SPI Training Manual

Safety Pro
-Active Indicator
Pro-Active
SPI Activity
Training Manual
For Supplier
Mr. Sombat Kongkheeree
Purchasing Engineering Dept.
TMAP-EM
TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
1. (Background)

Supplier TMT
TMT
TMT

Supplier
TMAP-EM SPI

Supplier

2. (Purpose)
-

TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
3.
Safety Pro-Active Indicator (SPI)
4.
(Zero Accident)
TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
5. (Concept)
1) 3M 1E (MAN, MACHINE, METHOD
ENVIRONMENT)
2) KPI
3)
VISUAL CONTROL BOARD
4) SDCA
(STANDARD, DO, CHECK, ACTION)
TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
SPI Concept : Breakdown & Select KPI focus on 3M +
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
1E
Control & Monitoring
Pro-active Indicator
on
Visualization Control Board
Safety Device Function
Machine
Equipment Condition
New Machine Condition
Maintain & Improvement
Communication
Method
Environme
nt
TOYOTA
Ergonomic Kaizen
Safety Key point
Completion
S
D
5S
Working Environment
Feedback
SPI
SPI Manual
Manual
C
5
Safety Pro
-Active Indicator
Pro-Active
SPI Board
TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
SPI Board
Man
TOYOTA
Man
Man
Man
Machine
SPI
SPI Manual
Manual
Machine
Method
Env.
7
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
9
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
10
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
11
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
12
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
13
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
14
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
15
Man : Good Health Condition
Man
TOYOTA
Man
Man
Man
Machine
SPI
SPI Manual
Manual
Machine
Method
Env.
16
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Safety Device
Function
Equipment
Condition
New
Machine
Condition
Communication
Method
Ergonomic Kaizen
Safety Key point Completion
Environme
nt
TOYOTA
5S
Working Environment Feedback
SPI
SPI Manual
Manual
17
TOYOTA
SPI
SPI Manual
Manual
18

Purpose 1.
2.
How to Evaluation
STEP 1
STEP 3
STEP 2
OK
NG
KYT
Health
Check
Sheet
TOYOTA

2 Way
Communication
KYT
1)
2)
SPI
SPI Manual
Manual
19

KPI Target : Good Health Attendance 98%
% Health complete
%
100 100
100
92
100
100
100 100 100 100
100 98
100
Target 98%
Self check
50
Daily
Monthly
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Confirm check
Month
Remark : Not include absent person
Daily Health Check Sheet

for operator and Confirm Check
100
:
TOYOTA
SPI
SPI Manual
Manual
20

Daily Health Check Sheet (Less than 17 Worker)
Line________ Shift _________ Month ________
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
_____
( TL.)
(GL.)
() =
=
=
()
//
A :
E2 :
/
E3 :
B :
E4 : ,
C:
E5 : ,
D:
E6 : ,
TOYOTA
SPI
SPI Manual
Manual
21

Daily Health Check Sheet (More than 17 Worker)
Line________ Shift _________ Month ________
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
9 10 11 12 13 14 15 16 No
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
_____
( TL.)
() = A :
=
=
() =
//
9 10 11 12 13 14 15 16
(GL.)
( TL.)
(GL.)
B :
E2 :
/
C:
E3 :
E4 : ,
D:
E5 : ,
E6 : ,
TOYOTA
SPI
SPI Manual
Manual
22

Daily Health Check Sheet Example
Line__MC1__ Shift __White___ Month _Sep
Apr '07__
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Line
10
( TL.)
(GL.)
10 10 10 10
10 10 10 10
10
10 10 10 10 10
235
10 10 10 10
10 10 10 10
10
10 10 10 10 10
237
//
TOYOTA
() =
10 10 10 10 10 10
=
=
()
04
1 14/09/07
04
2 15/09/07
10 10 10 10
10
10
E3 :
B :
E4 : ,
Part
Part
F3
F3
SPI
SPI Manual
Manual
A :
E2 :
C:
E5 : ,
D:
E6 : ,
23

Daily Health Check Sheet (More than 17 Worker)
A =
B =
C =
E2 =
E3 =
E4 = ,
E5 = ,
E6 = ,
()
D =
()
A
TOYOTA
()
()
SPI
SPI Manual
Manual
A Add circle mark

24

Graph For Health Check
% Good Health by self check ( ) ____________
%
100
95
TARGET 98 %
90
White ()
85
Yellow ()
80
75
70
65
60
55
50
Month
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
I)
* .
* .
II) % Health Preparation by self check
X 100
.
=
.
GL
Asst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
25

Example Graph For Health Check
2007
% Good Health by self check ( ) ____________
%
100
95
TARGET 98 %
90
White ()
85
Yellow ()
80
75
70
65
60
55
50
Month
Shift
I)
* .
* .
II) % Health Preparation by self check
07
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
237
235
2
X 100
.
=
99.16
.
235
X 100 = 99.16
237
GL
Asst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
26
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
27
Safety Pro
-Active
Pro-Active
Indicator
Health Condition
Man
PPE Rule Keeping
KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
28
Man : PPE Rule Keeping
TOYOTA
SPI
SPI Manual
Manual
29

(PPE)

TOYOTA
SPI
SPI Manual
Manual
30

TOYOTA
SPI
SPI Manual
Manual
31
.....
TOYOTA
SPI
SPI Manual
Manual
32

1.
2.
How to Evaluation
Purpose
STEP 1
STEP 2
OK
PPE

( 8.30 . )
** 2 **

GL kumi
Shop Safety Audit
TOYOTA
NG
PPE Rule Check Sheet
2 Way Communication
SPI
SPI Manual
Manual
33

KPI Target : PPE Rule Keeping 100%
1.2 PPE Rule Keeping Daily Control of KUMI____________
Shift ___________
Month ________
MC1
White
SEP '07
1
PPE
1.2) % PPE Rule Keeping
2007
( PPE ) _______________
9
100
95
Process__________ Process__________
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Process__________ Process__________ Process__________ Process__________ Process__________ Process__________ Process__________
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TARGET = 100 %
90
White ()
85
Yellow ()
80
75
70
65
60
55
50
Month
Daily
10
+ 0
10
( TL.)
(GL.)
10 10
0 0
10 10
9 10 10 10
0 0 0 0
9 10 10 10
10 10 9 10 10 10
0 0 1 0 0 0
10 10 10 10 10 10

