Page 35 - Toyota Annual Directory 2020-2021

ROVEMENTS
Date Managing Director Team Sponsor Champion 6/23/2020 Fatma AĞDAŞ İŞCAN Atilla ÇORUH Sultan EKREM
4. Root cause analysis
PROBLEM WHY 1 WHY 2 WHY 3 WHY 4 WHY 5
Cushionlayoutnotproperon x the table
Cushion not set between x folding blades
Blades pull the cushion
Blades opening/closing unproperly
Joint pin hole cracked
Pin Broken
Wrinkles seen on some cushions.
Folded edge seen on cushion
Mechanism of blades joint not stable, moving
Wall thickness unproperly (thin)
Pin type not proper
Unstable packaging existed in supplier
Not determined on design phase
1
PHOTOS
Between cushion and blades the touching area very thick.
Supplier operator SWI not detailed 2
PIN WITH RING
1
Scraper not seperate the cushion from blade
Blade pulling speed high
The cushion touch the scraper High pressure on discharge
Roll diameter narrow
Bacuse of the vibration, stopper moved
Distance between cushion and scraper too much
Air fluctuation on main line Air restrictor not existed
Valve broken
Scraper set at the back of 4 cushion
5
x
x
2
WRINKLES
x
6
Not predicted on design phase
Folded cushion wider than standard.
Compressing blade position on front of the proper position
Cushion set point gets close
After roll folding, distance between blades too much
Blades not set on proper position.
Stopper not on correct position
x
Servo rolling speed and blade travelling speed on gear not proper each other
Stopper used of normal nut
WITHOUT BEARING
Joint not designed with bearing to ensure load.
Not predicted on design phase
Servo set parameters not proper
3
WRONG FOLDING
Cushion folded very tight.
Mechanical blokage existed on
gear.
x
COMPRESSING PLATE SLIDING ISSUE
x x
to compressing plate Soft cover not fixed
Initial positon not set properly
x
Not predicted on design phase
SCRAPER POSITION
4
PROBLEM THEREFORE THEREFORE THEREFORE THEREFORE THEREFORE
5.Develop Countermeasures&6.Action Plan Implementation
ROOT CAUSE NO
1
2
3 4 5
6
RESPONSIBLE
Ersan Ç. Ersan Ç. Yusuf I. Yaprak V. Şeyma E. Şeyma E. Ersan Ç. Yaprak V. Yusuf I. Yusuf I. Yaprak V. Ersan Ç. Yaprak V.
Jan-20 Feb-20 Mar-20
WWWWWWWWWWWWWW 01 02 03 04 05 06 07 08 09 10 11 12 13 14
Apr-20
May-20
Jun-20
O:2, ∆:1, X:0 Overall 0-2:X, 3-4: ∆, 5-6: O
NO COUNTERMEASURES
CRITERIA o
∆
x
EFFECT
DIRECT INDIRECT NO EFFECT O
O ∆ X ∆ ∆ O X O O X O X
COST
<1000 € >1000€ <3000€ >3000€
O O O O O O ∆ O O O O O O
LEAD TIME
≤2W OVERALL PRIORITY >2W
≤1M >1M
O O 1 O O 1 O O 1 O ∆ 2 ∆ ∆ 2 O O 2 ∆ ∆ 2 O ∆ 2 O O 1 O O 1 O ∆ 2 O O 1 O ∆ 2
STATUS
1.1 Opening- closing joint wall thickness will be increased.
1.2 Pin type will be changed with bearing bolt.
1.3 Periodic maintenance control list will be updated for thickness check
1.4 Process design team will be informed,new design will be reflected for new projects
2.1 SWI will be detailed according to cushion wrinkle problems
2.2 Operator SWI training will be given in supplier.
3.1 Joint of gear mechanism will be changed with ball bearing.
3.2 Process design team will be informed, design will be reflected for new projects
4.1 Scraper position will be set again 5.1 Air restrictor will be added
5.2 Process design team will be informed, design will be reflected for new projects
6.1 Stopper will be change with bolt with gasket Periodic maintenance control list will be updated
6.2 Process design team will be informed, design will be reflected for new projects
BEFORE AFTER
PLANNED
ACTUAL
DENIED
TODAY FINAL DATE
7.Monitor Results&Processes
8.Standardize Succesful Process
12% 10% 8% 6% 4% 2% 0%
RESULTS OF PROBLEM TO TACKLES
0.0312
YTD 2019 (Jan-Sept.)
43831
43862
1.1 4.1 1.2 5.1
3.1 6.1
2.1 3.1 2.2
43891
WRONG FOLDING (ACTIONS 1.1, 1.2, 2.1, 2.2, 3.1, 4.1, 5.1) COMPRESSING PLATE SLIDING ISSUE (ACTIONS 3.1, 6.1)
1.1
WALL THICK
NE
SS INCREASED
NO 1
2
STANDARDIZATION & YOKOTEN PLAN
Similar airbag Line38 opening-closing joint tool will be checked, pin design and joint tool will be revised.
Cushion packaging process improvement actions will be declared to supplier for new and exist processes. (Line31, Line38, Line39)
PRIORITY RESPONSIBL Apr-20 May-20 Jun-20 STATUS E
1 2
Ersan Ç. Sultan E.
Şeyma E. Ersan Ç.
PIN WITH RING PIN WITH BOLT
3 Similar airbag Line38 gear mechanism will be 2 checked, ball bearing design will be implemented
Sultan E.
9
0.0192
1.2
0.0169
0.007
0
8
0
4 Air restrictor will be added to other lines 1 Yusuf I. (Line31, Line38) to control blade pulling speed.
5 TBP will be published to other Autoliv plants. 2 Sultan E.
96% 94% 92% 90% 88% 86% 84% 82% 80%
LINE45 (160B) OEE
EVALUATION OF THE TBP STUDY (Benefits and Improvements)
3.1
1. RESULT SHARING *TBP Results shared with global team.
*3 Actions shared as a Best Practise and Yokoten.
2. TBP TRAINING *TBP training given to kaizen groups
3. INTERNAL TBP *Activity performed for
(Welding problem TBP)
0.851
1,6%
Act. 1.1, 1.2 4.1, 5.1
YTD 2019 (Jan-Sept.)
43862 43891
Effect of
0.867 2,7%
43831
0.894 0.901 TARGET 90%
Effect of Action
3.1, 6.1
0,7%
Effect of
Action 2.1, 2.2, 3.1
WITHOUT BEARING WITH BEARING DESIGN TEAM PRESANTATION
2019-2020 PROJECT WINNER
P
3
0.020
35
CORE GROUP FINAL
TK REGION FINAL PAN EU TBP FINAL
JUDGEMENT CRITERIA