Page 27 - Toyota Annual Directory 2020-2021

CntInertneranl aUlsUesOenOlyn.ly. al Use Only.#
ternal Use Only. AGC Internal Use Only.
#
TEAM UK
CGCG1:11: 6106B0BAArmrmrersetsWt WrarpapipnigngPrPorcoecsesssKaKiazieznen CGSafe1ty:U1K:60B Armrest Wrapping Process Kaizen
Uy KU : K :
MPM
e
CHUTE
D
R
C
HIGHLIGHTS
afety UKC: ompetitiveness UK:
wokouerrsdkw)eordke)d) icant
million ed)
Walk Way
Tab Welder
Ta
b
90 Tab 90
8484
r Process Kaizen
ernal Use Only.
#
70 50 50 30
20 60 ➤ Pre recorded Video analy2s0is.
nc/dt ,
Tab
Welder
End of Line
enen
6%)
➤ WaitTabRackWalkWWaalkyWay
i
40 Line 30
60
still req'd
40 30
(LA7BO07U20R2HRS/W(-E1E(-K21)%2)%) Edge Wrap Edge Wrap 70
90
80 84
* Two teams
n:
P
1) Initial Condition 160B D 2) Final Condition:
te
(Hours/week)
nd, n g e
Compact
One proDce2s)sIdremntoifvyeiMndcUrDeAases C 3) Confirmation 4) Result - time saved
D 2) Final Condition: Front Glue
20 30 10 10
uda (hand, Ko:ut change work
etween duce
0
from cell. * Combine Process from*ceC*llo. CmobminbeinPerPorcoecsesss
a( hnadn, dD, mnillgioen
a
agement Control Improvements UK: 40Competitiveness UK: Safety UK: Method:-
cant
Walk
W
ay
100
92
ction:
∑Yearredu2c0 tion: SIPM * Two team20 s
6-1%6)%) /t
30 20 10
A
A
Average
C A
AvS
90
e gaege
No
=
1.3 (SOP)
→
Machine 1501
feet)
P
1) FF / RR A
60 50 40
still req'd
D
Glue Glue Skins PU Align PU Align
EOL
* Combine Process
HOLDING TABLE
1 1
HOLDING TABLE
71.0
71.0
(-45%)
D
6d0uHce LIGHCTSC3)3C)oCnofnirfmirmataiotinon
e savedSmall Walk
P
114 69
s
4) Next steps:
HOLD
ING TAB
LE
C
EL
L LA
YO
U
T
-45%)
Machine 1501
12
3 109 11 4
mall
table fo
1
64.1
62.9- Std work docs 55.4
55.4
160B
K a i z e n s :
P
:
(
C
78 6
C A R
CH
UTE
Pf)
1t.)0
1 7
of
6 CAROUSEL processes re
FG
Stilla
tillag
e
Welding machine
KAIZEN
23
8
= M12.b3r m2
23
c/t
C u r r e n t S t a t u s : - I m- I p m r p o r v o e v 4 e s 4 s
71.0
Auto c/t
Min
71.0
Mbr 1 c/t
Takt
.
geFG S quired (∑
- Std work docs
- Transferfrmaotmolorwmeebrwrvotolrukrmobe)ot 64.1 62.9 55.4
(
%)
Tab Welder
xt Steps - St*uPdryeprreoccoer0dssed2 further. Could A 5) Next Steps - Study prforcoefsrmso2mfcuertchlle.r.llC.ould
ca1hn2asg(n-e1g6%e)
Visualising the abnormality X.X
ed)
gWafolkraimlnkagicnhgine 134s → 1012s (9-016%) A
.
I1N) IInTitIiAal LCoCndOitiNonDITION 2) Final Condition 2. FINA3L) CReOsAuNlt -DtiImTeI
Elim
RXe
i
o
petitMivaenunfaectsusrin+g sSpacefesatvyingKPI XX
Front Glue
W
elde
r
Rear Glue
E
n
d of
ack Door Trim Process CKGaiz2e:nMollertech*BRaedcukceDenodor<TLrOimGPOro>cess
K a i z e n
6 264
Tab
- Video analysis 50
- Breakout groups
Combinebdottleneck c-/tBreakout groups
(-45%)
HOLDING TABLE
HOLDING TAB
LE
TWaeblder
#
AGC Internal Use Only.
