Page 30 - Toyota Annual Directory 2020-2021

AKPR-ESC Part
REGIROENGAILOHNIGAHLLHIGIGHTHSLIGHTS
AGC Internal Use Only.
#
OM/TOEIMmOB 402B PROJECT
- Create3xM&
aPratrt PaPratPrtarPt
- Machine C/T I
REGIONAL HIGHLIGHTS
Competitiveness TK: SAFETY TK:
Competitiveness Improvement KPI
(avg point per practical activites)
Start of Year End of Year SIPM
Management Control Improvements TK: Competitiveness TK:
4861
SIPM
l
lOysne.
REGIONAL HIGHLIGHTS
Safety TK:
PPH improvement in forming-assembly
Cycle Time reduction (sec) 360 seconds
bnormality X.X X.X (SIPM: SignificantMan/hour
XX hours
#
#
#
#
Management Control Improvements TK:
PPH improvement in
Setting the standard X.X
X.X
forming-assembly I avg. 1500pts
Change over reduction (sec)
39 seconds
incidents per million Target
& improVviseualising the aXb.nXormality
OEE (in %)
Machine CT reMdaunc/htoiourn
Regional Competitiveness + SafetGyHKPI
X.
X
hours worked)
(
incidents per million Impact Before
Competitiveness TK: 2
REGIONAL HIGHLIGHTS
X.X.X X.X
Start of Year End of Year
IREOIROEGNREGNIGAOEIA
C G2 1 Setting the standard X.X X.X Manufacturing space saving XX m
RREEG
OLNIHAOHNAILNGIALGHAHLHI
RG
OG
mprovements at Press, Welding and Paint Shops
85 4) 4La) yLoauyot1u1w4t%a)wsL4ac)syhLoaca4uhny)tagoLnweua4dgtyae).oswdLuca.thsywaocnuah 3) Owen isolatioL 1) Owen parameters were setup again
PartRESULT-SC/T Improvement at Quality Control Area - C/T Improvement at Quality Control Area
4P)ALRaTyout was cPR 2) Offline side of the owen was repair
LIN
LHGI
COMPETITIVRReEegNigoiRonEeRnaSgealRiSgCloeiCRonogIomeMainomglapniClPopeaoCnetlRmoiatCtimOilptoviCemevpVotenepimEneteiesMvptsiseievts+nteiEvi+entSeNiseaSvnsafseTes+fnseSt+eSsytasyS+KsfaKPeS+fPtIaeySIfteayKtfPKye h
Start of Year End of Year
IPt
ine 10 ImBpeaImfcBotperaefIocmtrepacItmAB
SeStetitntgintgShetehtSsteitntasStgtnieandtnghtaSdiernetadhtgsrtetditanhsngteadtsnahtdreadanXsArdt.dKXan.PrXdRaErSdXO.XT.OXXM.XO.XT.XIXV CGX.XMX.MEXEXMaT.nXIauNXnfG.uaXfcMaMtucaM&truninarIuMginAfnausCgacpfnMYtsaupIcVarfateiaunIncTcsruegYtiafnusavCgarpicnivOatnsgiupcngMreagisncPspegaLavEscsiaXpTenvXEagXsicDnamXevgmisFnaOgvXRinXgTXmHX EXmX mXX m X Regional Competitiveness + Safety KPI
14S Manufacturing space saving XX m
#
REGIONAL HIGHLIGHTS
2
2
2
222
Impact PHPPH PPH
Setting the standard X.X X.X Manufacturing space saving XX m2 ViVsuisauliasliinVsgiinsVtughiasteVulhisaeisiblnuiaVsngabiionlsntirughsomiaentrlhmagiaselbitatnhanlygiebotyntrahmobernamaloibtarynmlXiot.ayXrlmi.tXyalityX.X.XX.X.X.X X.X.XX.X X.X MMana/nh/ohuMoruaMrna/Mhno/XahunXMoXr/huXhaornohu/uohrusoXruXsXrhXoXhuXorsuhXroXsuhros u
M
LI
a
GH
c
h
GIHI
GH
in
IHL
GH
LI
TG
HILT
GS
IH
SL
IT
GHTSHTS
182182 INSULATOR SUB ASSY DRIVE SHAFT HEAT PART OF 402B PROJECT (SI(PSMIP:MSi:gSi(niSgiIifPni(cMSiafIinPc:a(tMSniIg:tPiSMn(iSigf:IiPncSaMifgniic:tnaSinfigitciannifticant C
Visualising the abnormality X.X X.X Man/hour XX hours MMainatinatinaMi&naM&inmatMiimapniratnpoaiMnrv&ionteavi&imientipma&rionpimvr&eopXvirm.eXo.pvXeroveX.X.XX.X.X.X X.X.XX.X XM.XMacahcinheinMCeaTMCcrThaeMicrdnheuaedincMCuhteTicaionCtcrnieTohendiCrneuTedcrCtueiXTcodXtnXurioesXcnedtsicuoeocncntoXidonXsnXdsXsecXsoeXncsoXdenXscdossencdosnds
ImpImropvreomvemntIemnpt rIPmoPvpHermoImveepnmrtoIevmneptmroenvet AKPRES OTOMOTIV CG MEECTOINGMMP&EI ATCIYTIVIVITYECNOMESPLSETIEMD fPorRthOeVINESUMLAETONRTSUSB ASSY DRIVE SHAFT HEiAncTiindcPeidnAetRsntpTisenprcoieimdnf(reScimlinIldPitnoieMslclniipo:dteisnSenrinpcgmiteidnsrieilpfmlnieoctirasnllnimpotenilrliomnillionImprovement
402B PROJECT
nternal Use Only.
