TCT Lean Standard

1. Lean Manufacturing
System Lean Waste
Value
Lean
“ Lean Lean
Manufacturing Standard)”
Lean Manufacturing
Over Production
Lean manufacturing
1

2. Tel -
40
“ Lean
Lean Manufacturing Standard)”
2

3. Lean Assessment
3

4. PQ (Product – Quantity
Analysis)
Pareto
Chart Variety
Volume
PQ (Product 2
– Quantity Analysis)
326A Painting 15% Lean
& VSM
Logic
Chart
4

5. 3Logic chart
Logic chart
Paint Process
Conveyor, Paint Process
QC
Conveyor
C/T Conveyor
Speed
5

6. Kaizen Action Plan
6

7. TCT Value Stream Mapping: VSM (Before Improve) sh a - h
ift/d y rs
m su p idlu chBre k m s
in n a n a in
Production Ne Ava b e= m
t ila leTim in
F/C Control F/C
Monthly Monthly
Weekly Daily
Supplier
and Daily orders Customer
1 # TCT F1, 2 # TGT
3 # TCT F1, 4 # TCT F1
orders TGT, TCT F1
Daily Production Plan 27,943/mo. Per day
1 # 10,255 513
Delivery 2 # 7,500 375
Schedule 3 # 6,548 328
4 # 3,640 182
20 days/mo. 1,398
Daily
Daily
Ship
Pass CT Pass Pass
Mount Mounting Paint Dry Off Sanding
Preparing 1: 93.74% 1: 34.8 sec/2pcs. 1: 99.56% 1: 99.14%
Re ork
w 2: 73.89% 3: 64 sec/ 7 pcs. 2: 94.71% 2: 99.62%
Base
QA Incoming PS Incoming 4 6 4 0 3: 83.89% 15 4: 65 sec/ 8 pcs. 3: 99.01% 3: 99.58% Store
4: 82.07% C/O = 0 4: 98.44% 4: 98.52%
CT CT CT CT (Conveyor Speed)
sec/times
/ PC
2 1: 20 sec/2 pcs. 1: 21.50 sec/2 pcs. 1: 39.75 sec/2 pcs. 1: 40 sec/2 pcs. Avail = 27,600
Re ork
w Re ork
w Store
CT = 40 sec/jig.
2: 16 sec/2 pcs. 2: 17.00 sec/2 pcs. 2: 39.00 sec/2 pcs. 2: 40 sec/2 pcs. Re ork
w 0 Times/day sec. /1 shift.
0 sec/day
3: 45 sec/7 pcs. 3: 49.29 sec/7 pcs. 3: 46.50 sec/7 pcs. 3: 54 sec/7 pcs.
QC Uptime = 99% QC QA
C/O = 0 sec.
4: 48 sec/8 pcs. 4: 50.00 sec/8 pcs. 4: 49.75 sec/8 pcs. 4: 54 sec/8 pcs.
Avail = 27,600 CT 2
sec. /1 shift. 5 Masking 3
C/O = 0 C/O = 1200 C/O = 1200 C/O = 1200 Paint 2: 27 sec/2 pcs.
Uptime = 99% sec/times sec/times sec/times sec/times CT CT
CT
0 times/day 10 times/day 10 times/day 10 times/day 2 1: 20 sec/ 2 pcs. 1: 10 sec/ 2 pcs.
1: 18 sec/ 2 pcs.
Pass 0 sec/day 12,000 sec/day 12,000 sec/day 12,000 sec/day 2: 25 sec/ 2 pcs. 2: 10 sec/ 2 pcs.
2: 21 sec/ 2 pcs. C/O Jig =
1: 95%
65 sec/times 3: 51 sec/ 7 pcs. 3: 15 sec/ 7 pcs.
3: 45 sec/ 7 pcs.
2: 95% Avail = 27,600
6 Times/day sec. /1 shift. 4: 52 sec/ 8 pcs. 4: 15 sec/ 8 pcs.
Avail = 32,400 Avail = 32,400 Avail = 32,400 Avail = 32,400 4: 44.38 sec/ 8 pcs.
3: 98% sec. /1 shift. sec. /1 shift.
sec. /1 shift. sec. /1 shift. 390 sec/day Uptime =
4: 97% 76.84%
Uptime = 99% Uptime = Uptime = Uptime =
62.98% 62.98% 62.98%
Production Lead
Time = 4 Days
2hr. 29 min.
80 min. =
3 days. 48 sec. 50 sec. 50 sec. 4,800 sec. 27 sec. 65 sec. 1 day. Value Added Time
Remark:
= 1 hr. 24 min.
10 min. 9 min. 20 min. 20 min. 6 min.
30/07/2555
7

8. 1) Work Site Control
4 Work Site Control @
Mounting, Painting Process
2. VSM
3. 3
Paint C/T
Booth
C/T
C/T Paint Process
Mount Process QC Process C/T
Conveyor Speed
Jig Hanger
Hanger Jigs ( Jig
)
Hanger Mount
Mount
Paint
Mount C/T Jig
8