MPachine CT reduction XX seconds
100
Walk Way
Tab WeldeTrab
Welder
y
-
l
70
60
* Two tVeidaeomansalysis. VidVeidoeaonanlyasliyss.is.
Front Glue
Substrate LHS RHS
20 ➤ Kaizen Pr3o0cess 10 10 10
Walk
W
ay
fgorfomr am
C 8o 0m
bi
ned
9X0X s9ec0onds 92
6
0
-78
MaiWntaainlk&iinm
50
(SIPM: Significant
from ce
ll.
Walking
Walk Way
a
b
We
ld
ingm
ne
123 78 9 6 C A R O U S E L
elding machine
incinrecaresaeses combine if TMUK TAKT
12 78
Remote study:
achi
i
ate non value a
dd. Redu
Front Glue
Rear Glue
Front Glue
Rear Glue
V60ideo an4a0ly4s0is.
VideToaaTrnageargltye:-sti:s-. *Reduceend
n
c
6 CAROUSEL
39 734
OMBINmEbDrs to reduce
el
der
60
still req'd
74
4
11
from m
to robot
60
12 78 6
39 734
10 5
85
D fromC mbr to robo4)tNext steps: 16106B0B
P P
D D
P
1) Initial Condition
2) Final Condition 3) Result - time saved
C A R O U S E L
Tab WelderWelder
Front Armr
st Assy8-4In
ital100808080 84
FrontFGrolunet Glue
Rack
Rack
2) Identify MUDA
Rear RGeluaer Glu40e
Glue GlueSkins PUAlign PUAlign Weld
EOL
WELD/EOL ΣCT
*SuCbostrmatebine ProcLeHSss RHS
* Kaizen Process
Target:-
1
7 1 . 0
CAROUSEL
7 1 . 0
3. RESULT - TIME SAVED
2 mbr process ➤ 160B Auto c/t Mbr 1 c/t
Kaizens: - Improve 4s Min Max Takt TCT Average
CHUTE
End of Line
Edge Wrap
End of Line
End of Line REadcEkgdegWeraWp rap
Welder End of Line
8
0
Method:-
92 90 70 70
D
2) Identify MUDA C
Walking 9 mbrs / 2
s
Walk
Way
W
a
lk
Way
- 7 -87 8
WaitiWn
5
) Ne
ldee
➤ Eliminate non value add. Reduced
d
Tab
70
Setting the staEW
radp aWr
in
ndegd
m
Tab
eW
r
ap
W
2
7 0 2 Video(a-n1a2lys%Ciso.)m bined
Wgprov
itainitgi n
X.X Man/hour
XX hours
LABOUR SAVING
g
for mach
n
Wa
c
Final Yamazumi [s]
Machine CT reduction
100
e
X
Waitingformachine
50
20 SmSamllaWllWalkalk
<LOGO> (Hours/week)
C
G
2
80
W ELD/EOInL
50 50 SsmtilallrleqW’dal*kCombineProceIssNITIAL
40
Target:-
* Kaizen Process
We
ldeWr
e
lde
r
Compact 70 Substrate 10 LHS RHS
Weld
EOL
30 20 10
624
:
P
Ed.gXg
7X0 nceall CoX.m
o
.X
X.