#
Maintain & improve X.X X.X Machine CT reductioAnGC InterXnXal sUesecoOAnGnldCys.I
line Week Impact Before After
PPH improvement in Management Control Improvements TK: Competitiveness TK: SahfoehutorysurwTsowKrkioh:nerocdkuihed)rodesu)nwhrtsos urwpkreohesrodwkum)eor#disrlW)lkwi#oeoWodrnkr)oiknrkegidSnhg)#ifStWh/if#otrW/kion#rgkWSinhogirf#tkSWhi/nifgotrS/khi
OTIV CG MEETING M& I ACYIVITY COMPLETED for the INSULATOR SUB ASSY DRIVE SHAFT HEAT hPoAurRs wTorkoedf)
AKPRES OTOMOTIV ‘s EXPECTATION and the TARGET
formWineWegk-eaesksembWleyeW#kWeeokWrkeienkgWSeheifkt /
Impact A-KAPCKR/PETRSEIOAmS KTOpAPOTrKRMoOPEAvMROSKeEPTOmASIRTVTKOEeOIPVCSTnMRGOtCEOMGTaMSTOtOMEIMQVETETOuIOCEVIaMGNTClIGiNOMVGtyGTMCEMICGEVM&TEoMC&IEnINGTAtEIGIrCENMAoTYMGClEINVYA&EMIGTrVTI&IeYINMATaIGCY&AOYCMCIMOVYA&IMPITCVLIYPIEATILCTVCYEOEIYTCTDMIEYOVDPIfCMToLOYfrEPoMTtLCrhEOPteDThLMEIEeNDfPToISELNrUfEDSotTLhUrEAfet UeLTSABOUINTSRALSOSASYURTSULDOYSABRUDTIARBVOSSIUERAVSBYSESHSUADSYASHRBDFSIAVTYRFSEIHDTVSSERYHEHAIEDVSATAHERFPTIATSVAPHFHERTAImETSRHpFAHaTcEoTtAfHoPFTETfAAPRHBTAeTfEoRPrAeoTATfRoPTAfAfteRor Tf
➤ MACHINE C/T IMPROVEMENTS AT PRESS, 2
SettingRtehegsitoanndardl ComReXp.gXeiotintiavleCnoeXm.Xssp+etSitaMifveaentunyfaecKts esatvyingKPI XX m X.XX
- CreatAeKP3RxEMSO&TIOfMorOrTeIdVuCcGinMgETEoTtIaNlGMMa&nuIfAaCcYtuIVrIiTnYgCLOeaMdPTLEimTEeD fort ATORSUBASSYDRIVESHAFTHEATPART of
Setting the standard X.X
X.X Manufacturing space saving X.XX
40420B2PBRPO4R0JOE42JC0BET24CPB0TR2PO4BRJ0EOP2CRJBETOCPJTREOCTJECT
Visualising the abnormality X.X
- Mach4i0n2eBCP/RTOIJmECpTroMveaimntaein&tsimaptroPvreess,WXe.XldingandXP.XaintShopsMachineCTreduction
X.X Man/hour Maintain&improve X.X COMPXE.XTITIVENEMSaSchiInMeCPTrRedOucVtioEnMEXNXsTecSonds
XX hours PPH
(SIPM: Siginificant
MA182IN KA2I0Z4 ENS 12% 12%
AKARPKERPSERUSEAOLSKTATOPSOKRTAPMOE➤RKSMOEPCAOSRTO/KTIETOTPVOSIRTMV'MOsOEP'SETOMsRXOETOPMXITVETPOCOEI'EVMsMTCAE'ITEOsVXTANETPI'TOTsXIEVIPNAEOC'EXTsNaCPAQEnTEaTXdUAnCIPOATdTtEhILANOCteIThTaNIeYTAOnAaCTdNRnAIOtGdaRhNnEGetTdhTEaRTeTontAOhTfdRoLeAtfGthARThtEeRhAGeTEeRETAoGTAfSERotThfGetoEhfTetohfethe T Improv-eCm/TeImntpsroavetmPernetsast,QWualeitlydCionngtraolnAdrePa aint Shops
incidentspermillion
1)Owenparameterswer 2) O10ffline s7ide of t3h0%e owe
AKPRES OTOMOTIV 's EXPECTATION and the TARGET of the
M &
I
30%
MMEMEMBEBMRESERMMaSErMaBeMrEe:BRME:SERBaMSErReaBSrE:eaR:rSea:re :
W
ement at Quality Control Area
eek
and implemented.