= PPE
No. PPE No.
Apr'__
Shift
10 9 10 10 10 10
0 1 0 0 0 0
10 10 10 10 10 10
10 10 10 10 10 10
0 0 0 0 0 0
10 10 10 10 10 10
= ___________
I)

249
250
* .
PPE
247
240
* .
PPE +
10
9 9 .2
96
May
Jun
Jul
II) % PPE Rule Keeping check
.= . PPE
..
X 100
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
Monthly
GL

= PPE
= PPE
3
247
2
249
= _________
A sst. Mgr. Up
Revision No. / Effective Date : 1 / Jun 01, 2007
Calculate :
%PPE rule keeping
TOYOTA
Total operator correct PPE rule (person)

Total all operator work per month (person)
SPI
SPI Manual
Manual
100
34

Daily PPE Rule Check Sheet (Less than 17 Worker)
PPE Rule Keeping Daily Control of Line____________
1
PPE
Process__________
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
_____
Process__________
Shift ___________ Month ________
Process__________
Process__________
Process__________
Process__________
Process__________
Process__________
14
18
22
26
10
11
12
13
15
16
17
19
20
21
23
24
25
27
28
29
Process__________
30
31
( TL.)
(GL.)
:
= PPE
TOYOTA
= PPE
= PPE
No. PPE No.
= ___________
SPI
SPI Manual
Manual
= _________
35

Daily PPE Rule Check Sheet (More than 17 Worker)
1
PPE
Process__________
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Process__________
Shift ___________ Month ________
Process__________
Process__________
Process__________
Process__________
Process__________
9 10 11 12 13 14 15 16
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
_____
( TL.)
( TL.)
(GL.)
(GL.)
= PPE
TOYOTA
= PPE
No. PPE No.
= ___________
SPI
SPI Manual
Manual
Process__________
Process__________
9 10 11 12 13 14 15 16
= _________
36

Daily PPE Rule Check Sheet Example
MC1
1
PPE
B process
Process__________
All Process
Process__________
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
C process
Process__________
C process
Process__________
10
11
12
All Process
Process__________
B, C process
Process__________
B, C process
Process__________
All Process
Process__________
Process__________
14
18
22
25
26
27
28
29
30
10
0
10
10
0
10
10
0
10
10
0
10
10
0
10
15
16
17
19
20
21
23
24
31
Ear Plug
13
Shift ___________
White Month ________ SEP
Apr '07
10
0
10
( TL.)
10
(GL.)
:
10
0
10
9
0
9
10
0
10
10
0
10
10
0
10
10
0
10
10
0
10
9
1
10
10
0
10
10
0
10
10
0
10
10
0
10
9
1
10
10
0
10
10
0
10
10
0
10
10
0
10
10
0
10
= PPE
TOYOTA
10
0
10
= PPE
= PPE
No. PPE No.
= PPE 3
SPI
SPI Manual
Manual
247
2
249
= PPE 2
37

Graph For PPE Rule Check
% PPE Rule Keeping
( PPE ) _______________
100
95
TARGET = 100 %
90
White (
85
Yellow ()
80
75
70
65
60
55
50
Month
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
I)
* .. PPE
* .. PPE
.
. PPE
=
..
X 100
GL
Asst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
38

Graph For PPE Rule Check
% PPE Rule Keeping
2007
( PPE ) _______________
100
95
TARGET = 100 %
90
White (
85
Yellow ()
80
75
70
65
60
55
50
07
Apr'__
Month
Shift
I)
* .. PPE
* .. PPE
.
. PPE
=
..
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
249
247
2
99.20
X 100
247
X 100 = 99.20
249
GL
Asst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
39
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method
Env.
40
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping
KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
41
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
42
Man : KY Ability
Purpose 1)
2)
How to Evaluation
Persons
Activity
1) Newcomer
1R
Basic KY
Ability
2) Operator
4R KYT
Ability
3) TL
4R KYT
Ability
4) GL
Shop
Safety Audit
TOYOTA
Eva. Step
Method/document
1.1 Pre-Test
1.2 Training
1.3 Post-Test
2.1 Select representative to
demonstrat
2.2 Find out dangerous job &
Find out high risk job
1.1 Model sheet

1.2 STOP6 & A-Rank Manual
1.3 Test KY sheet
2.1 Photo
Evaluator
Period
PA
Newcomer
Training
TL
Monthly
(Safety hour)
GL
Monthly
(Working hour)
Other GL
& Asst.
Monthly
(Inhouse shop
safety audit)
2.2 4R KY report
3.1 Select representative (Han)

3.2 Find out dangerous job
and Find out high risk
3.1 Actual work site observation

3.2 4R KY report
4.1 Select audit area

4.2 Self & Cross function
Check
4.1 Cross check

(Check sheet)
SPI
SPI Manual
Manual
43
Man : KY Ability
Persons
Activity
Eva. Step
Method/Document
Evaluator
Period
NEWCOMER
Basic KY
Ability
1) (Pretest)
PAS
Newcomer
Training
1R KYT Level
0-20
1
21-40
2
41-60
3
61-100
4
2)
Stop 6
A-rank Manual
Accident Case
CLASS
CLASS ROOM
ROOM
Practice
Practice Study
Study
3) (Post-Test)
TOYOTA
SPI
SPI Manual
Manual
Name
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
A
B
C
D
E
F
G
Total
( Not Same )
No. of Hazard
find out
6
7
5
8
4
7
9
10
Percentage
6
7
5
8
4
7
9
/
/
/
/
/
/
/
10
10
10
10
10
10
10
=
=
=
=
=
=
=
60
70
50
80
40
70
90
100%
%
%
%
%
%
%
%
Level
3
3
2
4
2
3
4
4
4R KY Level
Newcomer
2
Operator
3
Team Leader (TL)
4
Group Leader (GL)
5
44
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
45
Man : KY Ability
Persons
OPERATOR
Activity
Eva. Step
Method/Document
4R KYT 1) /Process HAN