X
Target:-
Welder End of Line
2 (-12%) 60 60 0 Processby>87's0 40
9
2
85 9 6
30
b
r
859
from mbr to rostbillorteq'd
Welder FG Stillage End of Line
2 mbr process - 3x Std work docs 40
FG
Stillag
e
(Hours/week)
End of Line
50
(Hours/week)
3) Result - time s- Barveaekodut groups
40
Walk Way
2) Final Condition
1) InitiCaolmCpaoctndition 10
Initial Kaicz/ten Final
Walk Way
1 mbr p3r)ocResessult - timeinscarveeadses
e
80 80
hours worked) 80
70 * Pre recorded FURTHER. COULD
End of LEined of Line
Edge Wrap EdgeEWdgraepWrap
ho80urs worked)
80
80 80 * Pre recorded 92
* Pre recorded
* P*rPerrecreocrodreded
RackRack
Rear Glue
* Kaizen Process
9 mbrs / 2 shift
0 503030 0
WELD/EOL ΣCT
CG 2: Mollertech20
W a l Wk a W l k a W y a y
Tab 0 60
70 70
59.4 52.4Tab9mTabrs/2shift 30
60
COMB
30
20
VL Cup Hold
e
r
r
o
Edge WraEpdge Wrap30 70 20 60
50 50
30 7300
* Kaizen Process
60
Small Walk
O
1
50
INE IF TMUK
C
Walk Way 80 Walk Way elements between Glue
702 (-12%)
624 624
D D2)2I)dIeRdnEetGniftIyOifMyNMAmUbLDrUs tHADo rIeAG
70
4 ) 4 R ) e R s e u s l u t l - t t - i mt i me e s a s v a e v d e d
rmrest Cell - Remote Study still req'd Welder End of Line 50
Eliminate non value addb.oRttelednueckecd/tEnd process combined
One process removed
n
M2. IDENTIFY MUDA F3r0ont Armrest As3sy.- ICnitOal NFIRM
N-
E
2) IWdaelknintgEifliymMinaUteDnAon value add. R3e)dCuocendfirmInait9it
End of Line
80
P 1) FF / RR Armrest Cell - Remote Study One process removed
liminate non value addC. ReducedEn
d
Start of Year End o9f0 Compac
ahcinheine
50 70
incidents per millionincreases 624
Tab 90
B
40 90 10
60 Video analysis.
0 0
Small Walk
50
End
o
f
Front Glue
e
( H ( o H u o r u s / r ws / e w e e k e ) k )
f L GE i n n Pl due eo
Lin
cGeleuesSskinKs aPUizAleignPUAlign
1
00
100 90 702 (-12%) 80
70
70
60
50
40 80
Ed
ge W
rap
7
hift
AGC Internal Use Only.
EdgeEWdgraepWrap 90 90
70 70
* Two teams
84
10 50
40 40
10 20
10
20
Rack
TAKT INCREASES
30
40 20 20
30
* R*eRdeudcuecenednd * Kaizen Process
e
= 1.3 (SOP) → 1.02 (2021) Final Yamazu=m1.i3[Ks(S]aOizPe) n→s:1.02 (2C0u2r1r)ent Status:
Current Status:
increases
2: Mollertech Back Door Trim Process Ka
<LOGO
2 W e l d i n g m a c h i n e
N
80 70 60
60 60
50 80 80 60 84
* Pre rTaercgeot:r- ded
Com5b0ined 30 30 still reqC'd
2) Identify MWaUlkWDWaAalkyWay C 3) Confirmation 4) Result - time saved combine if TMUK
m
H o Wl d a l e k Wr a y
Small table for clips
CHUTE
Small table for clips
sfer more work 702 (-12%)
Study process 2 further. Could
Mi
x Takt 2
T
CT
e
r
T aPb W e l d e r
Welder End of Line 40
A
W
ELD
/E
O
L
ΣCT
Eliminate non value add. ReducedEnd proceCssocmompbinaecdt
160B variants:
Tab T1ab. With Illumination
CuWp aiting for machine 90
CHUTE
-78 from cell.
- R e d u c e m u d a ( h a n d , E n d p r o c e s s c o m b i n e d O n e p r o c e s s r e m o v e d
W a W l k a l i k n Wg a y
Machine 1501
I
n
i
t
Machine 1501
K
CELL LAYOUT WeldeWr elder Remote study: cecllell Mbr 1 c/t 2. Without IlluminatioMn br 2 c/t
CELL LAYOUT
n
a
te
n
o
n
v
n
Ma
a l l g We a l k a
CG 2
hlysBis ack Do
CHUTE
T
rCm2an
f
T W105
- Std work docs
0
- Std work docs
W
alk W
ay W
1
7
0
lements between
0
: Mol-leVidretoeacn8a0
r i m7 0 2P r o c C
1
so%sbfme)Kirnwba-eoirVdni
kizdeedonanalysis Waitingforma
100
Remote study:
feet) by layout change Walking
<LOGOc>ocmobminbeinief TifMTMUKUTKATKATKT
8
70 Small Walk
Compact
o
r
-oT1s (e
from cell.
