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1. Fundamental TPS kaizen view point
(Issue on Aug 2'13 / Revise 02)
Category No. View point Illustration Possible Cause Standard Condition Countermeasure
Weight Cycle time
more than Takt time
Over Work load effect to
delay / line stop
NG Pokayoke job
setting
Pokayoke job setting
effect to delay / line stop
Poor Ergonomics
Push / Pull / Lift heavy
weight.(Tool & part )
Difference cycle time
in difference model
option work, incident work,
change over time
Repair / Rework
process
Have to repair / rework
before send the next
process
Advance operation
Over sub assy / Stock buffer
more than requirement
Double job / Over
inspection
Repeat / double job / over
Inspection / Work
unnecessarily
Long distance
Long conveyance time /
Complicate supply route
Many conveyance
methods per route
Long conveyance time /
Complicate supply route
Over necessary
stock
Over stock work in process,
large stock area, over
supply
- Rearrange work. ( Balance process )
- Apply equipment / tools to support.
(karakuri,pneumatic,hydraulic…)
3
- Apply equipment / tools to support.
(Manipulator, Hoist, Hanger,dolly,
shooter, etc.)
Fluctuation of cycle time not
over ± 5% of Takt time
Muri of
Workload
1
Mura of
Fluctuation
4
2
- Add / Modify machine / tools to
support.
- Rearrange work. (Pokayoke in begining
sequence)
- Set specific Pokayoke stop position
- Work load not match to production
ratio.
- Many model variation. ( Some model
has many option work )
Weight average cycle time = 95%
~ 100 % of Takt time.
- Rearrange work. ( Balance process )
- Keep heijunka condition.( Model ratio )
- By pass process
- Long cycle time job with Pokayoke.
(Machine Pokayoke)
- NG Pokayoke sequence setting.
- Pokayoke set at the end of process
due to Kanketsu condition.
Pokayoke setting area within
70% of Takt time
- Option work suffix.
- Incident work (Changing
dolly/tools/dies, empty box)
- Difference part / tools picking point.
- Part assy need setting or adjusting.
- Many model variation.
- Area limitation.
- No have equipment to support.
Part weight not over 20 Kg.
Tool weight not over 2 Kg.
Pull/Push force not over 5 Kg.
- NG process flow
- Not self completed process. (assure
major part done in process and can
confirm quality condition)
- No repeat job / operation
- Keep standard judgment.
- Self completed part in process
- NG layout
- NG route setting
- Many variation of supply quantity.
- Area limitation
- Part size / lot size supply control
- Shortest conveyance time
- Simple supply route
- Re-layout to direct supply.
- Compact line / area
- Combine process for short distance.
- Rearrange process flow
- Kanketsu activity
- Grouping process (part in process)
- Control stock area
- Automatic tool ( Shooter, hoist ,etc.)
9
- Area limitation
- Different line design
(Trim-->Chassis)
- Need special equipment.
1 method for 1 route
- Un-control area of stock.
- Supply don't match line require.
- Keep control standard stock
Stock = Transportation time
Takt time
Muda of
Conveyance
8
Muda of
Stock
10
Muda of
processing
7
- Update standard stock.
- Max-min stock control.
- Control ine speed.
Muda of
repair
5
- Machine error.
- NG material
- NG skill
- NG standard
- NG working environment
- No repair / rework process (in
production line)
- Keep good machine condition & PM
- Keep good part quality
- Develop & refresh operation skill
- Improve key point identification
- keep good environment
Muda of
over
production
6
- No Pull system
- Unsuitable of line speed
- Operation speed don’t relate with
part supply cycle.
Standard of work in process relate with
production require.
Heijunka production: WIP=1
Lot production: WIP= lot size
Assembly process
S/A process
E-Car
- Implement Kanban System
-Control Max-Min stock concern
Transportation time
Takt time
Stock part in process not over 1 Pcs. (Big
part) or 1 box (Small part) for next
round supply part
Hand
lif t
E- car
Line
E- car จอด Hand Line
1 1
1st
2 nd
Over stock
S/A Process
QG QC
Production
start
1 Pitch
Finish
Pokayoke
job
70%
If delay can't
cover with in
Takt time
Conveyor line Fixed station
NG OK
70%
100%
Cycle time
Pokayoke job
If delay can't cover
with in Takt time
T.T.