(
Ability
3 )
Evaluator
Period
TL
Monthly
(
)
4R KYT
1.3) 4R KYT ( KY Ability Test )
R1 :
Score
12
13
14
15
16
17
18
19
R4
2 :
KYT KEY WORD :
KYT
2
3
:
Shift :
White
Yellow
KY Ability level :
1R KYT Level
0-20
1
21-40
2
41-60
3
61-100
4
Revision No. / Effective Date : 1/ Jun 01, 2007
Operator
TOYOTA
5
6
Name
20
R3 : R2
1 :
Sco re
R2 :
R1 2 O

Mr.A
11
10
2)
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
A
B
C
D
E
F
G
Total
( Not Same )
No. of Hazard
find out
6
7
5
8
4
7
9
10
Percentage
6
7
5
8
4
7
9
/
/
/
/
/
/
/
10
10
10
10
10
10
10
=
=
=
=
=
=
=
60
70
50
80
40
70
90
100%
%
%
%
%
%
%
%
Level
3
3
2
4
2
3
4
4
4R KY Level
Newcomer
2
Operator
3
Team Leader (TL)
4
Group Leader (GL)
5
SPI
SPI Manual
Manual
46
Man : KY Ability
R1 :
Score
11
12
13
14
15
16
17
18
19
10
20
Score
R2 :
R1 2 O
R3 : R2
R4
1 :
2 :
KYT
KYT KEY WORD :
Shift :
White
Yellow
KY Ability level :
TOYOTA
SPI
SPI Manual
Manual
47
Man : KY Ability
R1 :
Score
1)
4)
Score
2) (PE)
5)

3)
"
R1 2 O
R2 :
R3 :
R2
R4
1 :
2 :
KYT
KYT KEY WORD :
1)
1)
2)
:
:
3)
Shift :
100982
White
Yellow
KY Ability level :
TOYOTA
SPI
SPI Manual
Manual
48
Man : KY Ability
(Mean Result each KUMI)

Name
Mr. A
Mr. B
Mr. C
Mr. D
Mr. E
Mr. F
Mr. G
Total
( Not Same )
TOYOTA
No. of Hazard
find out
6
7
5
8
4
7
9
Percentage
Level
6 / 10 = 60 %
7 / 10 = 70 %
5 / 10 = 50 %
8 / 10 = 80 %
4 / 10 = 40 %
7 / 10 = 70 %
9 / 10 = 90 %
3
3
2
4
2
3
4
10
100%
SPI
SPI Manual
Manual
Criteria
%
Level
0 - 25
1
26 - 50
2
51 - 75
3
76 - 100
4
4R KY Level
Newcomer
2
Operator
3
Team Leader (TL)
4
Group Leader (GL)
5
49
Man : KY Ability
(KY Ability)
Ability)
0-20
21-40
41-60
61-100
0-20
21-40
41-60
61-80
81-100
TOYOTA
1 (0-20)
2 (21-40)
3 (41-60)

STOP6
STOP6

4R KYT
STOP6
SPI
SPI Manual
Manual
4 (61-80) 5 (81-100)
,
,
STOP6
STOP6
4R KYT 4R KYT

50
Man : KY Ability
Persons
Team Leader
( TL )
Activity
Eva. Step
Method/Document
4R KYT 1) HAN KUMI

Ability
4R KYT

4R KYT
R1
R2
2)
Evaluator
Monthly
()
-
- R1 2
( 1 )
GL
Period
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
R3 ()
R4
( 1 )
(3)
1.
2.
3.
4.
5.
1.
2.
3.
4.
5.
Criteria
%
Level
0 - 20
1
21 - 40
2
41 - 60
3
61 - 80
4
81 - 100
5
Approved
Approved
Issued by
Form Revision no. / Issued date / Effective date : 0 / May. 21, 2001 / Jun. 1, 2001
Name
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
A
B
C
D
E
F
G
Total
( Not Same )
TOYOTA
SPI
SPI Manual
Manual
No. of Hazard
find out
6
7
5
8
4
7
9
10
Form no. SF-F-079
Percentage
6
7
5
8
4
7
9
/
/
/
/
/
/
/
10
10
10
10
10
10
10
=
=
=
=
=
=
=
60
70
50
80
40
70
90
100%
%
%
%
%
%
%
%
Level
3
4
3
4
2
4
5
5
51
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
52
Man : KY Ability
Work Shop 5
4 ( 4R KYT )
R1)
R2)
-
- R1
()
( R1 )
R3) ()
TOYOTA
(R2 )
R4)
SPI
SPI Manual
Manual
53
Man : KY Ability
Work Shop 5
4 ( 4R KYT )
R1)
R2)
-
- R1
()
( R1 )
(R2 )
1)
HOOD OUTER PALLET SET

STAND CHECK SURFACE
1.1)
1.2) HOOD OUTER PALLET
2)
HOOD OUTER CHECK SURFACE

+ REPAIR
2.1)
()
2.2) PART
3)
SET HOOD PALLET STOCK
3.1)
3.2) HOOD OUTER PALLET
R3) ()
1)
1.1) Part

2) 2.1) 4
2.2) ***********************
3)
TOYOTA
R4)
" Part

4 "
3.1) Part

SPI
SPI Manual
Manual
Work Standard Sheet

54
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
55
Man : KY Ability
How to calculate % of hazard find out performance
Name
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
Mr.
A
B
C
D
E
F
G
Total
( Not Same )
TOYOTA
No. of Hazard
find out
6
7
5
8
4
7
9
10
Percentage
6/
7/
5/
8/
4/
7/
9/
10 =
10 =
10 =
10 =
10 =
10 =
10 =
60 %
70 %
50 %
80 %
40 %
70 %
90 %
100%
Level
3
3
2
4
2
3
4
4
SPI
SPI Manual
Manual
Criteria
%
Level
0 - 20
1
21 - 40
2
41 - 60
3
61 - 80
4
81 - 100
5
56
Man : KY Ability
* GL KY Ability (Shop Safety Audit & HIYARI)
GL Cross Audit criteria STD.
(Shop Safety Audit)