ce
CAROUSEL
- Tra
nsfer m
ll
e
m
O
P
ore work 624
OP
CARO
USEL
1) Initial C- oBrneadkoituitogrnoups 2) Final Condition
FG Stillage Mbr 1 c/t D Mbr 2 c/t KaKizaeiznesn:
3)
s
u
lt
-
CELL LAYOUT CELL LCAEYLOL LUATYOUT
Min Max Takt TCT
Machine 1501
11 4
7 34 5859
red-uBrceaktou1tgmrRoubeprmsprotcesstudy:∑ reduction:118s→71s(-40%()-45%) Target:re-d2uc4e.to41lmabrporoucresshrs/w∑eerekdurcteiodn:u1c18tsio→n71s(-40%)
2 mbr pro5c8es.1s CHUTE 4
Welding maWcheinldeing machine c/t
9
78 4 59
s
Targ
from mbr to robot
1)
Current Status:
- 24.4 labour hrs /week reduction
- 7s Mould c/t increase (acceptable
FG Stillage
- Improve 4s - S-tdStwdowrokrdkodcoscs
CHUTE
6
t:
11 114 HOLDING TABHLEOLDING TABLE 1
OP CAROUSEL
1 mbr process frofrmombmrbtrotrorbobtot
at lower volume)
1(ScO/
10 5
11 4 6
c
/ t
➤ Improve 4s from mbr to robot
A
e
7
17
10 5 10 5
-24.4
Initial Y
bm
160B
- Yokoten to 1
2B (26hr scope)
Remote study:
FG Stillage
Max Takt TCT Average
No. of processes required (∑ /RTeCC
CHUTE Initial Yama-zuVmidie[os]analysis
CHUTE
➤ Reduce muda (hand, No. of processes required (∑c/t /TCT)
C
OUSEL
1.02 (2021) - Transfer more work
ELL LA
YOUT CHUTE Welding machine
1
2
- Std work docs
5.
- 27.7 labour hours / week reduction (-2
r clipsSmall table for clips )
tPr) b→pr1r.po02rc(oe20M
es1r )2
TarMgient:NreModua.xcoeftopTa1rkmtobcreTpsCrTsocees-
4) Next steps:
- Yokoten to 162B (26hr scope)
64.1 62.9
ge
- 24.4 labour hrs /week reduction
FG Stillage
c/t
a
m
a
z
5
64.1 62.9
Auto c/t Mbr 15c5/.t4 Mbr 2 c/t
CuCrurernretnSttaStuatsu: s:
INITIAL CURRENT
No. of processes required (∑
7
8 ➤ Std workc/tdocs
USEL
- T-raT➤nrasTnfreasnrfsefmerromroerrewewowrkokrk
Initia-l Y7asmaMzumoi -u16ld0B [cs]/t increase (FaincalcYeampatzuambi -le160B [s]
cs2b
s
2
2
- Video a➤naBlryeaskisout groups
A s s vr e Beraqr
2 mbr proces=s 1.3 (SOP) ➤ 1.02 (2021)
TargIenti:tRiaeldYuacemlabzouumr hio-u1rs6b0yB2[0s%] Final Yamazumi - 160B [s]
- Improve 4As
160B
1
c
/
t
Mbr 2 c/t
1
OP
CAROUSEL
Mbr 2 c/t
Auto c/t Mbr Auto- Uc/tilise spMabrre1cca/pt acity Mbr 2 c/t
Std
w
Average
2 mbr proce➤ss Utilise spare capacity
- R - e R d e u d c u e c me u m d u a d ( a h a ( h n a d n , d ,
55.4
1 m1 bm- 7rsbpMrropuoldrcoce/ctsiesncsresase (acceptable
NoN. o.fopfrporcoecsesesserseqreuqirueidre(d∑(∑ /T/CTC) T)
at lower volume)
kt
)N
e
Target: reduce to 1 mbr procescs/t c/t
∑c/t reduction: 118s ➤ 71s (-40%)
= 1=.31.(3SO(SPO)P→) →1.0172.01.(2020(2012)71.)0
1 mbr process
- Yokoten to 162B (26hr scope)
/TCT) Auto c/t TIaNTrIgaTeIrAgtL:erYte:ArdMeuAdcZueUcteMotI1-o16m10bBmr(bSpr)rporcoecses ss
Mbr 1 c/t Mbr 2 c/t