MEMAKBPERERSSOaTrOeM:OTIV CG MEETING M& I ACYIVITY COMPLETED for the INSULATOR SUB ASSY DRIVE SHAFT HEAT PART of - -CrCeraetae-te3C-r3xeC-MxaretMC&ea-rtI&e3eCfaIoxr3tfreoMxar3et&MredxeIu&3dMfcoIuxi&rfncoMirgInref&TgdoroeIurTtdfocraouietlnracdMgilruneMTacgdoinauTtungaocfuiltaTnaMfcogalttcuaMTatnroluiauntMrnafignaulacLgMfnateuLucaefrtdnaiaunucdTrgtfiiunaTmLcrgiemitenLaugedriaLnTdegimaTLdiemTaeidmTeime
MAIN KAIZENS
ST
PPH
99
Impact Before
KyI PKI P
I
(SXIPXMs:eScigoinidfiscant Improvement
PPH
182 Improv2e0m4ent
# Working Shift / 10 Week 7
MA
MM&&I I MM& hI&MourIs&MwoIrk&ed)I hours worked) # Working Shift /
incidents per million
#
10 10
AGC Internal Use O
nt Control Improvements TK: Competitiveness TK:
Safety TK:
AGC Internal Use Only.
#
Regional Competitiveness + Safety KPI
Space Saved 228,34 m2
2.27
he standard ProcXe.sXs Saved (H/SCt)art oXf.Y5Xear End ofMYeaanr ufacturing space saving
XX m
2
X.XX
A XX seconds
slrOenUnaOsllyenU.
ly.
#
ysntUe.eae
#
: Siginificant
lOy.n
enCsArtOeneGInanrOCntlyneUaIl.rlnil
nternal Use Only.
11%
ts perlimneillion 182 Improvement
Maintain & improve Regional Competitiveness + Safety KPI VMiMsaunalanisgianMegmeMatmhneeaMnaenagtnbaeMCtngmoCearnoemgmntnenareamtoglnritCeloetyIomlnmCnItoemptCnrpotorlnCvoIXteomvlr.mnXIeopmtmlerIponmervltnospIetmvrmTsoeKpTemv:rKneoe:mtXvns.eXetTmsnKTte:sKnT:tKs :TCKoC: mompepCteiotCimivotieCpmvnoepemntCMeiseotpstaismivenTtsei/tKpvThnit:eoKeintuv:siretsinsvTseKsTn:sKXeTX:sKsh:oTuKr:s
Maintain & improve X.X
X.X Machine CT reduction XX seconds
Improvement
X
.
X
XX
se
conds
C G 2
hours worked)
AinGcCid StSatratrotfoYSfCetYaSerOtrtaSrortMfaoYErSftentEPYadonerfEodtaYfroeTYfaEeIYrYnaTeErdaInroVdEfnoYEdfeEYNaonerfdaYEroefSaYreSarIMPROVEMENTS SI
orming-asse inelineline Shift /
COMPETITIVENESS IMPROVEMENTS
e
C
T
r
e
d
u
c
t
i
o
n
hoursXw.XorXked) SaSfaefteytySTaKTSf:Kea:tfSeyatfTySeKatT:yfKeT:tyK:TK:
# Working Shift /
10
PPPHPiHPmPiHpmropPvrPoeHPvmPeiemHmPnpiePtmrnHiontpPvirimPenoHmvperie
Week
Management Control Improvements TK: Competitiveness TK:
182 (SIPM: Siginificant PPH improve
Safety TKf:orfmorimngin-agfs-osaersfmsoeirbmnmflgyobi-nralymgsfs-oiaenrsmgms-ebai
IGH
LATOR
in+g sSpacfe OVRENPEVONTRMEVTSO
eVtitEiveMn ine CT red
LoDThAIrONeTtfROSohINUreSRStULIShUANB
2e uPsrinI+g sSpacf
Man
XX m
he INSUL
Start of Year End of Year SIPM
REGIORNegRAioELnGaHlICOIoGNmHpALeLtIiGtHivHIeGnTeHSssL eTtySKPI Setting the standard X.X
AKPRES OTOMOTIV 's EXPECTATION and the TARGET of the M & I
AKPRES OToOfMthOeTIMVECMGBMEERESTaINreG:M& I ACYIVITY COMPLETED for the INSU SUB ASSY DRIVE SHAFT HEAT PART of
COMPETITICVOEMNEPSE
M4E0M2BBPEROSJEaCreT :
Visualising the abnormality X.X
2
X.X Manufactur saving XX m X.XX
CCOOMMPCPEOCETOMCTITMOIPTICVMEPIOVETEPMENITENEIPITVESEISESVTSNIEIVMTNIEMISVPENSPESRESNIROSMOIESVMPSVEISMRPEMOIRMPMEMESEVNMEENTEMSTNESTNSTS
➤ CREATE 3 X M&I FOR REDUCING TOTAL
- Create 3 x M&I foMrarneadguecminengtTCCotnOatlroMl IamPnpuErfoTavceItmTueIrVnintsgETLNKe:aEdSTSimIeMPCoRmOp esEsNTKT: S Sa(fSPeIPtHMyi:mTSKpigr:ionvifeicmaenntt in
OTIV 's EXPECTATMIOainNtaina&nidmptrohve TARXG.X ET of thX.eX Mach uction XX seconMds &
I