Ｓ F
S/A
Table
Many Stock
S/A
Process
Main line
A B C D E
actual takt
actual takt-5%
OPT work
Waight
average
LIMIT of
average
A B C D E
actual takt
actual takt-10%
OPT
W aig ht
averag e
LIM IT o f
averag e
actual takt+10%
Page 1 of 2

2. Fundamental TPS kaizen view point
(Issue on Aug 2'13 / Revise 02)
Category No. View point Illustration Possible Cause Standard Condition Countermeasure
Many times of
returning
Frequency of walk between
work position and flow-rack
Many working
position change
Number of movement for
change working position
(Buishuyaku)
Part area over
working area
Part area over working area
/ 1 pitch
NG work posture
Reach, bend (body), twist,
turning (body,face), looking
for
Double handling
Many handling job for parts
/ tools
Interfere process
Interfere of Man-Man, Man-
Part/Tool, Man-Machine
Multi processes
work together
Dual process, Continuous
process
NG time matching of
man & machine
Waiting machine operate /
home position
Weight average cycle
time lower than Takt
Waiting before start next
vehicle assembly
15
- Same part same process
- Rearrange work sequence
- Direct supply
- Grouping process
- Rearrange working position (Bui) &
suitable density.
- Design suitable working area
( Machine operation route, swing arm of
wagon dolly)
- Working in same position-same time
- Area limitation
- High density process
- Area limitation
- NG production line design
(overhead assy)
- Part/tool direction not match with
assy condition.
- Big size part
- Temotoka (STD. work posture)
(Movement within 1 reach)
- Body bend 45 degree
- Body turning 90 degree
- No have judgement by eye.
- Cannot keep same part in same
process.
- NG work sequence (pick & assy)
- 1 side supply condition.
- Many tools in process
Single handling part / tool
- SPS supply
- Sequence part supply
- Slim flow-rack
- Improve flow rack efficiency
- Rearrange work. (Balance process)
- Grouping job for working position
- Auto jig return (spot / spray)
Muda of
Waiting
- Different working position in
same working time.
- Keep standard density process.
( Ex. Conveyor : 2 processes in 1 pitch)
18
17
- Together work start different time.
- Safety condition (Clamp - Unclamp)
Together work start same time
- Work load unmatch to production
ratio.
Weight average cycle time = 95%
~ 100 % of Takt time.
19
Muda of
Motion
11
16
Part area within the length of
the pitch
- Apply equipment / tool to support
(Sliding seat, Stand, balancer, flow-rack
level, shooter, Auto turning)
- Lamp,light (DPS), voice signal. (for
judgement)
- Rearrange work.
- Modify machine to speed up.
- Add hand work while machine operate.
- Machine work & hand work unrelated.
- Low machine speed.
- Keep safety condition while machine
operating.
Must have hand work while
machine operating.
- Rearrange work
- Apply automation to support one
process operating.
( Manipulator, Hoist, Hanger, Auto spot,
Auto spray )
- Using synchronize dolly
- Relocate flow-rack to match with work
sequence.
- SPS supply
- Shooter supply
- Big part picking
- Many part assy.
- Flow-rack location not match with
work sequence.
1 pitch 1 return
14
13
- Long cycle time work (part quantity)
- Many part variation
- Big size part
- Long cycle time work
- Many model variation
12
0 ~ 1 working position change
０ TT.
Waiting
M/C operate
Right process
Left process
A
Interference
!
B
1
2
3
(Part area）
work area
1 Pitch
Flow rack
part area
work area
1pitch
1 Pitch
Flow rack
1
2
3
4 5
6
7
8 9
Flow rack
1
2
3
7
4
8 9
5
1 return
Wagon
6
4 working position
transfer
CF
LF
C1
C2
C3
L3
R3
C4
C3
C5
C9
C8
C7
L2 L1
L4
R4 R2 R1
LE
CE
L1 RF
RR
CR
LR
1
4
3
2
1
2
3
4
Jig
Fix Station
Conveyer Line
CF
LF
C1
C2
C3
L3
R3
C4
C3
C5
C9
C8
C7
L2 L1
L4
R4 R2 R1
LE
CE
L1 RF
RR
CR
LR
1
Jig
Conveyer Line
Fix Station
actual takt-5%
A B C D E
actual takt
Weight
average
LIMIT of
average
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