Min Max Takt
= 1.3 (SOP) → 1.02 (2021)
Max Takt 64.1 62.9 55.4
Initial Yamazumi - 160B [s]
646.41.1 626.29.9
64.1 62.9
c/t
4) Next steps:
- 2-42.4.l4ablaobuoruhrrhsr/sw/eweekerkedreudcuticotnion Current Status:
Auto c/t Mbr 1 c/t Mbr 2 c/t
reduction: 118s → 71s (-40%)
F i n a l Y a m a z u m i - 1 6 0 B [ s ]
Target: reduce to 1 mbr process
- 24.4 labour hrs /week reduction
Min
Max
Takt TCT Average Min
I n i I t n i a i t l i a Y a l Y m a a m z u a mz u i m - i 1 - 6 1 0 6 B 0 [ B s ] [ s ]
Final Yamazumi - 160B [s]
Auto c/t
AuAtoucto/tc/t
Mbr 1 c/t
MbMr 1brc1/tc/t MbMr 2brc2/tc/t
Takt TCT Average
Auto c/t
4) Next steps:
- Yokoten to 16(2B6H(2R6hSrCscOoPpeE)
Min Max
Min Max
Takt
TCT Average
TCT Average
Min
M ax Tca/kt TCT Average
- Yokoten to 162B (26hr scope)
MinMin MaMxax TakTtakt TCTCT AveArvaegreage Auto c/t Mbr 1 c/t Mbr 2 c/t
Auto c/t
Min
Min Max Takt TCT Average
c/t
A
)
l table for clip
- Utilise spare capacity
(LABOUR HRS/WEEK)
CHUTE
s
CHUTE
feet)Current Status:
1 mbr process
➤ Video analysis
- V-idVeidoeaonanlyasliyssis
2
Auto c/t Mbr 1 c/t
Mbr 2 c/t
55.4
A
- Y-oYkoktoentetnot1o6126B2(B26(2h6rhsrcoscpoep)e)
a
at lower volume)
HUTE
feet)
2)2F)inFianla CloCnodnidtiiotinon
3 )3R) eRseus
l u t l - t t - i mt i me e s a s v a e v d e d
C
23
624
#
CG1:1:601B6A0rmBreAst RWMrapRpinEgSPTrocWessRKaAiCzPGenP1:I1N60GB ArPmRreOst WCrEapSpSingKPrAocIeZssEKNaizen XarXSIPM SIPM
K:
P P 1 ) 1 F ) F F / F R / R R R A r A mC r G m r e 1 r s : e t 1 s C 6 t e 0 C B l e l - l A l R r - m e R m r e e m o s t t o e W t e S r t a S u p t d u p y i d n y g P r o c e s s K a i z e n
peXt.iXtXMivaenunfaectsusrin+g sSpacefesatvyingKPI XX m2 X.XX
igfinciafinctant P W1a)lkWFWaFalky /WaRy R Armrest Cell - Remote Study P
1) FF / RR Armrest Cell - Remote Study
Method:- Method:-
P Man/hour XX hours FroFnrotnAtrmArmesrteAstsAsyss-yIn-iItnailtal 100100 1) FF / RR Armrest Cell - Remote Study
/
RR ARMREST CELL - REMOTE STU
PM: Significant 1. FF (SIPM: Significant MethodF:r-ont Armrest Assy - Inital pemrilmlioilnlion Front Armrest Assy - Inital 100 92 90 90
ents per million 1) FF /
R
Armrest Cell - Rinecimdenots tper mSiltlioundy
Wal
k Way
R
Wal
k Way
Method:-
D
Y
9292 92
*9T*2wTowtoeatemasms * Two teams
90 90 90 90
Method:-
Front Armrest Ass
Rack
Inita
* Kaizen Process
0 5100*Reduceend 50 30 30 0
100100
combine if TMUK TAKT combine if TMUK TAKT
10 5
11 4 6
elder
40 40 A
1)InitialCondciteiolln D 2)FinalCPondi1t)ioInitialCondition 3)Result-Dtime9s2ma)bvrFse/in2dsahifltCondition C
* Reduce end
2 -mImbrpprorovcee4ss
∑ reduction:
- Improve 4s
s
e
* Two teams
0 EdgeWrap 10700