PPH improvement in Improvement
# Working Shift /
Before oBefnefit
182 204 10 7
After Benefit
Management Control Improvements TK: Competitiveness TK: Safety TK:
AKPRES OTOMOTIV 's EXPECTATION and the TARGET of the M & I
in
forming-assembly
- Machine C/TMImANpUroFvAeCmTUeRnItNsGatLPErAeDssT,IWMEelding and Paint Shops Start of Year End of Year
forming-assembly hSoIPuMrs worked)
MEMBERS are : Start of Year End of Year SIPM
e:
&I for redViusuacliisningtheTaobWntoEarLmlDaMlIiNty GanANuDfX.aXPAcItNuTrSiHnOgX.PXLSead Time Man/hour XX hours
line
X.X /hour XX hours
PPH
cidents per million
line Week
Part
3) Owen isolation were d
402B PROJECT COMPETITIVENESS IMPROVEMENTS RESU-LTCSreate 3 x M&CI fOoMr rePdEuTcIiTnIgVTEoNtaElSMSaIMnuPfaRcOtuVriEnMg LEeNadTSTime
1) Owen parameters we 4) Layout was changed.
- -MMacahci-hnieM-neCaM-/cCTah/MciTI-nmhaIeiMmcpnhCrepaoi/ncrCTvohe/eIviTmCne/IempemTrCneopI/tmnvrsTotepasIvmrteaoPetmpvrnrPeotrmsnvesteaes,stmnW,atPeWtsernePaledtstrslisednP,asigrWnste,agPseWnsrale,dneWsidlPnsd,aegPiWnilanadgitnienaSdltdgnhSPidoanhanpgPoidnsapatisnPnSdathiSnPohtapoiSsnphtsoSphsops
and implemented. M 1)
P
I for reducing Total Manufacturing Lead Time
MAIN KAIZENS
- Machine C/T Improvements at Press, Welding and Paint Shops
2) Offline side of the ow
- -C/CT/TIm-ImpC-rpo/ArCTvo-K/eIvPTmCeR-/ImEpemTSrCneopIO/tmnvrTaotepOtIvmamrMQetoempvuOQnreaTeuotmlInaiVvattleyti'stmanQCyEtoeuXCQanPaotuEtlniQrCataotyTlutrilAtoCaQAyTloiruIACtOneayortaNlernCitoatoynlrnodACtlortAehonearlterAToaArleRAaGrEeTaof the
M & I
3) Owen isolation were
pTEIrVRo
OT
MKSsNAcKhIIMZNaAEnAINKZgIeA2ESNdNI)Z.K
1 Press Shop Machine Cycle Time reduction
sec’s
sec’s
sec’s
8,17
37
95
7,34 10% an 2) 2O)fOflifnfleins2eid)seOi21dof)effOlOio2tnfwhf)feleteOinshnoif2edfw)plesionOaeiwdorenfeafeslwmtnionhdaf PART PR
SUTESLSATKUPSLRTESOTOMOTIV 's EXPECTATION and the TARGET of the M & I hine C/T Improvements at Press, Welding and Paint Shops
TIV 's EXPECTATION and the TARGET of the M & I S MEMBERS are :
3) anadnidmipmlepmalenemdnaetniemndtape.inmlded.pmailmenmndptleiemndmt.pel 35 5% 2) Offline side of
RESULTS
SCvGaerMmeE:eET # 402B PR
AKPRES
n I N t G a Mt &Q I u A a C l Y i I t V y I T C Y o C On Mt r P o L E l T A E Dr e f a o r t h e I N S U L PROCESS DESCRIPTION
TOMOTIV CG MEETING M& I ACYIVITY COMPL
JECT
ETED for the INSULATOR SUB ASSY DRIVE SHA
ATOR SUB ASSY DRIVE SHAFT HEAT PART of
IMPACT
FT HEAT PAR
UNIT
of
BEFORE
AFTERM
IANB4I)EKNLNAaKyMIEAoZFuEAIMZtNIITEwNSANaI
O
e 3 x M&I for reducing Total Manufacturing Lead Time
1) 1O)wOewnepna1pr)aO1mMrw)aemOAet1enwIe)NrtepsOenaKrw1rspA)aewamOrInreZewaepErsmteaNenretrs
mprov2emenWt aetldQinuagliStyhCoopntrol Area Machine Cycle Time reduction
4)L
- Create 3 x M&I for reducing Total Manufacturing Lead Time
3) 3O)wOewneins3oi)lsaoO3taliw)anotOdnei3onwiw)mneiOeswnporw3lelei)asermdtoOneioloweaidnsnteoeoitown.le
art IN3 VEQNuTalOityRCoYntTroUl RNOVER RATCIyOcleITMimePrRedOucVtiEonMENT - Machine C/T Improvements at Press, Welding and Paint Shops
4 Material Warehouse Conveyance reduction
AKPRES OTOMOTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFFECTING WORKLOAD MAINaKnAdIZimENplSemented.