MGR & Safety window (1 time/month/Kumi)
Cross Functional Check Result
Items
Rank A
10
Rank B
Rank C
8
3
6
4
2
other GL,Mgr
Window (In house safety audit)
1
1
Feb
Mar
KPI Target (KY ABILITY)
Jan
1
1
0
Apr
2
1
0
May
2
0
Jun
3
1
1
Jul
Rank
5
4
3
2
1
A
0
1
2
3
4
* GL A-Rank

KY Ability GL
Level
1
0
Aug
1
0
Sep
1
0
Oct
1
1
0
Nov
1
1
0
Dec
Month
level 3 80 %
KY Ability Result
No.
Name
KY Ability Result
Position
1 Mr.Sompong
GL
2 Mr.Anusorn
TL
3 Mr.Tawee
TL
TL
Operator
Operator
Operator
4
2
3
2
4
3
3
3
4
3
3
3
4
3
2
3
4
3
3
3
4
3
3
3
4
3
4
3
4
4
3
3
4
4
3
3
5
4
3
3
5
4
3
3
5
4
3
3
4
5
6
7
Mr.Narong
Mr.Weerasak
Mr.Damrong
Mr.Kamol
% KY Ability Separate by Level
100%
75%
25
50%
23
30
25%
0%
28
10
5
5
20
20
12
15
10
Jan Feb Mar

No. Person not achieve target
TOYOTA
34
34
20
12
24
15
17
Apr May Jun
Level 5
SPI
SPI Manual
Manual
22
Level 4
35
26
28
20
22
38
30
25
Jul Aug Sep
Level 3
Level 2
35
30
32
27
35
30
25
Target Above
level 3 80 %
38
32
Oct Nov Dec
Month
Level 1
57
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
58
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
59
Man : KY Ability
TOYOTA
SPI
SPI Manual
Manual
60
Man : KY Ability
10
11
12
13
GL
TOYOTA
2008
2008
2007
4/8
3
4/8
3
4/8
3
4/8
3
9/10
4
5/10
3
5/10
3
5/10
3
6/7
4
4/7
3
4/7
3
4/7
3
5/9 11/12
4
3
5/9 6/12
3
3
5/9 11/12
4
3
5/9 11/12
4
3
(_432_)
(LEVEL)
M AR
2008
4/7 5/11 4/9

3
3
3
4/7 5/11 4/9
3
3
3
4/7 10/11 4/9
3
4
3
4/7 10/11 4/9
3
4
3
2007
2007
2007
FEB
JA N
DEC
NOV
2007
OCT
5/10
3
5/10
3
5/10
4
5/10
3
2007
4/8
3
4/8
3
4/8
3
4/8
3
SEP
5/7
3
5/7
3
5/7
3
5/7
3
2007
9/10
4
5/10
3
5/10
3
9/10
4
AUG
( _108_)
( LEVEL )
( _108_)
( LEVEL )
( _108_)
( LEVEL )
( _108_)
( LEVEL )
(
)
( LEVEL )
)
(
( LEVEL )
)
(
( LEVEL )
)
(
LEVEL
)
(
LEVEL
)
(
LEVEL
)
(
LEVEL
)
(
LEVEL
)
(
( LEVEL )
Level 1
Level 2
Level 3
Level 4
Level 5
JU L
JU N
M AY
APR
No.
2007
2007
KY Ability Evaluation Yearly Record of Kumi___MC1___ Shift _Yellow_ ( ___2007___ )
108
3
108
3
108
3
108
3
- Level
100
- Level
Operator TL
/
level
0
0
2
2
0
0
0
4
0
0
0
0
4
0
0
0
0
3
1
0
0
0
4
0
0
0
0
2
2
0
0
0
4
0
0
0
0
4
0
0
0
0
3
1
0
0
0
3
1
0
0
0
4
0
0
0
0
1
3
0
SPI
SPI Manual
Manual
61
Man : KY Ability
1.3) % KY ABILITY LEVEL 3 UP
( 3
) _____________________
%
100
90
TARGET LEVEL 3 UP 80 %
LEVEL 3 ()
LEVEL 4 ()
LEVEL 5 ()
80
70
60
*
50
%
Level 3, 4 5
Level5 -->
Level 4 Level 3
40
30
20
10
Month
Shift
May
Jun
Jul
Aug
Oct
Y
10
* % . Level 5
(3/10) x 100 = 30%
(2/10) x 100 =
* % . Level 4
(4/10) x 100 = 40%
(3/10 ) x 100= 30%
* % . Level 3
(2/10) x 100=
(2/10 ) x 100= 20%
* % . Level 2
(1/10) x 100 = 10%
* % . Level 1
90%
70%
20%
Sep
10
A ) .
B)
Apr'__
(3/10) x 100=
Nov
Dec
Jan'__
Feb
Mar
20%
30%
% Level 3 Up
=
. . Level3,4,5 X 100
.
GL
A sst. Mgr. Up
(2+4+3) x 100
10
(2+3+2) x 100
10
TOYOTA
SPI
SPI Manual
Manual
62
Man : KY Ability
KY Ability Operator
1 2 3 4 5 6 7 8 9 10 11 12
GL
GL
Shop
MGR
GL
GL
PA
Safety
GL
GL
Shop
MGR
GL
GL
PA
Safety
GL TL
( KUMI )
TOYOTA
SPI
SPI Manual
Manual
63
Man : KY Ability
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
64
Safety Pro
-Active
Pro-Active
Indicator
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
65
Man :Hiyari Suggestion

Purpose
1. (Near miss)
2.