60 9600 VideoManeatlyhsios.d: 5050 60
Target:-➤ Two teams
40 40 84 * Pre recorded 40
9 mbrs / 2 shift 40Process by >8's
irmation D 2) Ide4n) tRifeysuMltU-DtAime savedC 3) Confirm➤atioRneduce*eR2n0ed4Pu)rcRoecseu0snlstdb0-yti>m8e’ssaved Kaizens: 20 00 0
Rear Glue
3) Conf
ΣiC
inal
* Kaizen Process
<LOGO> 24 <LOGO>
tTisalltlirlel qre'dKqa'dizen
702
F
Rear Glu
5)NextSteps- Studyprocess2 0
Kaiz2e0ns2:0 160B InIintiiatKliaizlens: KaKizaeiznen CURRENT 624
Weld
- Ut1ili0se10spaKraeizecnasp: acity
0 0 Elimi
l5 -78
- Utilise spare capacity
- Reduce muda (hand,
- Reduce muda (hand, -78
feet)
5
)
t
)
A
chin
e
1
00
C
PCG CGCG2:2M:MololellretretcehchBaBcakckDDooroTrrTirmimPrPorcoecseiszsesKnaKiazieznen10 <<LOLOGGOO>>
%) -2
7.N7ol.aobfopurohcoeussrses/ rweeqeukirreedd(u∑cti0o/TnC(T-2)2%)
Tab
Welder
Tab
Welder
CELL
cell c/t c/t
160B Combined combine if TMUK TAKT
<LOGO>
20
D
Compact
1 mbr process
0 A 5) Next Steps - Combined
Study process 2 further. Could
134s → 112s (-16%)
A 5) Neo.xotfSptreopcses-ses Sretuqduyirperdo(c∑ess/2TCfuTr)ther. Could
cell
Target: reduce to 1 mbr process ∑ reduction: 118sT→ar7ge1ts:(r-e4d0u%c)e itnoc1remasbers-p2ro4c.4eslsabour hr∑s /wreedkurcetdiounc:ti1o1n8s → 71s (-40%)
- 24.4 labour hrs /week reduction
CG 2: MOLLERTECH B5A9.C4 K D
T
OCESS KA
c/t
<LOGO> CG 2: Mollertech Back Door Trim Process Kaizen at lowe<r vLoOlumGe)O>
llertech Back Door Trim Process Kaizen
LAYOUT
52.4 - Reduce muda (hand,
accep
tab
le
Remote study: 1)1I)n-IinVtiidateiloaCalnoCanloydsnisidtiiotinon
mazumi -I1n6it0iaBl[Ysa]mazumi - 160B [s]
Initial Yamazumi - 160B [s] Final Y
C
Small table for clips
OP
Final Yamazumi - 160B [s]
Machine 1501
:
Mo
-
7
M1inmbMrapx rocTaekMst sin TCTMax AveTrakgte - Reduce muda (hand,
10 5
9
oAte3s)tRuesdulyt:-timesaved Tm
Smal
- Improve 4s
c/Rt eRmeomtoetsetusfetdeuty) d: y: OP CAROUSEL
feet)
umi - 160B [s] Final Yamazumi - 160B [s]
1
2 8 2 8 6 6CAROUSEL CAROUSEL 33997373
8 45 8 4
9 5 9
6 6
/TCT) - B-rBearekaokuotugtrogruopusps
euair∑ekdoru(e∑dtcugc/trio/nT:uC1p1T8s)s → 71s (-40%)
55.54.4
717.10.0 71.0 71.0
NEXT STEPS:
Mbr 2 c/t
∑
TCTc/t Average
- 7-s7Ms Mouoldulcd/tc/int cinrecaresaes(eac(aceccpetpabtaleble Current Status:
Small table for clips
- Utilise spare capacity
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Mo
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Small table for clips
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HOLDING TABLE
∑ ∑ rerdeudcFutINicotAniLo:Yn1A:1M181As8Z→Us M→7I1-17s61(0s-B4((0-S4%)0)%)
71.0 71.0
at➤alot2wl4o.ew4rleavbrovluormhlursem/)wee)ek reduction - 7s Mould c/t increase (acceptable
