1. My Safety declaration
My Safety declaration
“Do everything with Safety awareness”
“Do everything with Safety awareness”
Presentation time : 10 Mins.

2. Samrong Plant

3. Sub Material
Sand paper source change
Activity No. PD1.-VC.144/243
[4-1] Source change
Before
Before
Line: PDQC
Process: Polishing for cut check Housing.
Problem: High price
After
After
Improve by: Change maker to cost down.
Step improvement: 1.Find out new maker
2.Compare cost.
3.Small lot for test and summary.
No.600
No.150
Brand “HERMES”
Price:
300 Baht/Pcs
Tool life:
6 Pcs
Baht/Unit :
Cost :
50 Baht
20,000 Baht/Month
No.150
No.600
Brand “EKAMANT”
Price:
Tool life:
Baht/Unit:
Cost:
150 Baht/Pcs
6 Pcs
25 Baht
10,000 Baht/Month
4/7
4/7

4. Sub Material
Reused insert of Housing
Activity No. PD1.-VC.125/243
[3-1] 7R Technique >> Reused
Before
Before
Line: Housing main
OP260
OP190
Subplate facing
Deburr friction
New tool
Rough process
“Used”
Reused from finished process to rough process.
OP260
Subplate facing
New tool
New tool
Finished process
After
After
“Used”
Finished process
“Reused to OP190
rough process”
SCRAP BOX
Price:
150 Baht/Pcs
Tool life:
250 Pcs/Corner
Baht/Unit:
0.3
Cost:
4,500 Baht/Month
SCRAP BOX
Same.
Quality
No cost
for OP190

5. Sub Material
Sub Material
Reduce Foil by resize
Activity No. PD2.-VC.112/114
[3-2] 7R Technique >> Reduce
Before
Before
Line
: EDP&BUSH
Process : Chemical Check %NV
Detail : Use foil contain ED baking to find %NV
After
After
Improvement : Reduce Height of cup But still
the same cup base.
30 cm.
30 cm.
10
12
cm.
cm.
180 cm2/Cup.
100 cm2/Cup.
3 cm.
Foil Paper = 0.0019 Baht/cm2
ED Paint 10 g.
Don’t Effect for Contain ED Baking
Quality: Pass
Safety: Pass
5 cm.
Cost : 180 x 0.0019 = 0.34 Baht/Cup
Total Used 24 Cups.
1 Day Cost = 0.34x24x22 = 180.5 Baht/Month
2 cm.
ED Paint 10 g.
5 cm.
Foil Paper = 0.0019 Baht/cm2
Cost : 100 x 0.0019 = 0.19 Baht/Cup
Total Cost = 0.19x24x22 = 100.3 Baht/Month
Reduce Cost = 80.2 Baht /Month

6. Sub Material
Sub Material
Modify old Jig for Make Upper Clamp
Activity No. PD2.-FC.90/92
[3-3] 7R Technique >> Reused
Before
Before
Line
: Frame
Process : Small 3 LH,RH
Detail : Upper Clamp Spring No.4 Jig 1815,1816
Damaged By Use for 5-10 years.
Damaged
After
After
Improvement: Modify By use old jig from
Frame Line 2 for make Upper Clamp.
M/N
(Damaged only)
Change new part
(all set)
Upper Clamp
Supplier
Life Time
Used
Price
Cost
: S mate & gear
: 5-10 year
: 2 Unit in Process
: 5,500 Baht/unit
: 11,000 Baht/unit
Upper Clamp
Supplier
Life Time
Price
Total Cost
: Made by JDM PD 2
: During Study
: - Baht
: 400 Baht (labor Cost)
Reduce Cost = 10,600 Baht/Unit

7. Sub Material
Modify handle Chisel by use scrap
Activity No. PD2.-FC.91/92
[3-4] 7R Technique >> Reused
Before
Before
Line
: Deck
Process : Side Panel
Detail : Chisel for Process Senouke damage
from Hammer smashing.
After
After
Improvement : Modify By use Scrap weld on
Handle old chisel and used for percuss Spatter .
100 mm.
70 mm.
More long 40 mm.
but not effect
with Production
130 mm.
70 mm.
Quality : Sharp
Safety : Pass
Quality : Don’t Sharp
Safety : No Good
Used Length Remain 50
Life Time
Use
Price
Cost
%  Reject
Used until Length Remain 20
: 6 month
: 8 unit in process/2Shift
: 300 Baht/unit
: 300 x 8 = 2,400 Baht/6Month
Total Cost = 4,800 Baht/year
Steel
Stainless Steel
Stainless Steel
Detail
Life Time
Use
Total Cost
%  Reject
: Use Chisel increase 1 cycle
: 1 year
: 8 unit in process/2 Shift
: 300 x 8 = 2,400 Baht/year
Reduce Cost = 200 Baht/month

8. Repair & M/N
Localize rotary seal for overhaul ATC rotary interlock valve
Activity No. PM.-FC.251/256
[8-1] Localization
Back ground
Machine : Toyoda machine model FH-45II
Problem : Hydraulic oil leak from ATC Rotary Interlock Valve
Countermeasure : Period maintenance 3 year
Replace seal mechanical
Inter lock valve
Before
Before
Order rotary seal from japan
Rotary seal model “TG32-00800-T10N“
Brand Captain industry
= 1,500 Bht./set
ATC 1 unit use 5 set
= 7,500 Bht./Unit
Plan overhaul 40 units
= 300,000 Bht.
After
After
Rotary seal
Trial local maker to making.
Trial on NCM-0101 on Jul-2013 ok.
=
ATC 1 unit use 5 set
= 4,250 Bht./Unit
Plan overhaul 40 units
Rotating Shaft
Local making cost
850 Bht./set
= 170,000 Bht.

9. Thank You

10. Thank You