Page 28 - Toyota Annual Directory 2020-2021

KPI
BEFORE
Maintain & improve
X.X X.X
X.X Man/hour X.X Machine CT reduction
XX hours XX seconds
REGIONAL HIGHLIGHTS
AG AGC Internal Use Only
REGIONAL HIGHLIGHTS ManagementCoCmopnettitrivoenleIsms EpU:rovements UK: SAFETY EU: CompetCiotmivpetintivesnsessUImKp:rovement KPI AGC Internal USseaOfen
Process Saved (H/C) 9,5
AGC Interna
Start of Year End of YSeIaPMr (avg point per practical activites) S
REGRIONAL HIGHLIGHTS
EGIONAL HIGHLIGHTS REGIONAL HIGHLIGHTS
2 MSeatntainggemthensttCanodnatrodl ImproRvXe.mXgeinotsnUaK:l CoX.XmpeCotmitMpievatneituinfvaecenteussrsisnUg+Ks:pSaacefseavtiyngKPIXXSamfety UK:
Space Saved 66
2516
2 5m
2.83
Visualising the abnormality X.X X.X Man/hour
XX hours
Cycle TMimaenraegdeucmtioen(tseCco) ntrol23Imsepcroonvdes ments UK: CompTeatrigteitveness UK: ManagemStaernttoCf oYenatrol ImEnpdrofvYeem(aSreIPnMt:sSUigKni:ficant Competitiveness UK:
Safaevgt.y15U00Kp:ts
SIPM Safety(USIPKM: :
MChaaingteaionve&r reimdupctrionv(esec) 39X3.7Xseconds X.X Machine CT reduction incidents per million
XX seconds
incident
RXe 0.X%
gional CoX.XmpetitMivaneunfacetusrsing+spSaacefseavtiyngKPIXX m
Start of Year End of Year
Setting the stanOdEaErd(in %) Start of Year End of Year
SIPM
SIPM
X.XX Setting the standard RXe.Xgional CoX.XmpetitMivaneunfacetusrsing+spSaacefseavtiyngKPIXX m 2 X.XX
Man/hourCG1 XXhours2 MaVinistuaainlis&inigmthperoavbenormalityX.X X.X X.X X.X Machine CT reduMctaionn/hour XX sXeXcohnodusrs
CG2
BEFORE AFTER BEFORE AFTER ManBaEgeFmOeRntEControl Improvements UK: Competitiveness UAKF: TER
1 Operator
1
1 Operator
1 1
Disuse of repacking operation
1 Operator Disuse of repacking operation
Sta • V
ASSEMBLY Q-WALL
VISUAL SYSTEM
111
Deck Bo
D De
Maintain & improve
X.X 1 Operator
X.X 1 Operator
Machine CT reduction1 Operator XX seconds
operator
1 Operator
operator
operator
1 Operator
1 Operator ELIMINATE REPACK OPERATIONS
DisuseofrepackiBnEFgORoEperation Disuse
AFTER
0,5 operator
1,0 operator
Interprocesses stock
0,5 operator
Interprocesses stock
1,0 operator
Interprocesses stock
INTERPROCESSES STOCK
ASSEMBLY
1,5 operators
1,5 operators
1 Operator
1 Operator
1 Operator Autoneum Genk
1,5 operators
1,5 operators
De Sta
operator
operator
AFTER Interprocesses
1,5
operator
BEFORE BEFORE
o
BEFORE
0,5
operator operator
Interprocesses stock
ASSEMBLY ASSEMBLY
ASSEMBLY DEVICE
AFTER
INJECTION
2 I4nt9erpmrocesses
0,5 stock BEFORE
STANDARDTOOLS USEDDURINGACTIVITY ASSEMBLY
INJECTION
ASSEMBLY
Interprocesses stock
INJECTION
0,5
operator
0,5 operator
1,0 operator
1,0 operator
stock
oito UK Bourbon Automotive Plastics Brink BrinkDisuse of repAuatocnekuimnGgenok peration
28
Interprocesses stock
Interprocesses stock
1
ASSEMBLY
ASSEMBLY
23 m 2
Operator
1 Operator STANDARDTOOLS USEDDURINGACTIVITY
hours worked) 2
AGC Internal Use Only. hour
Visualisingtheabnormality X.X X.X
Setting the standard RXe.Xgional CoX.XmpetitMivaneunfacetusrsing+spSaacefseavtiyngKPIXX m(SIPM: Siginificant X.XX
Visualising the abnormality X.X REGIXO.XNAL HIGHLIGHMTaSn/hour XX hours
(SIPM: Siginificant
PROCMEainStaSinC& AimPprAovBe ILITYX.XIMPROVXE.XMENT - RMEaMchinOe CVTEredQucAtionWALXXLsecoincdidsents per million
(SIPM: Siginificant Maintain & improve X.X X.X Machine CT reduction XX seconds hours worked)