Final Yamazumi - 160B [s]
➤ 7s Mould c/t increase at lower volume)
-
45 la
A
TCT Average Min
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2
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Auto c/t Mbr 1 c/t
Mbr 2 c/t
Mbr 2 c/t Average
Min Max Ta 4
ps:
717.10.0
Mbr 1 c/t
MiMnin MaMxax TakTtakt TCTCT AveArvaegreage Mbr 1 c/t Mbr 2 c/t
Max Takt TCT Average 27
➤ (acceptable at lower volume) A A 4 ) 4N) eNx et xs t t es pt es p: s :
AuAtoucto/tc/t
MbMr b1rc1/tc/t
MbMr b2rc2/tc/t
Target: Target:-
Glue GlueSkins PUAlign PUA4lig0n Weld 20EO2L0
Process by >8's
2/s2hisfthift PrPorcoecses sbsyb>y8>'s8's 9 m9bmrsb/rs
10
9 mbrs / 2 shift Pr1o0cess by >8W'sEWLDE/LDEO/ELOΣLCTΣCT
Eliminate non value add. R- RedeudcuecdeEmnuddparo(hcaenssdc, om1b0ined EliminatGeluneGolnuevGallueGelSuakedindSsk. iRnPesUdAPulUcigeAndliEOgnPndUepApPWrlUroiogEcAncLeleDisgs/n➤sEcWrOoemLemClWΣdboCievnTmleddbinEOeLEPOrLocess * ReOdneupcroecessnrdemoved
CG 1: 160B Armrest Wrapping Process Kaizen
WELD/EOL ΣCT
Waiting for machine - Transfer w90ork Waiting for machine
Glue Glue Skins PU Align PU Align Weld
EOL Substrate0 LHSubSsturbaRsHtteSrate -78 LHSLHS
RHSRHS 0 -78 WELD/EOL ΣCT
feet) by layout change Walking
Process by >8's
* Combine Process
#
Glue Skins PU Align PU Align
3 ) C o n f S i mr ma l l a WS u t a b i l o s k t r n a t e 4 ) L H R S e s u l t R H - S t i m
Tab
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0ailonKaizen Final Initial Kaizen Final
c/t 100 Compact t10 80 84 10
End process c
X.XcXell mbined
ATIO
(Hours/week) (Hours/week)
748. RESULT - TIME SAVED 5. NEXT STEP 30
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uce
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from mbr to roboLtABOUR SAVING - Breakout groups (-45%)
m
*KaizenProcess * Combine Process
Edge Wrap
Edge Wrap
Edge Wrap Edge Wrap
Edge Wrap
Edge Wrap
Edge Wrap
Edge Wrap
<<LOLO>GGOO>> combine if TMUK TAKT
(-4
%
ThHionlsduinlagtedoplalyds
HOLDING TABLE
M/C 1501 M/C 1501
ThHionlsduinlagtedoplalyds
HOLDING TABLE
WELDING MACHINE
WELDING MACHINE
ThHionlsduinlagtedoplalyds
HOLDING TABLE
ThHionlsduinlagtedoplalyds
HOLDING TABLE
WELDING MACHINE
M/C 1501
MWAECLDHINGE
WELDING MACHINE
M/C
1501
M/C 1501
ThHionlsduinlagtedoplalyds
HOLDING TABLE
ThHionlsduinlagtedoplalyds
HOLDING TABLE
MWAECLDHINGE
M/C 1501
WELDING MACHINE
Thinsulate pads Holding dolly
HOLDING TABLE
ThHionlsduinlagtedoplalyds
HOLDING TABLE
WELDING MACHINE
M/C 1501
M/C 1501
YOKOTEN TO 162B
-4
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5
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X
X X
XX X
XX