- Improvement at Raw Material Stock Level
CES
S DE
SC
RIPTI
➤ IMPROVE-MImEpNroTveAmTeRnAt aWt PMreAsTsELiRnIeAsLSSemTOi FCinKishLeEdVGEoLod Stock Level and AKPRE-SIOmTpOroMveOmTIeVngtoattRhaewMMERatITerPiaRlISZtEoockf ILNeTvEeRl NATIONAL SAFETY AWARDS 2021
- Improvement at Raw Material Stock Level
RERSEU-SIULmTRLprTEoRvSeEUmRSLeUETnSRLtUTaEtLS-TPUIrmeLspTsroLvineemseSnetmatiRFianwishMeadteGroiaoldStSotcokcLkeLvevlel and
OTIV's TReAaRdyGfEorTfuitsurteoNeimtwporkoinvgeacItnivviteiens taosrayHTosutrCnoomvpeanryRfoartsihoar1in3g t%hebyest practices.
- Improvement at Raw Material Stock Level
SAFETY
RRESEUSLUTLT WWithiththteWheciWtochRuioWtEnthuhStinUetWthrLecmeTitorthmcehueoanetuscthauenoesrtuemecnrsoretemuIesanresIvmntuaevsrenreumatsnrosetuIrosnayrrvesITyneusuvnrTIrentunosnvrornteIyvononervTvtyreouenRTryntuaRotrTairnvouytoeiroiTvnrmueoiRmprvanrReptoirarovotReivoamdretiRidp1moar01optimi0%vrooe%pivdmreo1dpv0re1o%d0v1e%0d %10 %
t at Press Lines Semi Finished Good Stock Level and
eRaedaAydKfyPoRfreEoRSafrueOdftaRTyuOdetfruyMaoeRrdrfOeNoyfTaureNIfRVdtofeuywugratortdfwofetuoyurt SAKPFRESTOYTOM
AKPRES OTOM
sures Inventory
Ready for futu
Ready for future Networ
RESULT
AKRPERSE➤USLTOWTITOHMTOHTEIVCOgoUtNtThEeRMEARSITURPERSIZIENVoEf NINTTOERRYNTAUTRINOONVAELRSRAAFTEITOY AWARDS 2021 WitWhithethceoWcuointuhtnettheremrmcoeeuanstueurmesesaIInsnuvvrensntIontrvoyernTytuoTrunyorTnvueronrvoRevaertrRiRoaitmiiopimriompvrepodvreo1dv01e%0d%10 %
t at RawRMeWadaityhtetfhorericfaouultnuStretermoNecaekstuwrLeoserIknvivnegnltoarcytTivuirtnioevseraRsataioHimopstroCveodm1p0 a%ny for sharing the best practices IMPROVED 10 % SASAFEFETSTYASYFASEFATESFYTAEYFTEYTY
termea
OTIV got the MERIT PRIZE of INTERNATIONAL SAFETY AWARDS 20 1) Change line layout accMto oaniensiKdeafeizeedi
AKPRE
SAFETY
SAFETY
3) Add sub assy statio
AKAPKRPERSEAOSKATOPOKRTAPMOERKSMOEPAOSRTOKTIEOTPVOSIRTVgMOEogSTOMtoOTtOhMITtVeThOIgeMVMToMgEItOVoRtETthgIRITetoVIhtTPMgeRtPohEMIRtZeRItEZIMhTRoEeIEPfToMRIfNPIETIZRTNREPIETZIRToENfIRPZoIANRENfTIAoITZNITfEOETIRINOoNENfARNTAINLEANTRSALTINAOTESFAIRANOETNFATNIEALOYATTSNYALIAOAWSAFLANWEASFATRAEAYLDTRFSAYESDAWTA2SFY0WAE22ATR0A1YW2DR1ASADW2RS0DA2SR01 S OATOKPMROETSIVOgToOtMthOeTMIVEgRIoTtPtRhIeZEMoEfRIINTTPERINZEAToIfOINATLERSANFAETIYOANWALARDS 2021
OTIV got the MERIT PRIZE of INTERNATIONAL SAFETY AWARDS 2021
