Page 34 - Toyota Annual Directory 2020-2021

TBP - AUTOLIV
KPIs & Trend of Last 12 Months
4.05 0 0 PPM DPM QPR
TOYOTA LINES OEE IMP
1. Clarification of the problem
A-Background
1.1 Autoliv Gebze Plant and Toyota
TMUK
B-Problem Statement 1.4 Team Strategy
1.2 Main Processes
Airbag Module Assembly Line
1.3 Products & Projects
SIDE AIRBAG
CHR (560A)
CURTAIN AIRBAG
TMMT
COROLLA (160B)
DRIVER AIRBAG
DRIVER AIRBAG
EFFECT TO AUTOLIV
1.5 Purpose of job
TOYOTA LINES OEE (YTD 2019 Jan-Sept.)
100% 95% 90% 85% 80% 75% 70%
91%
TOYOTA LINES OEE
95%
LINE39 (560A DAB)
92%
LINE40 (560A SAB)
91%
LINE41 (560A IC)
GLOBAL
85% GAP 5%
LINE45 (160B DAB)
FFECT TO TOYOTA
*OVERTIME (%5) * APPROXIMATELY COST (20 K€)
*DPM RISK
ULTIMATE
100% EFFICIENCY, ZERO STOPAGE
2. Breakdown
2.1 Grasping the problem
2.1.1
12% 10% 8% 6% 4% 2% 0%
LINE45 (160B DAB)
OEE INEFFICIENCY BREAKDOWN
0.00%
O
2.1.5
LINE45 (160B DAB) STATION BREAKDOWN
O
ST60-SCREWING
12% 10% 8% 6% 4% 2% 0%
5.48%
∆=7,29%
ST30-WELDING
2.1.2
12% 10% 8% 6% 4% 2% 0%
LINE45 (160B DAB) AVAILIBILITY BREAKDOWN
O
LINE45 (160B DAB) X
SHIFT BREAKDOWN 12%
2.1.3
2.1.4
∆=10,60%
10% 8% 6% 4% 2% 0%
2.57% SHIFT C
2.44% SHIFT A
2.28% SHIFT B
0.00%
0.00%
10,60%=100% - 89,4%
000
OEE = AVAILABILITY X PERFORMANCE X QUALITY
2.1.6
12% 10% 8% 6% 4% 2% 0%
0.00%
LINE45 (160B DAB) FAILURE MODE BREAKDOWN
0.00%
O
0.00%
0.00% 00000
0.00% 0.00% 0.00%
0.00%
∆=7,29%
LINE45 (160B DAB) X REFERANCE BREAKDOWN
12% 10% 8% 6% 4% 2% 0%
∆=7,29%
3.71% 3.58%
640751100BD 640751100BE
COMPRESSING PLATE 000
SLIDING ISSUE
PROBLEM TO TACKLE 1.WRONG FOLDING
PROBLEM TO TACKLE 2.COMPRESSING PLATE SLIDING ISSUE
NOK
OK
NOK
OK
ST20-FOLDING
ST40-SUB ASS.
ST50A/B- CRIMPING
0.62% 0.56% 0.38%
0.25%
2.2 Point of occurrence by checking the process through Genchi Genbutsu
O X OOOOO
O
PACKAGING
STEP-8
∆=5,48%
3.1.1
12% 10% 8% 6% 4% 2% 0%
TARGET SETTINGS FOR LINE45(160B) AVAILABILITY BREAKDOWN
ST10 SUB ASS.
STEP-1
ST20 FOLDING
INVESTIGATION OF FOLDING PROCESS STEPS STEP-2 STEP-3 STEP-4
ST30 ST40 WELDING SUB ASS
STEP-5 STEP-6
ST50A/B CRIMPING
ST60 SCREWING
STEP-7
ST70 LABELLING
O
O
O
O
2.3 Problem to Tackle; High Breakdown Ratio Caused of ''Wrong Folding'' and ''Compressing Plate Sliding Issue'', The Problems Occured on ST20 (FOLDING STATION) and Step-7 & Step-8
O
O
96%
94%
92%
90%
88%
86% 85% 84%
90,1%
X
X
3. Target setting
3.1.2
96% 94% 92% 90% 88% 86% 84% 82% 80%
TARGET SETTINGS FOR LINE45(160B) AVAILABILITY BREAKDOWN
2,09%
94,61%
94,5% TARGET
89.4% 3,12%
AVAILABILITY
TARGET APR. 2020
3.1.3
TARGET SETTINGS FOR LINE45(160B) OEE BREAKDOWN
3.12%
WRONG FOLDING
2.09%
0%
0%
TARGET APR. 2020
COPMREPSRSEUSSRINEG PLATE SLIDING ISSUE
TARGET APR. 2020
WRONG
COMPRESSING PLATE
82% 80%
OEE
TARGET APR. 2020
90% TARGET
3.1.4
TARGET SETTING
TO REACH 100% EFFICIENCY ZERO STOPAGE
*BREAKDOWN (WRONG FOLDING, COMPRESSING PLATE SLIDING ISSUE WILL BE DECREASED FROM 5,21% TO 0%
*OEE WILL BE INCREASED
34
TARGET 90% E