KPI Target 1.Hiyari Suggestion Result

1. = 1 //
Hiyari Suggestion Book
KY CAPABILITY EVALUATION
Hiyari Suggestion Record
Items
4R KYT
5
4
Hiyari hatt
suggestion
3
2
Hiyari Suggestion Summary
Instruct KY
through job
instruction
1
0
Skill of detect
Safety rule
danger
Name .............................. Line .................Func ................Tel. .........
Date Rank Suggest
Problem
Plan Satisfaction
() ( ) ()
A
MGR.
()
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
1.0 1.0
1.2
1.2
1.2
Target 1
Item/Man/M
onth
Month
: Hiyari
1
TOYOTA
1.0
1.05
1.7
1.5
1.3
1
1.8
1.75
() ()
100%
SPI
SPI Manual
Manual
Hiyari .

66

Hiyari Suggestion Book
KY CAPABILITY EVALUATION
4R KYT
5
4
Hiyari hatt
suggestion
3
2
Instruct KY
through job
instruction
1
0
Skill of detect
Safety rule
danger
Name .............................. Line .................Func ................Tel. .........
Date
Rank Suggest
Problem
Plan
Satisfaction
() ( ) ()
A
MGR.
TOYOTA
()
( )
()
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
MGR.
100%
GL.
80%
TL.
50%
SPI
SPI Manual
Manual
67

1.4) Hiyari Monthly Plan & Result of KUMI ____________
No
Plan
Actual
Rank

No
Man M/C Method Envi A B C
18
19
20
21
5
6
7
Plan
Hiyari
Shift ___________ Month ________
Plan
Actual
Rank

22
23
24
25
26
10
27
11
28
12
29
13
30
14
31
15
32
16
33
17
34
TOYOTA
SPI
SPI Manual
Manual
68

1.4) Hiyari Monthly Plan & Result of KUMI ____MC1_____ Shift ___White____ Month ___SEP '07_____
Rank
No
Plan
Actual
1/11/07
1/11/07
18
1/11/07
1/11/07
19
1/11/07
1/11/07
20
1/11/07
1/11/07
21
No
22
23
24
25
26
10
27
11
28
12
29
13
30
14
31
15
32
16
33
17
34
TOYOTA
SPI
SPI Manual
Manual
Plan
Actual
Rank
69

1.4) HIYARI HATTO SUGGESTION
( )
____2007_______
Item
2
1.8
TARGET = 1 It em/Man-Mont h
1.6
White ()
1.4
Yellow ( )
1.2
1
0.8
0.6
0.4
0.2
0
Mont h
Apr'__
I)
II) Hiyari
Shift
* Rank A
* Rank B
* Rank C
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
May
III) Hiyari Suggestion

=
.Hiyari X 100
..
100 100
GL
A sst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
70
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
71
Man :Problem & C/M

MAN
KPI Problem & C/M
No
TOYOTA
//
Month ____________Year ____________

SPI
SPI Manual
Manual
72
Man :Problem & C/M
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
73
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
74
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition

Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
75
Machine :Safety Device Function

TOYOTA
SPI
SPI Manual
Manual
76

*
# Emergency Stop
# Photo eye
# Safety Door
# Safety plug
# Safety block
# Safety Fence
*
#
#
Mode
#
TOYOTA
SPI
SPI Manual
Manual
77

*
1)
2)
3)
4)
5)
TOYOTA
SPI
SPI Manual
Manual
78

TOYOTA
SPI
SPI Manual
Manual
79
TOYOTA
SPI
SPI Manual
Manual
80
TOYOTA
SPI
SPI Manual
Manual
81

KPI Target : % Completion = 100%
Result & KPI Target
Method
Evaluation Item
Safety Device list
Safety Device
** 2 **

GL kumi
Shop Safety Audit
1. (Emergency Stop)
Daily
2. 2
Daily
3. (Photo Eye)
Daily
4. (Safety Plug)
Weekly
5. (Safety Block)
Weekly
6. (Mat SW.)
Weekly
7. (Key SW.)
Weekly
TOYOTA
Calculate :
No. of complete
X 100
No. of all set day
% of complete safety device
Target =100 %
% Completion =
%
100
80
100 100 100
80
100 100 100
100
90
100
100
50
SPI
SPI Manual
Manual
Month
82

Safety Device Function Check Plan & Result
TOYOTA
SPI
SPI Manual
Manual
83

Device
How to Check
Code
Shift
No Safety Device
2.1) SAFETY DEVICE FUNCTION CHECK KUMI __MC1___ Month __Sep' 07___
1
10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Checked by
BS 1-2
Result
Daily
Bottom Switch
Plan
Plan
Result
Actual
Daily
PE 1
Photo Eye
Plan
Plan
Result
Weekly
SB 1-2
Safety Box
Result
Plan
Safety box
Hemming
Plan
Result
ES 1-2
Result
Daily
Emergency Stop
Plan
Plan
Result
SP 1-2
Checked (GL)
Weekly
Safety Plug
Plan
Result
Plan
safety plug
operate
Result
safety device Botton Switch = BS, Photo Eye = PE

Botton Switch 2
BS 1-2
TOYOTA
SPI
SPI Manual
Manual
X Problem
Machine List
84

2.1) % COMPLETED OF SAFETY DEVICE
( ) ___________
%
100
95
TARGET = 100 %
90
White ()
85
Yellow ( )
80
75
70
65
60
55
50
Mont h
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
I) Safety Device
* .
* .
II) % Complete of Safety Device
. X 100
.
GL
A sst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
85

2.1) % COMPLETED OF SAFETY DEVICE
( ) ___2007____
%
100
95
90
TARGET = 100 %
White ()
85
Yellow ()
80
75
70
65
60
55
50
Month
Apr'_07_
Shift
79
78
* .
78
79
78
79
97%
97%
= .
.(Plan)
GL
Asst. Mgr. Up
TOYOTA
X 100
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
1. Safety Device = (
plan )
2. . = result
3. . = X result
79
78
II) % Complete of Safety Device
* .
I) Safety Device
May
SPI
SPI Manual
Manual
86
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
87
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
88
Machine :Equipment Condition
TOYOTA
SPI
SPI Manual
Manual
89

KPI Target : % Completion = 100%
Method
Result & KPI Target
(Equipment Condition)
STOP6
1) Inspection
Check Sheet 1 / 1

Check 1 /
Inspection
Sheet
** 2 **

Process
GL kumi
Shop Safety Audit
100
No. of safety equipment

No. of all equipment
80
100 100 100
80
100 100 100
100
90
100
=100 %
X 100
TOYOTA
100 Target
50
Calculate :
% Completion =
% of complete safety device
SPI
SPI Manual
Manual
Month
90

Equipment Condition Check Plan & Result
TOYOTA
SPI
SPI Manual
Manual
91

Equipment Condition Check Plan & Result
X
Problem Machine List
TOYOTA
SPI
SPI Manual
Manual
92
TOYOTA
SPI
SPI Manual
Manual
93
TOYOTA
SPI
SPI Manual
Manual
94
TOYOTA
SPI
SPI Manual
Manual
95
TOYOTA
SPI
SPI Manual
Manual
96

SAFETY FENCE
1 :
1) ( Safety Fence )
1.1) ( Safety Fence Machine )
1 '' , T = 2 mm
1,400 .

