Page 26 - Toyota Annual Directory 2020-2021

Cycle Time reduction (sec) Change over reduction (sec)
263,6 sec 186 sec
Tab hoursworked)Welder80084*Prerecorded
P
P
Cup Holder
D
Glue Glue Skins
PU Align Weld RHS
Mbr 1 c/t Mbr 2 c/t older Process KaiIznietianl Yamazumi [s]
C
A
2 mbr process
40
30 A
n ation
- Reduce muda (hand,
Eliminate non value add. ReducedEnd pro - 27.7 labour hours / week reduction (-22%)
s
b
i
CA
2 mbr process
58.1
∑
/t reduction:1-1V8sid→eo71asn(-a4l0y%s)is -24.4
l
a
b
our hrs /wefeekeret)duction
Min Max Takt TCT Target: Reduce labour hours by 20%
Average
75.8
Mbr 2 c/t
Front Glue Rear Glue
2. FINAL CONDITION
D
2) Final Condition: Mbr 1 c/t
1
58.1
Takt TCT Average 9 mbrs / 2 shift
Min Max
Takt
TCT
Average
Kaizens:
C A 3) Result - time saved
FG Stillage
s co
REGIONAL HIGHLIGHTS
REGIONAL HIGHLIGHTS
Management Control Improvements UK: Competitiveness UK: Start of Year End of Year
AGC Internal Use Only.#
Start of Year End of Year SIPM
OECEG(i2n:%P)VL CupV2Hi4suo%aldisienrg PthreoacbensosrmKalitzyen X.X
ac
k
1) Initial Condition
1. With Illumination
D
hours worked)
Welder
75.8
UTE
Mbr 1 c/t
Min Max
3) Result - time saved
- 27.7 labour hours / week reduction (-22%)
26
Maintain & improve
2) Final Condition:
Mach9 minbres /C2 Tshirfteduction
Walk Way
Safety
UK:
#
H (avg point per practicalCaGct1i:v1it6e0sB) Armrest Wrapping Pro
X
Settingthestandard RXe.XgionalCoX.mX2petitMivaneunfaectsusrin+gsSp P 1)FF/RRArmrestC3e4ll5-R7emoteStudy
(SIPStMar:t SofigYenairficaEnntd of Year
incidents per million
End
of
Line
Setting the standard RXe.Xgional CoX.mX petitMivaenu
0
Target:-
hours worked)
X.X
X.X X.X
Front Glue
Rack
XX
XX seconds
0
0
0 Significant
10 WELD/EOL ΣCT EinOLcidents per million
- 27.7 labour hours / week reduction (-22%) No. of processes required (∑c/t /TCT)
Mbr 1 c/t
Mbr 2 c/t
Machine 1501
Initial Yamazumi [s]
FINAL YAMAZUMI [S]
c
m
n
ed
Mbr 1 c/t
Welder
Walk Way
End of Line
Min
Mbr 2 c/t
➤MbBrr1eca/ktout groups
= 1.3 (SOP) → 1.02 (2021)
Mbr 2 c/t Edge Wrap Target: reduce to 1 mbr process
Remote study:
S
Max Takt 3) Result - time saved
TCT Average
Initial Yamazumi - 160B [s] M
CHUT
E
Min
60
TARGET: RE-D27U.7 laCboEur hLoAursB/ wOeekUreRducHtionO(-2U2%R) S BY 20%No. of processes required (∑c/t /TCT)
P
elements between
➤ Transfer work elements between mbrs to redmucbers to reduce bottleneck c/t Tab
Small Walk s t i l l 6r 4e . q1 ' d
bottleneck c/t
Max Ta
Mbr 2 c/t
∑
c/t
red
Min
30
20
T10CT Average
Auto c/t
Target: Reduce labou
134s → 112s (-16%)
Tab 0A
Autoc/t
Min Max
Takt TCT Average Min Max Target:reduceto1mbrprocess
0 ∑c/t reduction:118s→71s(-40%) CELL LAYOUT
59.4
Average CHUTE - Video analysis 1
LABOUR SAVING (LABOUR HRS/WEEK)
Mbr 2 c/t
CHUTE
Small table for clips
OP
- 27.7 LABOUR HOURS / WEEK REDUCTION (-22%)
Takt TCT
CAROUSEL
HOLDING TABLE
10 5
114 69
FG Stillage
AGC Internal Use Only.