UTRuNrnI
SAFETY
SAFETY
MoVvEeRrPR R aA
AKAPKRPERSEOAS KTOAPOTKRMOPEAMROSKEPTOASIRTVTKOEOIPVSTMRTOSEAOTMTSTATOEOTIMDVTETODIOSVATMTCASITOVTCUAETSADTIUTVELADASITLNTCEIAVDTNTCEUVENTAEDUTCLNOATITANULROCVYAIRTNELTUYVNUIATNETRULNVONRITERNONONYVORTEOYVUNRETRTRUYNOARTRORTUNAYVIOROTETINVRUOIOESRVINASEROTONRAIVTOTREITANROISTIRNTINIOASTOTRNAITGSOROIEGNTIEOSITANTNANATIRODNAGTRDTEIGHANTERIHASTGNIAESAERDFTENFGFTEADEFHCNTETITDCSHAINTENITSIGFNHDFEGIWEFSTCFHWEOETIFRCSIOFNKTERGILFCKNOFTWLGEAOINCODWAGTRDIOKNWRLGOKWLAROKDOALRODKALDOAD
TmUpA
INVENTORY TURNOVER RATIO IMPROVEMENT
O
IN T
T AND THIS EFFECTING WORKPLAORT AD PROCESS DESCRIPTION
R- EImSUprLoTvement at Press Lines Semi Finished Good Stock Level and
BALANCE - STOCK AREA EFFICIENCY - WAITING MUDA NEGATIVELY AND DECIDED TO SOLVE THE PROBLEM BY MLINAE 3K9 IDNABGM&IA TBP
TBTPBP TBTPBPTBPTBP
INVENTORY TURNOVER RATIO IMPROVEMENT
LMPU (Labour Minute PeIrmUpnriotv)
BALANCE - STOCK AREA EFFICIENCY - WAITING MUDA NEGATIVELY AND DECIDED TO SOLVE THE PROBLEM BY MAKING A
- ImproveAmKPeRnEtS aOtTIORNMaVwOETMINV aTSTtOAeTrREiaYDl TSAtCUoTRcUkANLOIeNvVeElNRTORAY TUIORNOIMVEPR RAOTIVOEISMNEONT ITN TARGET AND THIS EFFECTING WORKLOAD
With the countermeasures Inventory Turnover Ratio improved 10 % LINE 39 DAB M&I
ImprLoINvEem39enDtAB M&I Space Saving
Space S
OTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFFECTING WORKLOAD
TBPBALANCE - STOCK AREA EFFICIENCY - WAITING MUDA NEGATIVELY AND DECIDED TO SOLVE THE PROBLEM BY MAKING A AKPRES OTOMOTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFF
S
hange line layout mprove LMPU valu adidn sKuabiazsesny statio
Change line layout mprove LMPU val
MMaianinKaMKiazaMeizineaMsniKnsaMKinzaeaiKzninaesin Main Kaizens
AKAPKRPERSEAOSKATOPOKTRTBAPMOEPRKSMOEPAOSRTOKTIEOTPVOSIBRT'VsMAOEL'TsSATOMANTOTCROAMIETGVRT-OEO'GISsVTMTEOT'sIiTCOAVsKTRiT'sAstGIRoVRTEtE'AoAGisTmREiTFimpGTsFAIrECpRiotsITrEoGvoNteiEiCsvomTYeIntip-imoIvsWnreopivAtmnvreoITotenpIoNivmtrIrGeonoypMrvITynreUouvnDTIvreAntuneonvrNornteIEyvononGervTvAtyreouTeInRTrVyntuaERoLotrTYarinvouyAtoeiNro1TvnrD3ueo1RDrv3%aEnReCto%IirabDovtEyRbeiD1oary3TtO1Ri%o3aSOt1%biL3oVyEb%1Ty3HbE%yPRbO CK AREA ERFEFSUIACLKITEPRNECSYOT-OWMOATIITVI’sNTGARMGEUT Dis Ato iNmEpGroAveTIInVveEnLtYorAy NTuDrnoDvEerCRIaDtiEoD13T%ObySOLVE TH