( Danger Zone )
1
1,400 .
150 .
150 .

12 x 70 . 4

120 .
120 .

: TOA-G177 , Jotun 1022
TOYOTA
SPI
SPI Manual
Manual
: .
(Height of danger zone )

1,600 . ( Horizontal
distance to danger zone ) 800 .
(Height of guard ) 1,800 .
97

ELECTRIC POWER SUPPLY
2 : / /
7)
A power supply breaker
Illumination
SDD Sw itch
Locking Jig Lock
Out Breaker Off
SDD Switch
Off
Lock Out
Live part, a terminal part
An emergency stop button
Cover

Terminal
*
Lock Out
Admission device
* Lock Out
Safety Plug
Locking Jig
Lock Out
Emergency stop range indication

AUTO
AUX1
ON OFF
MASTER ON
TOYOTA
MANUAL
SPI
SPI Manual
Manual
AUX1
START
AUX1
STOP
AUX2
ON
OFF
AUX2
START
AUX2
STOP
ALARM
STOP
ALARM
RESET
Key SW
Selector

Locking Jig
Lock Out
Key SW Selector
SW Off
98
TOYOTA
SPI
SPI Manual
Manual
99
TOYOTA
SPI
SPI Manual
Manual
100
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
101
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition

Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
102
Machine :New Machine Condition

KPI Target : When fine the problem should be solve before start
Method
New or Modify M/C
Result & KPI Target

1) Inspection
Evaluation Item

(Safety Device
Function & Equipment Condition)
Inspection
Sheet
2) Result
B-Rank
10
A-Rank
Total
30
C-Rank
15
1. check Sheet
Equipment condition check Sheet
1 check sheet 1
2.
Process
3. Process update
Safety Device Function Equipment
Condition
TOYOTA
SPI
SPI Manual
Manual
103

New M/C or Modify E/Q Check Plan & Result
TOYOTA
SPI
SPI Manual
Manual
104

New M/C or Modify E/Q Check Plan & Result
2.3) New Mechine or Modity Equipment Check of KUMI ___MC 1____
No.
1
Plan
Process
Machine
Process 1
Machine A
//
14-Aug-07
Rank
Problem
Emergency
Countermeasure
Target
Result
20-Aug-07
Asst.Mgr up
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
: Result check sheet
TOYOTA
= check
SPI
SPI Manual
Manual
= check
105
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
106
Machine Problem List

MACHINE :
New or Modify Equipment Condition
Method

TOYOTA
SPI
SPI Manual
Manual
107

2.4) Machine Problem List of KUMI __________
No
Process
Machine &
Equipment
//
Problem
Process B
Equipment
Name B
9/7/2007
Process A
Safety Box
Process A
Rank
Target
Fence
fence
9/10/2007
9/8/2007
Safety box
Hemming
safety box
Hemming
9/15/2007
Equipment
Name A
9/22/2007
guard
guard
9/30/2007
Process B
Emergency
Stop
9/25/2007
9/30/2007
Process 1
Machine A
20-Aug-07
14-Aug-07
A B C Hiyari E/C S/D New or Mod. M/C
Emergency
Asst.Mgr up
= O.K.
= NG.
( E/C = Equipment Condition , S/D = Safety Device , Mod. = Modify)
TOYOTA
SPI
SPI Manual
Manual
108
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
109
Machine :Problem & C/M

MACHINE
KPI Problem & C/M
No
TOYOTA
//
Month ____________Year ____________
SPI
SPI Manual
Manual
110
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
111
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
112
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Method
Environment
TOYOTA
Communication
Ergonomic Kaizen
5S
SPI
SPI Manual
Manual
113
Method :Communication (Low Frequency Job)
TOYOTA
SPI
SPI Manual
Manual
114

Purpose 1)
2) (
) ( PM )
How to Evaluation
Activity Step
Communication time
TOYOTA
Job
Leader
Operator
Operator
and
Job
Leader
SPI
SPI Manual
Manual
115

KPI Target :
100%
GL. ( No. of Job)
1
(A)
(B)
2
GL.
TL.=>T/M=>Job implement =>TL.
Remark :
Skill
Calculate :
% Completion =
Communication sheet
Team register
% Percentage of Communication
100
95
100 100
97
100 100 100
Target =100 %
100
97
90
100
50
X 100
Month
Team Register (B)
Communication Sheet (A)
TOYOTA
100
SPI
SPI Manual
Manual
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
XX
116

3.1) Communication Register
No.
//
Shift
()
No.
( / / - - -)
=
=
: Problem Machine List
TOYOTA
SPI
SPI Manual
Manual
117

3.1) Communication Register
()
No.
//
Shift
9/5/2007
Yellow
9/5/2007
Yellow
Cleaning
No.
( / / - - -)
Kumi A/2007/09_01
Kumi A/2007/09_02
STD Work

Operation STD Level 3

(Plan of Operation STD. Improvement to
Level 3 Form)
=
=
: Plan of Operation STD. Improvement to Level 3
TOYOTA
SPI
SPI Manual
Manual
118

Kumi A/2007/09_02
..................
Kumi
05/09/2007

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Kumi
Kumi A
Cleaning

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
()
()
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
2
3
4
5
6
7
8
9
10
11
12
13
14
15
TOYOTA
SPI
SPI Manual
Manual
119

