Show up our Lean manufacturing solutions Poka yoke

1. KVL COMP Kft.
we solve it for you...
KVL201205JCXXVISA0001654XPvFR005.12
REDUCE
In business from 1996

2. FORWORD
This document is a visual aid of our
oral presentation and is not a
complete description of
ours activities…
2
http://www.musiciansfriend.com/pro-audio/nady-center-stage-microphone-and-stand-kit

3. Introduction
CONTENTS

4. 1996: Foundation
2005: MSZ EN ISO
9001/2000 qualification
KVL Comp Kft.
Izabella u.81
1064 Budapest
HUNGARY
KVL Comp s.r.o.
P.O BOX 44
94301 Štúrovo
SLOVAKIA
KVL Comp Kft.
Avenue Van Volxem 400-402
B-1190 Bruxelles
BELGIUM
4

5. KEY FIGURES
The following chart provides key highlights of the company.
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6. CONTENTS
what?

7. POKA-YOKE
mistake-proofing
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8. POKA-YOKE
mistake-proofing
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© KVL Comp. All rights reserved
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9. CONTENTS
why?

10. www.kvlcomp.eu
© KVL Comp. All rights reserved

11. http://www.gomonews.com/visa-pays-e2bln-to-push-mobile-payments/

12. CONTENTS
who?

13. Pharmaceutical
Computers & Electronics
Health & Beauty
Music/Publishing
Catalog/e-Commerce
Retail
Grocery & Convenience
Direct Marketing
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14. CONTENTS
How?

15. CASE STUDIES
01: Special equipement (e.g: glass roof workstation)
02: Pick-to-light shelf examples
03: Part conformity
04: Screwdriver workstation
05: ANDON system
ISSUE
CONSEQUENCE
SOLUTION
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16. ISSUE:
The operator picks up the wrong glass roof.
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17. CONSEQUENCE:
The error is discovered afterwards, when the part is already fixed into the bodycar.

18. SOLUTION:
Provide a system to check the part before assembling.
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© KVL Comp. All rights reserved

19. Bar code reader
1- The operator picks up the part.
2- The operator puts the part to the conveyor.
3- KVL checks the part number of the part and let the roof be installed.
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© KVL Comp. All rights reserved

20. CASE STUDIES
01: Spécial equipement (e.g: glass roof workstation)
02: Pick-to-light shelf examples
03: Part conformity
04: Screwdriver workstation
05: ANDON system
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© KVL Comp. All rights reserved

21. ISSUE:
The operator picks up the wrong part.
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© KVL Comp. All rights reserved

22. CONSEQUENCE:
The error is discovered afterwards, when the part is already fixed into the bodycar.

23. SOLUTION:
Provide a system to show the right part, and check the picking.
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© KVL Comp. All rights reserved

24. The correct location is shown by the light-
curtain by the red indication light.
The light-curtain detects
the hand and switch to
green color.
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© KVL Comp. All rights reserved

25. Here is an application of our Pick-to-light system along the engine line.
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26. The correct location is shown by the switch by the red indication light.
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© KVL Comp. All rights reserved

27. Video link
3 2 1
PICK-TO-LIGHT SUPERMARKET system.
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© KVL Comp. All rights reserved

28. Ajust the height of the indicator light
PICK-TO-LIGHT SUPERMARKET system.
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© KVL Comp. All rights reserved

29. CASE STUDIES
01: Spécial equipement (e.g: glass roof workstation)
02: Pick-to-light shelf examples
03: Part conformity
04: Screwdriver workstation
05: ANDON system
www.kvlcomp.eu
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© KVL Comp. All rights reserved

30. ISSUE:
The operator picks up the wrong part.
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© KVL Comp. All rights reserved

31. CONSEQUENCE:
The error is discovered afterwards, when the part is already fixed into the bodycar.

32. SOLUTION:
Provide a system to check the part before assembling.
www.kvlcomp.eu
© KVL Comp. All rights reserved

33. The operator has to scan the part before assembling. www.kvlcomp.eu
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© KVL Comp. All rights reserved

34. CASE STUDIES
01: Spécial equipement (e.g: glass roof workstation)
02: Pick-to-light shelf examples
03: Part conformity
04: Screwdriver workstation
05: ANDON system
www.kvlcomp.eu
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© KVL Comp. All rights reserved

35. ISSUE:
The operator forgets to tighten screw(s) or the tightening is not correct.
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© KVL Comp. All rights reserved

36. CONSEQUENCE:
A faulty screw of a lack of screw can cause critical damage for the vehicule.

37. SOLUTION:
Provide a system to make sure that all the necessary screws have been tightened correctly
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38. Displays the quantity of remaining tightening per tool.
The work is finished when the 3 displays are 00 00 00.
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39. Video link
- Controls until 3 tools.
- Radio communication based.
- Controls tightening and loosening.
- Disable the use of the tool if the work
is over or no need any work.
- If a torque is not correct, the systems
can count -1 or go to initial value.
MISSING
bolts? www.kvlcomp.eu
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© KVL Comp. All rights reserved

40. CASE STUDIES
01: Spécial equipement (e.g: glass roof workstation)
02: Pick-to-light shelf examples
03: Part conformity
04: Screwdriver workstation
05: ANDON system
www.kvlcomp.eu
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© KVL Comp. All rights reserved

41. ISSUE:
An anomaly is found during the production but cannot be pointed out to the team leader.
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© KVL Comp. All rights reserved

42. CONSEQUENCE:
The anomaly is not repaired from its origin, or will stop the production line for a while.

43. SOLUTION:
Provide a system to show up and visualize the anomaly by a quick look.
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44. 1- The operator has noticed an anomaly.
2- The operator points out the anomaly to his team leader by pulling the signal cord.
3- The team leader received an error signal from the display and go to the workstation.
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© KVL Comp. All rights reserved

45. Here is a KVL Andon system LED display in car maker application.
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© KVL Comp. All rights reserved

46. Here is a KVL Andon system plasma display in car maker application.
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© KVL Comp. All rights reserved

47. Visit us!
www.kvlcomp.eu
www.kvlcomp.eu
© KVL Comp. All rights reserved
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