Subassy
in Kaizens
AKPRES OTOMOTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFFECTING WORKLOA
RtTiIoO
PART PROCESS DESCRIPTION IMLINPAEC3T9 DLAMBPMU &( BABLALNACNEBCA-EBLS-ATSLNOBTACONLEKCBAC-AKAENSRLAC-TAEREOSANETC-CAEOKSEFCTEFA-OKFIRSCFCAETIKCERAONIEAECEACRNKFYEFECAIFYC-RFEWIEI-ECFANWAFIEICICATNFYIFCENTI-YNICGNWCI-EGMYANWMUIC-TADYWIUINTAD-AGINAWINTMGEIANUGMIEGTDAGIUNATMADIGVTUANIEMVDELNEGAYULEADYGNTNAEIVDNGTNEIDADVLETEYEGDICLAVEAYICNEDTALIEDVYNDEDADLTENYODCTDAEIOSDCNDOESIDEDLDOCVEDLITEDVEOTCETHDSIOTDOEHTESLPOEDOVRPLESTOVROTBEOLHLSVBTEOEHLMPLETVRMHBPEOYERBTOMPYHLREBEMAMOLKPEABRIMBKNLOYIEGNBMGYALEABMAMKYAIMNBKGYIANMKAGINAKGINAG A LINE 39 DAB M&I
AKPRES OTOMOTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFFECTING WORKLOAD
O1I3S
V %N
E
M
ObyT
LINE 39 DAB M&
E
AR
N
T
COMPETITIVENESS
GE
sec’s
2 MAIN KAIZENS 1) Owe3n) pOawraemneitseorslawtieorne sweeturpe adgoanine.. 5) F
ECTING WORKLOAD
1330
1122
16%
👍
ours worked)
# Working
.X.XX X.XX.XX.XX.XX
rs
X.XX PPHPPH PPHP
RERSEUSULTRLSTERSEURSLUETSRL
AKPRES OTOMO
- Creat
- Mac
RESULT
MEMBERS are :
- C/TI
BALANCE - STOCK AREIAN5EVFFEIMCNIaEtNTeCrOiYalR-&WYSAhTIiTpUINmGRenMNtUWODaAVreENhoERGusAReTIAVETSLpIYaOAcNeIDSMaDvEiPnCgIRDEODVTOESMOLEVENTTHE PROBmLEM BY MA8K,4ING A 7 175)%Felt and NW zones we
TBP RESULTS
and implemented. 6) Finish good boxes wer 2) Offline side of the owen was repaired 7) O
Part
RESULTS 1) Owen parameters were setup again.
2) Offli4n)eLsaidyeouofttwheasowcheannwgaesdr.epaired
6) Fi
AKPRES OTOMOTIV STATED ACTUAL INVENTORY TURNOVER RATIO IS NOT IN TARGET AND THIS EFFECTING WORKLOAD
3) Owen isolation were done.
Part
8) O 8) Owen table closingcdycisl
3) Owen isolation were done.
Part 4) Layout was changed.
BALANCE - STOCK AREA EFFICIENCY - WAITING MUDA NEGATIVELY AND DECIDED TO SOLVE THE PROBLEM BY MAKING A
PALIRNTLEIN3E CO
and implemented.
7) Owen buton was tsriadne
PsAidRPeTA. RSTo walkPinAgRPTwRAaORPsTCRPeEOAlSiCmRSE
AKPRES OTOMOTIV's TARGET is to improve Inventory Turnover Ratio 13 % by
4) Layout was changed.
TBP ININVVEENINTINVTOIEOVNRNERYIVNTYETOVTNTUEORUTRNYRORNTYTNROUTYOVRURTVEYNRUERTNORUOVNRAREVOATNRETIVORIREOVARIMEITARMRITPOAIPROTIRAOIMOITVMIPVEOIMRPEMOIRMPMEOVRENPEVONTRMEVTOMEVNMEENTEMTNETNT - Improvement at Press Lines Semi Finished Good Stock Level and
cycle time.
