpet inside hull 109 109
16 Take to trash 13 13
17 Replace ladder 13 13
18 Lay cables in Hull 105 105
19 Remove edges @ bow of hull carpet 44 44
20
21
22
Name & Date: Shannon Fisher 8/3/2016 UM
Total 1573 1573 MIN
TOTAL
26.22 OPERATOR 2
602
#
MANUAL
TASK TIME
AUTO RUN
TIME
SUB TOTAL
FOR REF.
TIME ( draw red vertical line at tact time ) Each block = 2 minutes
YJBM Standard Work Combination
Worksheet
Process
Name Hull Assembly TAKT TIME 28 OP
Standard
Work
Part
List
17. Operator 3 @ Hull 1 Operator 3 @ Hull 4
Travel fromHull1 to Hull4ea.cycle
Operator 1 Work Area Operator 2 Work Area
11.8
15.7
9.7
10.5
8.9
3.2
4.6 1.6
1.3
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Operator 1 Operator 2 Operator 3
Time(Sec)
Hull 1 Operators
Gemba Summary
Value Semi Value Inspection Non value Preparation
New Hull 1 Configuration @ 28 min pitch time
Reduce Muda (eliminate waste movement)
Balance work based on task precedence
Zone work areas and avoid overlap
12.7
15.7
9.1
10.2
8.9
3.2
3.6 1.6
2.3
0.0
5.0
10.0
15.0
20.0
25.0
30.0
Operator 1 Operator 2 Operator 3
Time(Sec)
Hull 1 Operators
Gemba Summary
Value Semi Value Inspection Non value Preparation
New Hull 1 New design(Detail) Big line
18. Hull 1 new design practice session
1, Result
2, Found
3, The following actions necessary
20. Mock Practice Review
Work Area Operator Body/Motion Time & Misc.
Operator 1
• Op 3 setup adhesive
mix on table instead
of boat
• Portable mini table
for tool setup and
under boat work
• Check operator 3
sequence for
adhesive mix
• Review Bostic
application/cleaning
process for
improvement
Operator 2
• Fix vacuum, battery
stand and other
accessory fixed in
station layout
• Review mounting
plate installation in
hull 1 for operator
ease (cover)
• Check different tool
for alcohol based
cleaning (mop)
• Review Hull dolly
design for stability
• Review carpet
installation time and
SOP
• Starboard drain
holes and floor
drains not done
correctly (Hole cut
issue)
Operator 3
• Fix operator motion
and work area
• Review SOP and
communication
method
Hull 1: Video Check Items & Operator Feedback
21. Future Action After Mock Practice
• Separate test area for
kaizen simulation and
training
• Mimic layout with portable
work stations and
equipment for realistic
results
• Employee scheduling for
kaizen practice and training
(regular work hours or over-
time)
• Immediate leadership
creation (TL, CL and floater)
and training for future
• Kaizen design review by
production and TVP
members once a week
Suggestions For
Future
New Design
Review Process
Design
•TVP performs time –studies and evaluates current condition
•New design of stations proposed
Review 1
•New process basic design sent to leadership (Managers, Supervisors,
Group Leaders, Team leaders) for 1st review
Operator
Selection
•1st draft standard work developed by TVP (detailed design)
•Management and TVP discuss on standard work, operator selection and
equipment for support (Once a week)
Review 2
•TVP and production (GL, TL and some operators) review new design
material and make final changes (once a week)
•Decide training days with management and proceed for kaizen simulation
in the next week
Finalize
•Review all processes and implement additional kaizen ideas
•Finalize work standard and update in overall workforce training agenda
23. How to “PDCAS” ① (Outline)
TVP
Team
Mgmt.
Prod
T.L
Prod
Mgr.
Prod
Oper
Simulate
work
sequence
and review
Review TVP
material
Review TVP
suggestions
and SOP
Operator
training and
changes
Mock trial,
review and
final
changes
Kaizen Kai
(Line through)
↓
Check
↓
Standardize
No Ok
Feedback
Notification
to Mgmt.
and
approval
Notification
to TVP team
and
approval
End
Selecting an operator
TVP team also join
Process
Design
&
Re-balancing
Design new
SOP and
station
layout
Start
Each station 5 weeks
Line through
2 weeks
24. Deployment plan
New design deployment plan
1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W
Hull DESIGN
St1
St2
St3
St4
Through
Deck DESIGN
S1
St2
St3
St4
Through
FA DESIGN
Pinning
St1
St2
St3
St4
Through
DESIGN
FF/FI St1
St2
St3
St4
St5
Through
Done
Big
Dec
Ongoing Not yet
Aug Sept Oct Nov
2 Month 1 Line
1 Line all station Kaizen completion , then next design
10~14
Months
26. Assembly area material flow
Small
Big
H D
St.4
H D
St.3
H D
St.2
H D
St.1
H H
H D H D H D H D H H
WIP
H H
D D
H H
D D
D DDD
HELMS
INSERT
Hole cut
Hole cut
Large
small
WIP WIP
kitunit
1cycle
26min
Kit parts
Going round
6min +
Paying out
4min×4
Stowing
4min+ =
Check the boat
Check the boat
WIP
2boats buffer
28min×2=56min
Kit
2boats buffer
28min×2=56min
HH D D
H
D
H
D
27. Warehouse & Sub assembly
Warehouse
Sub & Kit
(Small line)
Sub & kit
(Big line)
Assembly line
Image
Split line
Synchronized with the assembly
2sets buffer
28min×2=56min
28. Kit supply
3.Paying out : detail
H D
H D
H D H D The nextempty
At work
1min1min
Classify the parts into the kit to be able to carry onetime, and design the dolly
4.Kit design
※AMAKUSA parts supply example
Picking list
pinning
Under 27ft over 27ft Fisherman’s
AMAKUSA 2’nd plantwarehouse
D H
Pick parts according
to the list
Hardware kit
Parts rack
Pay out on
the day before
36. Category,1 Category,2
Mix 1 line Streaming 2 lines
Q
D
Investment
Inventory space
Production plan
C
Direct OP
Indirect OP
Expenses
New model 〇 ◎
Summary
・34boats/day
・After design
Final summary
YJBM Soga san
38. Current
Option C
■ Line Balance
Option A
Option B
24ft:136H
21ft:121H
19ft: 95H
17ft : 85H
41H
10H
15H
If we expand the Plant1 and produce at 2 lines, we may raise productivity.
Option A Option B Option C
Production 35 BPD 35 BPD 30 BPD
Small Parts Outsourcing In house In house
組立部分のみにして
詳細を見える化
FF
FA
Assy
FF
FA
Assy
Lamination
YJBM
39. Focus operator loss (Hull line)
24ft
21ft
19ft
17ft
Mix 1 line Streaming 2 line
24ft
21ft
17ft
19ft
Balance
loss
Loss by mix line
Non value
14min
St.1 St.2
St.1
St.1
St.2
St.2
St.3 St.4 St.5 St.6 St.7 St.8
Total №.of station 8
Total №.of operator 17+1
28min
28min
St.3
St.3 St.4
St.4
Total №.of station 8
Total №.of operator 15+1
Hull line
Hull line
Hull line
St.1&4
St.2&4
