TPS入门(中级英语版)

Production system: safely, better and cheaper part
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2. How to perform KAIZEN
（１） To clearly define the need ・ production increasing? ・ over time? ・ reduce lead time? Etc... ◎If the need can not be defined by an external ‘soto’ division (in order to get an equal situation for every work place) then the manager concerned by the Kaizen activity should define it （２） To clearly define the targets ◎Set high goals Low target is non-KAIZEN & keeps hard work for worker ◎Kaizen is an activity that never end （３） Check oneself ◎Worker and explanation，get his own opinion ， (rather then someone else’s)
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“14”work elements
№ １ ２ ３ ４ ５ ６ ７ ８ ９ １０ １１ １２ １３ １４
Motion standard
(TPS technical terms)
Example Take a part and assemble it Pick up Cut / Plunge / Bend Stretch out / Put back Grip / Pick up / Apply pressure Push / pull / Slide Put / Release / Drop Search for first part to be assembled Find out an part Catch a part Check Return a part up side down
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Movemenቤተ መጻሕፍቲ ባይዱ analysis
Observe the worker’s motion
Operations raise value added: 『 assembly 』 『 disassemble』 『 work 』 3 types of movement
These 3 motion standards “DOUSO” have to be incorporated to a worker motion in order to get the best global result
performance analysis board
② Conditions of KAIZEN
In scheduled time
Reduce lot size,reduction of worker Reduce set-up time
Production quantity (target)
Over time
Work KAIZEN (reduce MUDA) ＆ work balance
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KAIZEN
（２） Hand work line ① Make a system
ⅰ） one-piece-at-a-time production ⅱ） make to Takt-time Make a continuous flow HYOUJUNSAGYOU
Split into the ‘14’ work elements
Observe the worker’s motion: time study
『Apply the aim of KAIZEN 』
『Build in quality at the production process 』
In order to, inspection standard has to be incorporated too! 『check』 』
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（４） Lot production
① Make a system
ⅰ） SHINGOU-KANBAN (signal KANBAN) system to build up lot ⅱ） find out abnormal （ANDON etc...） ） ⅲ） understand production quantity
（３） KAIZEN ideas （４） Produce KAIZEN proposal （５） Perform KAIZEN idea （６） Check … new problems, effects etc.
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… expectation, effect Relation, target
4．Conditions of KAIZEN ．
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② Conditions of KAIZEN
（at Takt-time ）
KAIZEN
Line does not stop Line
Reduction of worker （at over time Takt-time)
Speed up conveyor to Takt-time
Line stops
Rise BEKIDOURITSU (target = 100%) Improve machine capacity
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5．Shop floor observation / TPS “attitude” ． (“independence”&”workshop”)
（１） Operations/points to be observed carefully & “Time study”
Improve BEKIDOURITSU
(target = 100%) 7
scheduled
Many abnormality
（３） Automatic line
① Make a system
ⅰ） find out abnormal （ANDON etc...） and stops ） ⅱ） understand process capacity (find out neck machine)
Toyota Production System Introduction（the middle class） ）
TAKASHIMAYA NIPPATSU KOGYO CO., LTD. OPERATION MANAGEMENT CONSULTING GROUP PRODUCTION CONTROL DIV.
Achieve quantity scheduled Output
(finished quantity) Check Long ＣＴ Do not worker ability achieve Check Long ＭＣＴ quantity machine capacity
Reduction of workers Work KAIZEN Reduce ＭＣＴ
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（２） Points of observation
（３） Worker’s operations motion
Observe and analyse the work operation elements for few cycles
『 First perform motion KAIZEN,then equipment KAIZEN 』
① Difficult operation to perform e.g. Poor visibility/accessibility during part assembly ② MUDA in conveyance e.g.Temporary unloading,load transfer,removal of small quantities and movement from one spot to an another etc. ③ MUDA of ‘lay out’ or action
（１） Conveyor line or assembly line ① Make a system A production system which makes an efficient & full use of a conveyor Know behind / ahead of schedule Be able to change the speed Know if the conveyor is running or stopped Find out abnormal ⅰ） fixed- position stop system ⅱ） ANDON Leveled production (HEIJUNKA) （Production sequence table or Cycle list ）
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3. KAIZEN steps
（１） KAIZEN: necessity to clarify need and targets （２） Analysis the actual situation ・ Produce standard “OMOTE” （3 TYOUHYOU） ）
KOUTEIBETSUNOURYOKUHYOU HYOUJUNSAGYOUKUMIAWASEHYOU HYOUJUNSAGYOUHYOU ・ Aim of KAIZEN (search for MUDA in order to define the counter-mesures)
KOUTEIBETSUNOURYOKUHYOU
ⅲ） Leveled production (HEIJUNKA) ⅳ） understand production quantity ⅴ） produce only conformed parts Counter