3.1) % Communication ()
______________
%
100
TARGET = 100 %
White ()
Yellow ()
95
90
85
80
75
70
Month
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
I)
* (Abnormal)
* (Low freq)
II) (4R KYT)
III) % Communication
= . (4R KYT ) X 100
.
GL
Asst.Mgr
TOYOTA
SPI
SPI Manual
Manual
120
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
121
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Environment
TOYOTA
Ergonomic Kaizen
5S
SPI
SPI Manual
Manual
122
Method :Ergonomic Kaizen
TOYOTA
SPI
SPI Manual
Manual
123

Purpose 1) Operator
2)
Method
1. Ergonomic Kaizen 1
2. Kaizen
(Asst.Mgr up) Operation STD
TOYOTA
SPI
SPI Manual
Manual
124
TOYOTA
SPI
SPI Manual
Manual
125
TOYOTA
SPI
SPI Manual
Manual
126

KPI Target : 1 Item/Person/Month
TOYOTA
SPI
SPI Manual
Manual
127
TOYOTA
SPI
SPI Manual
Manual
128
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
129
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Environment
TOYOTA
Ergonomic Kaizen
5S
SPI
SPI Manual
Manual
130
Method : Safety Key Point Completion
TOYOTA
SPI
SPI Manual
Manual
131

Purpose
1)
2)
Safety Key point
KPI Target :
Operation STD Level 3 = 100 %

Low Feq. Work Level 3 = 100 %
How to Evaluation
Method & Auditor
KPI Target
1. Operation STD
Low Feq. Level 3
2. Operation STD Low Feq.
Level 3
TOYOTA
% Operation STD level 3 =
Total Operation level 3

Total operation
X 100
% Low Feq.work level 3 =
Total Low Freq. LEVEL3

Total Low Feq.
X 100
SPI
SPI Manual
Manual
Target : Operation STD

Level 3 = 100 %
Target : Low Feq. Work

Level 3 = 100 %
132

3.3) Plan of Operation STD. Improvement to Level 3 Kumi ____________
No
Work Name
//
Shift
Type of work
W Y OPR. STD Low Freq. Comm. Ergo. Hiyari Changing point
Target
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
= O.K.
:
(Comm. = Communication , Ergo. = Ergonomic Kaizen)
= NG.
TOYOTA
SPI
SPI Manual
Manual
133

3.3) Plan of Operation STD. Improvement to Level 3 Kumi __MC1_____
No
Work Name
//
Shift
Type of work
W Y OPR. STD Low Freq. Comm. Ergo. Hiyari Changing point
Target
1)
Cleaning
9/5/2007
PPS_07_001
9/15/2007
2)
9/15/2007
PPS_08_013
9/30/2007
3)
4)
Asst.Mgr up
Level 3
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
= O.K.
:
(Comm. = Communication , Ergo. = Ergonomic Kaizen)
TOYOTA
= NG.
SPI
SPI Manual
Manual
134

3.3) % Operation STD. (EIS) Level 3
( 3)
________________
%
100
TA RGET = 100 %
80
OPR. STD (EIS) ______ 60

40
20
Month
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
Dec
Jan'__
Feb
Mar
I) Operat ion STD.

II) Operat ion STD
Level 3
III) % Operation STD Level 3
=
. OP R . STD Level 3 X 100

. OP R. STD
GL
Asst.Mgr
3.4) % Low Frequency STD Level 3 (Operation ST D )
________________
%
100
TA RGET = 100 %
Low Fre q. Job ______
80
60
40
20
Month
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
I) Low Freq.
II) Low Freq Level 3
III) %Low Freq. have Operation Level 3
. Lo w Freq. Level 3 X 100
=
. Lo w Freq. Jo b
GL
Asst.Mgr
TOYOTA
SPI
SPI Manual
Manual
135

3.3) % Operation STD. (EIS) Level 3
( 3)
_____2007_______
%
TARGET = 100 %
500
OPR. STD (EIS) ______
100
80
60
40
20
Month
Shift
Apr'_07_
I) Operation STD.
II) Operation STD Level 3
III) % Operation STD Level 3
=
.OPR. STD Level 3

.OPR. STD
X 100
W
500
485
485
500
Y
500
485
485
500
97%
97%
GL
Asst.Mgr
May
Jun
Jul
Aug
3.4) % Low Frequency STD Level 3 (Operation STD )
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
_____2007_______
%
TARGET = 100 %
40
Low Freq. Job ______
100
80
60
40
20
Month
Shift
I) Low Freq.
II) Low Freq Level 3
III) %Low Freq. have Operation Level 3
=
.Low Freq. Level 3 X 100

.Low Freq. Job
TOYOTA
Apr'_07_
W
40
Y
40
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
33 33
33
33
40
40
82.5% 82.5%
GL
Asst.Mgr
SPI
SPI Manual
Manual
136
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
137
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
138
Safety Pro
-Active Indicator
Pro-Active
METHOD
KPI Problem & C/M
No
TOYOTA
//
Month ____________Year ____________
SPI
SPI Manual
Manual
139
Safety Pro
-Active Indicator
Pro-Active
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
140
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
141
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
SPI
SPI Manual
Manual
142
Environment :5S Condition
Purpose
KPI Target : 5S Condition 70%

How to Evaluation
Method
Result & KPI Target
5S Activity
1) 5 70 % ( 5)
%
100
5S Evaluation Score
80
82
78
80
82
80
85
90
90
85
73
Target 70 %
1) 5 GL/TL (Weekly)
2) 5 Shop Safety Audit
(Monthly)
50
5S CONDITION Check Plan
Month
Calculate :
% 5S Score =
TOYOTA
85
SPI
SPI Manual
Manual
Total score
No. of audit
143

4.1) 5S CONDITION CHECK PLAN OF KUMI ____________ Month ____________
No.
Han Name
SHIFT
W
1
Y
W
2
Y
W
3
Y
W
4
Y
W
5
Y
W
6
Y
W
7
Y
W
8
Y
W
9
Y
10
11
12
13
: Plan Shop Audit