INAVKPEREA NSKPOT
P
E
RTEO S MO
ROTOTYIMV'OsT TIAV
INVENTORY TURNOVER RATIO IMPROVEMENT
LINLEIN3E
UR S GT
INVENTORY TURNOVER RATIO IMPROVEMENT
C
O
M
R
AETN
EiDs OtAoCiV
ErLoR
IvNeVIR
EnNvA
TeOntT
R o Y r I yT
O
PART P
RO
yBLEM BY MAKING A
E PROBLEM BY MAKING
D
BALANCE - STOCK AREA EFFICIENCY - WAITING MUDA NEGATIVELY AND DECIDED TO SOLVE THE PROBLEM BY MAKING
TBP
TBP
- I-mImprporv-oAeIvmKm-ePImpemR-rneEopItmnSvra-otepOtIvmamrTetoPeOmpvrPnreMeortsmenvsaOstetLsTmaniInPLtVeierna'ePnsetsrtTseSPaAseLtrSsRmienGPLsmeisrEnFseiLTeisnFiSsnsisenseLSmhisitseneohimeSdeFisemidGnmFSoipGiseinorhoFmiodseoivnhideiSeFsGtidhISnonoetiGcvosodkehocdGneLkoedtdoSLovtoeGreoSvdyolcteokoTalScudnLtakorednScLvdotkeovlLceakrlvnLReadelanvtdaeionl d1a3nd% by
With the countermeasures Inventory Turnover RSaAtioFiEmTpYroved 10 %
AKPRES OTOMOTIV's TARGET is to improve Inventory Turnover Ratio 13 % by
➤ IMPROVEMENT AT PRESS LINES SEMI FINISHED GOOD STOCK LEVEL - I-mImprporv-o-eIvmIm-meImpemp-rneropItomnvra-votepteIvmamrmRetoemapvRenwreaneotmwtnvMaatetMatmanRtaePeRtawrneitaeatrwMsRilasaStalMLwtRStoienatacMoretwkiecsaLkrlMtieSaeSLvealtreeoimStvaelcteliokrlSiFcaLtikolneScLvistkehovlLecekdlvLeGelovoedl Stock Level and
AKPRES OTOMOTIV's TARGET is to improve Inventory Turnover Ratio 13 % by
- Improvement at Press Lines Semi Finished Good Stock Level and
AKPRES OTOMOTIV's TARGET is to improve Inventory Turnover Ratio 13 % by
A
bassy
. 1) 2) I
Main Kaizens
R rorkNhfteorueifernkuNrSMftigetAunweuEtFagNtuRroEwcreIaeTreTtYkoctiNPvwtirAnReiektvWotIgtiZwienrwtAEaokisgReorociknDfsatariignIkcSsvNagtii2anTaitsav0EcigceHai2Rtis1aNivovHecRiAistaosteiTteisaseIvsCOatdaistsoaNyCisHmeAafoaosLsmrHpHSsafaoAtupnsHFstCatuEytanoCrTCeofysmYHomtoNAforpmCopeWsasatortpwhnAmsyCaoRyhnforDpoafkiymSaonrirni2srgfngpho0ysatga2arhrf1ncitosanetyhigrvebiafitnstoherihbgeirsnaestbtsrgshehpitnsetartphgarpbreicrtnaeathbcgcisceteiteicscpbhesterese..apsb.ctrate s 1)1C)hCahnagne1g)leinC1leh)inaCle1anh)yglaoCenyu1hgolt)aienunCaetlcghinacelacentylci
Turnover Ratio improved 10 %
SAFETY
re Networking activities as a Host Company for sharing the best practices.
1) Change line layout acc to one s 2) Improve LMPU value with balance workl ayout acc to o2ne)2Ism)idIepmfrepoerve2oed)vinLIe2mgM)LpIPMm2rU)oPpIvUmre2aov)lpvLuaIreMemlouLvPwpeMeUri
kingasacatiHviotisetsCaosmapHaonsyt fCoormshpanriyngfotrhsehabreinsgt pthraecbteicsetsp.ractices. ReadyforfutureNetworkingactivities asaHostCompanyforsharingthebestpra
2)ImproveLMPU1v)aCluheawnigtheblianlae 3) Add sub assy station in to the line to elim
OTIV got the MERIT PRIZE of INTERNATIONAL SAFET3Y0 AWARDS 2021
re Networking activities as a Host Company for sharing the best practices.
3) Add sub ass
M
1)
XX hours
2D210S21021
p i c s c r t t e a i c p s c . e t r i a s c . c e t s i c . Me s a . i n K a i z e n
1) Change line l 2) Improve LM
SIPM
GACG CI n ItneAtreGnAraCnGl aIUACnl sGtUI AGC I
Safety TK:
X.XX(SIPM
SIPiMnciden SIPM: Siginificant
Iennttesrpnearl mUsilelioOnnly.
PSIMPM SIPSMIPSMIPMSlinIPleinMe linel
f SIPM ImWpImeaecptkact l
#
SuA
Ma
1) C 2) I 3M) A
21
ctices.
PU value with balance workload 3)3A)dAddsdu3sbu)abA3s)dasyAsd3sdsy)tduAasbt3stdiau)oadtbAsnisosdauiynsdbsit
3) Add sub assy station in to the li 3) Add sub assy station in to the line to elimi2na)tIempurdoavs eanLdMst
e
a n
M T
M
M /
P f
P m
#
W mom
mn
p
O
M n n
n
L e a u
a e n
u
Kz
Ma
u
C 2) I
O
i
ST
e
o r
T
2
A
e
O d
SOE
aSu
d
ewe e O O
d
an L
gts
h e
e
e
s
T
t e
9 9
n
on
i o wtoP
n sntya
y