Management Control Improvements UK: Competitiveness UK: Start of Year End of Year
incidents per millio
Setting the standard Visualising the abnormality
RXe.Xgional CoX.XmpetitMivaneunfacetusrsing+spSaacefseavtiyngKPIXX m2
X.XX
(SIPM: Siginificant incidents per million hours worked)
• V •
HEADCOUNT
SPACE 49 m2 23 m2 -26m2 ➤ -53%
2 operators
1 aperator
-1 ➤ -50% Process capability improvement - Remove QA👍wall
Process capability improvement - Remove QA wall
AFTER
BENEFITS
Standard • Video A
Process capability improvement - Remove QA wall Process capability improvement - Remove QA wall
Process capability improvement to remove the QA Wall
Process capability improvement to remove the QA Wall Process capability improvement to remove the QA Wall
AGC Internal Use Only
Safety UK: SIPM
X.XX
(SIPM: Siginificant incidents per million hours worked)
Process capability improvement to remove the QA Wall ProcesSsTcAaNpDaAbRiDlitTyOiOmLSprUoSvEeDmDeUnRItN-GRAeCmTIoVvITeY QA wall
STANDARDTOOLS USEDDURINGACTIVITY
STANDARD TOOLS USVEDIDEUORINAGNACLTYISVISTY+ PROBLEM SOLVING REPORT
STANDARD TOOLS USED DURING ACTIVITPYrocess capability improvement to remove the QA Wall STANDARDTOOLS USEDDURINGACTIVITY
VVIDIEDOEOANANLYASILSY+SPISRO+BPLREMOBSOLELVMINSGORLEVPOINRGT REPORT VIDEO ANALYSIS + PROBLEM SOLVING REPORT
REGIONAL HIGHLIGHTS
VIDEO ANALYSIS +SPTRANODBALREDMTOOSLOSLUVSIENDGDUREINPGOARCTIVITY AFTER VIDEO ANALYSIS + PROBLEM SOLVING REPORT
BEFORE
Start of Year End of Year
Setting the standard RXe.Xgional CoX.XmpetitMivaneunfacetusrsing+spSaacefseavtiyngKPIXX m2
Visualising the abnormality X.X X.X Man/hour XX hours
BEFOREBEFORE AFATSSEAERMFTBLEYRWITH
Operator
BEFORE AFTER
Standard • M&I Ana
Disuse of repacking operation Disuse of repacking oper
1
Disuse of repacking operation Disuse of repacking operation
Operator Operator
Disuse of repacking operation Disuse of repacking operation
i
STANDARD TOOLS USED DURING ACTIVITY
VIDEO ANALYSIS + MTM
23 m
2
STANDA2RDTOOLS USEDDURINGACTIVITY
49m STANDARDTOOLS USEDDURINGACTIVITY
St Sta
VIDEO ANALYSIS + MTM
STANDARDTOOLS USEDDURINGACTIVITY
VIDEO ANALYSIS + MTM VIDEO ANALYSIS + MTM
• • M
AFTE23Rm Process capability improvement - Remove QA wall
BEFORE
Interprocesses
stock
INJECTIONASSEMBLY ASSEMBLY
2
23 m
49m 49m2 2
STANDARDTOOLS USEDDURINGACTIVITY 23m 23m2 2
49 m
2
49 m
2
VIDEO ANALYSIS + MTM 23 m Process capability imIpNrJoECvTeImONent to remove the QA Wall
VIDEO ANALYSIS + PROBLEM SOLVING REPORT
1,5 operators
Lighting Systems IP Plastics Tow bars
Towbars Deckboard STANDARDTOOLS USEDDURINGACTIVITY
Deckboard
1,0
INJECTION
2
Disuse of repacking operation
VIDEO ANALYSIS + MTM
IN
CTI
epacking operation
AFTER
JE
ON
AFTER
f
r
IN
N
a
n 1 Operator o
JE
t
CT
IO
3023
incidents per million
Safety UK: Sta
hours worked)
SIPM hours worked)St
#
INJECTION
ASSEMBLY
INJECTION
INJECTION
INJECTION
INJECTION
ASSEMBLY
ASSEMBLY
INJECTION
ASSEMBLY
ASSEMBLY
INJECTION
INJECTION
INJECTION
INJECTION
Assembly device
SYSTEM Assembly
SYWSTIETMH
ASSEMBLY
ASSEMBLY ASSEMBLY
Q-WALL
Q-WALL Q-WALL
Assembly device
ASSEMBLY WITH
ASSEMBLY WIATsHsembly
device VISUAL
AVSISEUMABLLY
device
SYSTEM ASSEMBLY
INTERPROCESSES STOCK
ASSEMBLY ASSEMBLY
Assembly device
VISUAL ASSEMBLY
Q-WALL ASSEMBLY
Q-WALL
ASSEMBLY WITH WITH
WITH
VISUAL VISUAL
Q-WALL
SYSTEM VISUAL
SYSTEM SYSTEM