9. Mount , Internal External
Work site control
7 Visual Control 8
Jig
Kaizen
ANDON
9 Kaizen 3
Andon
9

10. Kaizen
SMED
Mount JIG
QC
10 Kaizen
SMED
Kaizen Stand
Stan
11 Kaizen
Kaizen
1.
Defect
2.
3
/JIG
12 Kaizen
@ Kaizen 10
Mount

11. TCT Value Stream Mapping: VSM (After Improved) sh a - h
ift/d y rs
m su p idlu chBre k m s
in n a n a in
Production Ne Ava b e= m
t ila leTim in
F/C Control F/C
Monthly Monthly
Weekly Daily
Supplier
and Daily orders Customer
1 # TCT F1, 2 # TGT
3 # TCT F1, 4 # TCT F1
orders TGT, TCT F1
Daily Production Plan 27,943/mo. Per day
1 # 10,255 513
Delivery 2 # 7,500 375
Schedule 3 # 6,548 328
4 # 3,640 182
20 days/mo. 1,398
Daily
Daily
Ship
2S QCO
Pass CT Pass Pass
Mount Mounting Paint Dry Off Sanding
Preparing 1: 93.74% 1: 34.8 sec/2pcs. 1: 99.56% 1: 99.14%
Re ork
w 2: 73.89% 3: 64 sec/ 7 pcs. 2: 94.71% 2: 99.62%
Base
QA Incoming PS Incoming 4 6 4 0 3: 83.89% 15 4: 65 sec/ 8 pcs. 3: 99.01% 3: 99.58% Store
4: 82.07% C/O = 0 4: 98.44% 4: 98.52%
CT CT CT CT (Conveyor Speed)
sec/times
/ PC
2 1: 20 sec/2 pcs. 1: 20.00 sec/2 pcs. 1: 20.00 sec/2 pcs. 1: 20 sec/2 pcs. Avail = 27,600
Re ork
w Re ork
w Store
CT = 40 sec/jig.
2: 16 sec/2 pcs. 2: 35.00 sec/2 pcs. 2: 40.00 sec/2 pcs. 2: 40 sec/2 pcs. Re ork
w 0 Times/day sec. /1 shift.
0 sec/day
3: 45 sec/7 pcs. 3: 44.57 sec/7 pcs. 3: 50.00 sec/7 pcs. 3: 54 sec/7 pcs.
QC Uptime = 99% QC QA
C/O = 0 sec.
4: 48 sec/8 pcs. 4: 47.50 sec/8 pcs. 4: 52.50 sec/8 pcs. 4: 54 sec/8 pcs.
Avail = 27,600 CT 2
sec. /1 shift. 5 Masking 3
C/O = 0 C/O = 624 C/O = 624 C/O = 624 Paint 2: 27 sec/2 pcs.
Uptime = 99% sec/times sec/times sec/times sec/times CT CT
CT
0 times/day 10 times/day 10 times/day 10 times/day 2 1: 20 sec/ 2 pcs. 1: 10 sec/ 2 pcs.
1: 18 sec/ 2 pcs.
Pass 0 sec/day 6,240 sec/day 6,240 sec/day 6,240 sec/day 2: 25 sec/ 2 pcs. 2: 10 sec/ 2 pcs.
2: 33 sec/ 2 pcs. C/O Jig =
1: 95%
65 sec/times 3: 51 sec/ 7 pcs. 3: 15 sec/ 7 pcs.
3: 45 sec/ 7 pcs.
2: 95% Avail = 27,600
6 Times/day sec. /1 shift. 4: 52 sec/ 8 pcs. 4: 15 sec/ 8 pcs.
Avail = 32,400 Avail = 32,400 Avail = 32,400 Avail = 32,400 4: 43.88 sec/ 8 pcs.
3: 98% sec. /1 shift. sec. /1 shift.
sec. /1 shift. sec. /1 shift. 390 sec/day Uptime =
4: 97% 76.84%
Uptime = 99% Uptime = Uptime = Uptime = 2S
80.74% 80.74% 80.74%
Production Lead
Time = 4 Days
2hr. 19 min.
80 min. =
3 days. 48 sec. 50 sec. 50 sec. 4,800 sec. 27 sec. 65 sec. 1 day. Value Added Time
Remark:
= 1 hr. 24 min.
10 min. 9 min. 10.40 min. 20 min. 6 min.
30/07/2555
11

12. 74.54% 92.62% 18.42
15% (24%)
Jig Order = 801.57
baht/jig.
Good passed = 70%
C/T = 44.41 sec/jig.
C/T = 37.11 sec/jig.
1 = 57,600 sec.
jig
- C/T = 907.90 jig/day.
- C/T = 1,086.50 jig/day.
- = 178.60
jig/day.
- = 143,157.31
baht/day.
- 1 =
3,435,775.56 baht/month.
- Model
-
12

13. -
- Lot
- Robot
-
- U-Cell Motion Study
Lean
13