#
REGIONAL HIGHLIGHTS
Management Control Improvements UK: Competitiveness UK:
Competitiveness UK: SAFETY UK:
Competitiveness Improvement KPI
Safety UK:
SIPM
1SIPM CG 1: 160B Armrest Wrapping Process Kaizen
GyingKIPOI XX RN
acefEesatv
AL HIG
LIGHTS
hours wo
ed)
Target
0 avg. 1500pts
12 78 6 C A R O U S E L 3973
- Std work docs
- Breakout groups
k
Edge Wrap
Edge W
rap
70EdgeW0 SIPM
a ec t n
P I X X
2 8 45
Rear Glue
0 Man 20
ur
/
F
h
o
ro
nt G
lue
600Videoanalysis.
v
3
10
CELL LAYOUT
- Std work docs
- Breakout groups
64.1 62.9 55.4 71.0 71.0
-
s
52.4
2 We
lding
machi
ne
HOLDING TABLE
Rack
1) Init
i
MFainxal YamazumTia- k16t0B [s] TCT Average 50 at lower volume)
17
2 8 6
3 109
CAROUSEL
734 5859
6
FG Stillage
from mbr to rob - Improve 4s
4
11
n
c
table for
clips
Edge Wrap
70
Current
CH
tatus:
Mbr 1 c/t
CMoamx pactTakt
40
cell
Min Max
mrest Assy - Inital 10 Safe
rap Edge Wrap 707 6
59.4
1 CAROUSEL
1 mb4)rNperxotcsetespss:
20 - Yokoten to 162B (26hr scope)
Mbr1c/t Mbr2c/t =1.3(ASuOtoPc/)t →1.M0b2r1(c2/t021)Mbr2c/t 10
AGC Internal Use Only.
Setting the standSarpd aceRXeS.Xgaiovenadl CoX.mX p2et9itMmivaenunfaectsusrin+g sSpacefesatvyingKPI XX m2 X.XX
Visualising the abnormality X.X Visualising the abnormality X.X X.X
X.X Man/hour XX hours P 1) FF / RR Armrest Cell - Remote Study
Maintain & improve X.X MaPinrtoainc&eimspsroSveavedX.(XH/C) X.X
Man/hour XX ho
(SIPM: Significant incidents per million
Walk Way
Front Ar
Method:-
* Two teams
urs
X.X Machine CT reduction XX seconds
Front Armrest Assy - Inital
.99
2 m
X.X
(SIPM: Significant
1 ManaMgacehmineeCTnrtedCucotionntrolXXImsecponrdos vements UK: incidentsCpoermipllioentitiveness UK: ty UK:
Walk Way
0 92 Tab0
r
Welde9r0 End of Line
1
542
9
0
susrin+g sSpacefesatyingK
50 40
CG 2: PVL Cup Holder Process Kaizen
f
0
.XX
* KaizPen Pr1oc)eFssF / RR
* Reduce end
Process by >8's
R
2) Identify MUDA
AGC Internal UseOnClyE. SS
CG1 0
C 3) Confirmation
CG2
Glue Substrate
Glue Skins PU Align PU Align Weld
* Combine P
PU Align LHS
r
ocess
m2
605 504 403
hours 302 Rear Glue (SIPM201:
LHS 9 mRbHrSs / 2 shift
4) Result - timeSusbastvraeted
C 3 ) C- 7 o8 n f i r m a t i o n
f r o m c e l l .
9 808
0
Ta
b
X
160B variants: 1) Initial Condition
Kaizens:
D
2) Final Condition:
- Reduce muda (hand,
Eliminate non value add. ReducedEnd process combined
One process removed
K:
d o f Y e a r
1. INITIAL CONDITION
Final Yamazumi [s]
∑ reduction: c/t
Combined
Walk Way
Kaizens:
increases D 2) Identif Initial
t:hou Holder - Video analysis
in
atio
n
Cup
mbrs to reduce bottleneck c/t
7
0
624
90 (Hours/week)
AL HIGHLIGHTS
- Transfer work
60 50
still req'd
100
80 702
Competitiveness UK:
Safety UK:
Compact <LOGElOim>inate or Trim Process Kaizen <LOAGO5>) Next
2 oX.mX petitMivaneunfaectsusrin+g sSpacefesatvyingKPI XX m
160B
.1
Kaizens:
2. Witho1u6t0IlBlu
1. With Illumination
f e e t ) b y l a y o u t c h a n g e
# K a i z e n s W: a l k i n g
D 2 ) I d e n t i f y M U D A 100
4 ) R e s u
Front Glue
Remote2s.tuWdyi
t Illum
t) by
layo
ut
cha
nge
W
a
lk
- 3x Std work docs
t
s
b
4
0
- Breakout groups Remote study:
∑ reduction: c/t
W
a
lk W
ay
Compact
30 20 10
Initial K70aizen FinSaml all Walk
mvainrai
CG
VL CUP HOLDER PR
KAIZ
atinonts:
CG 2: PVL Cup Holder Process Kaizen Eliminate non value add. Reduced
- Video analysis
- 3x Std work docs - Breakout groups
1) Initial Condition
Cup
H o l d e r
134s → 112s (-16%) 160B variants:
D 2) Final Condition: bottleneck c/t cell
A
60
Study proscteislls r2efqur'dther. Could
2: P
EN
P
TWaeblder 0Tab
50 40 30 20 10
- Transfer work Waiting for machine 90
- Reduce muda (hand, End process combined
elements between Walk Way 80
ing Small Walk
702 (-12%)
1. With Illumination
134s →C1G12s: (M-1o6%lle) rtech Back Do Welder
- Reduce mu
da (hand,
59.4
52.4 2. Without Illumination
feet) by layout Ccohmabningeed Walking INITIACLGYA1M:A1ZU6M0IB[S]Armrest Wrap - Transfer work Waiting fo
160B variants:
fee
etween mbrs to reduce
elemen
Walk Way
Tab
W
a
iting for machine
Welder
End of Line
Welder
End of Line
combine if TMUK TAKT
Tab
cell
0
5) Next Steps -
F i nS aI Pl YMa m a z u m i [ s ] ➤ With Illumination
1 ) I n i t i a l C o n d i t i o n
2 ) F i n a l C o n d i t i o n 3 ) R e s u l t - t i m e s a v e d
C Walk Way
Remote study:
➤ W- VitihdeoouatnIlalluysmisination
D
elements between
X.XX
CG 2: Mollertech Back Door Trim Process Ka
P
59.4
75.8
58
mbrs to reduce
izen
52.4
- Utilise spare capacity
Tab Welder
P
- Redubceomttuldean(heacnkd,c/t
1) FF / RR Armrest Cell - Remote Study
X.X X.X
Man/hour Machine CT reduction
Initial Yamazumi [s]
XX hourMs in Max XX seconds
- Video analysis
- Std work docsP - Breakout groups
feet)
C A
3) Result - time saved
90 80
Welder
Mbr 1 c/t
- 3x MStbdrw2 oc/rtk docs RTeamkt -oBtreTeCasTktoutdAgvyreo:ruapges
Remote study:
CHUTE
(SIPM: Significant in➤cideVnidtsepoearnmalilylisoisn
1
56 9 y
OP CAROUSEL
2) Final Condition
Tab
CELL LAYOUT
Machine 1501
Walk Wa
8
FG Stillage
2 mbr process
Tab
Welder
W e l d i n g m a c h i n e
Front Armrest A
HOLDING TABLE
(-45%)
12 78 3
11
6 C A R O U S E L 2 10 95 7 34
from mbr to robot
4
134s → 112s (-16%)
CHUTE Small table for clips
Walk Way
➤ho3uxrsSwtdowrkoerdk)docs FinalYamazumi[s]
End of Line
1 mbr process
- T r a n s f e r∑m o r er ew do ruk c t i o n : 1) Initial Condition c/t D
-1Im6p0rBove 4s
Kaizens:
- Utilise spare ca - Reduce muda (
7
Mould c/t increase (accepCtabGle 2: - Transfer more
Sm
Oa l l P
Mbr 1 c/t Mbr 2 c/t Glue Glue Skins PU Align PU
Initial Yamazumi - 160B [s]
Final Yamazumi - 160B [s]
Min Max Takt 64.1 62.9
TCT Average
55.4 71.0 713 .0 9
CHUTE
2) Identify MUDA
C 3) Confirmat2iomnbr process
D
Walk Way
HOLDING TABLE
Auto c/t Mbr 1 c/t Mbr 2 c/t
Au
to Average Min
Substrate LHS
e
c/
t
M
br
1c
/
t
Mbr 2
12 78 6 C A R O U S E L 114105
2 7 34
856 9
Target: Reduce labour hours by 20%
Kaizens:
Min Max
Takt
TCT
59.4
Max
No. of process
feet) by layout change Walking ➤ Redu7c5e.m8uda (hand, feet) by
52.4
100
Takt TCT Ave = 1.3 (SO
Target: redu Initial Y
58-.1Transfer work Waiting for machine
90
80
70
60
50
layout change
kt TCT Average ∑c/t reduction:
uction:
134s ➤ 112s (-16%) r hours by 20%
3. RESULT - TIME SAVED
CG 2: Mollertech Back Door Trim Proces
Final Yamazumi [s]
52.4
INITIAL CURRENT
Welder
Combined
1) Initial C
ondition
160B
KAIZEN
Remote study:
D
W e l d i n g m a c h i n e
2) Final Co
P
128.4
Kaiz - Uti - Re feet - Tra fro
- Im
∑c/t reduction:118s
100.7
CELL LA
-27.7
YOUT
Machine 1501
No. of processes required (∑c/t /TCT) = 1.3 (SOP) → 1.02 (2021) Target:reduceto1mbrprocess
1 mbr process
Initial Yamazumi - 160B [s]
Final Yamazu
N
C
y
n r
s
h
wM o
R
oe P
s
a
s
n
e l d )
m p
→ m
c
Edge Wrap
Edge Wrap
Edge Wrap
Edge Wrap
X
X
Thinsulate pads Holding dolly
HOLDING TABLE
WELDING MACHINE
MWAECLDHINGE
M/C 1501
ThHionlsduinlagtedoplalyds
HOLDING TABLE
Thinsulate pads
WELDING MACHINE
M/C 1501
ThHionlsduinlagtedoplalyds
HOLDING TABLE
MWAECLDHINGE
M/C 1501
M/C 1501