Plan Self Check
:
Environment Problem List
TOYOTA
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
SPI
SPI Manual
Manual
= check 70%
= check < 70%
144

4.1) 5S CONDITION CHECK PLAN OF KUMI ____MC1________ Month ___SEP' 07_______
No.
Han Name
SHIFT
W
Han Name A
Y
W
Han Name B
Y
W
3
Y
W
4
Y
W
5
Y
W
6
Y
W
7
Y
W
8
Y
W
9
Y
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
Plan
Result
10
11
12
13
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Self
Audit
Shop
Audit
GL, TL (Weekly)
70% X
: Plan Shop Audit

Plan Self Check
: Environment Problem List
TOYOTA
14
SPI
SPI Manual
Manual
= check 70%
= check < 70%
145
check
check 5S
5S
TOYOTA
SPI
SPI Manual
Manual
146

4.1) 5S Condition
__________________
( 5 )
100
White ()
Yellow ()
95
90
S Score from check sheet 70 % 85
80
75
70
65
60
55
50
Mont h
Shift
Apr'__
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
I)
5S
II)
III)
% 5S Score
=
GL

A sst. Mgr. Up
TOYOTA
SPI
SPI Manual
Manual
147

4.1) 5S Condition
( 5 )
100
_____2007__________
White ()
Yellow ()
95
90
5S Score from check sheet 70 %
85
80
75
70
65
60
55
50
Month
Shift
I) 5S
Apr'_07_
12
12
II)
956 978
III) % 5S Score

956 97
12 812
80% 82%
GL
Asst. Mgr. Up
TOYOTA
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
Plan
SPI
SPI Manual
Manual
148
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
149
Safety Pro
-Active Indicator
Pro-Active
Health Condition
Man
PPE Rule Keeping

KY Ability
Hiyari Suggestion
Machine
Equipment Condition
Communication
Method
Ergonomic Kaizen
Environment
TOYOTA
5S
Working Environment
Feedback
SPI
SPI Manual
Manual
150
Environment :Environment Feedback

Purpose
How to Evaluation
Method
Environment feedback
Result & KPI Target

1. Environment
Feedback ()
2. two way communication
1)
2)
PA (PA
)
3)
3)
TOYOTA
3. Target
% ( Target
)
SPI
SPI Manual
Manual
151

TOYOTA
SPI
SPI Manual
Manual
152

4.2) Environment Feedback of Kumi ___MC1____ Month ____SEP' 07_____ Shift ___YELLOW_____
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
//
8/5/2007
9/9/2007
Target
Layout
9/15/2007
9/13/2007
Target
Target 100%
Asst.Mgr up
Target

Aug Target Sep

Target
Target
target
target
Target (A)
= O.K.
(B)
= NG.
: Environment Problem List
TOYOTA
SPI
SPI Manual
Manual
153
Environment :Environment Feedback C/M

Purpose
KPI Target :
ENV. Feedback C/M 100 %
How to Evaluation
Method
Result & KPI Target
Environment feedback
Target ENV Feedback C/M = 100 %
1.
Environment Feedback
2. two way communication
3. Target
% (
Target )
TOYOTA
SPI
SPI Manual
Manual
154
Safety Pro
-Active Indicator
Pro-Active
TOYOTA
SPI
SPI Manual
Manual
155

4.2) Environment Feedback Countermeasure () __2007___
%
100
White ()
95
Yellow ()
90
TARGET C/M = 100%
85
80
75
70
65
60
55
50
Month
Apr'_07_
Shift
I) (B)
II) Target
(A)
2
2
2
2
III) %
=
(B)
100
Target (A)
TOYOTA
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan'__
Feb
Mar
100% 100%
GL
Asst. Mgr. Up
SPI
SPI Manual
Manual
156

Environment :
Method

TOYOTA
SPI
SPI Manual
Manual
157

Environment :
4.3) Environment Problem List of KUMI __MC1____

No
Process
Shift
//
Hiyari ENV Feed.
5S
Target
9/15/2007
Process A
8/5/2007
Process A
9/9/2007
Layout
9/13/2007
Han Name A
9/9/2007
5 S
9/13/2007
Han Name B
9/22/2007
5 S
9/30/2007
Asst.Mgr up
= O.K.
= NG.
(ENV Feed. = Environment Feedback)
TOYOTA
SPI
SPI Manual
Manual
158
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
159
Environment :Problem & C/M

ENVIRONMENT
KPI Problem & C/M
No
TOYOTA
//
Month ____________Year ____________
SPI
SPI Manual
Manual
160
Man
TOYOTA
Man Man Man Machine

SPI
SPI Manual
Manual
Machine
Method Env.
161
Safety Pro
-Active Indicator
Pro-Active
1.8
16 cm
3 cm.
2.5 cm. 4 cm
1.8 cm.
44.3 cm.
21 x
21 cm.
2.5 cm. 5.5 cm
KPI Problem & C/M Form KPI (Man,Machine,

method,Environment)
22 cm.
2.5 cm. 4.5 cm
A4
22 cm.
2.5 cm. 9 cm
22 cm.
KPI 1.8 cm. 13 cm ()
21 cm.
Man
TOYOTA
14cm.
Man
186 cm.
Man
Man
Machine
SPI
SPI Manual
Manual
Machine
Method
Env.
162
Safety Pro
-Active Indicator
Pro-Active
SPI
5 cm.
Future Board

8
29 cm.
10 cm.
24 cm.
10 cm.
24 cm.
10 cm.
TOYOTA
SPI
SPI Manual
Manual
163
Safety Pro
-Active Indicator
Pro-Active
5 cm.
29 cm.
10 cm.
TOYOTA
24 cm.
SPI
SPI Manual
Manual
164
Safety Pro
-Active Indicator
Pro-Active
Man
1. (White Shift)
2. (Yellow Shift)
Man
1. KY Ability Test (White Shift)
2. KY Ability Test (Yellow Shift)
Man
1.Hiyari Monthly Plan & Result (White Shift)
2.Hiyari Monthly Plan & Result (Yellow Shift)
Man
1.PPE Rule Keeping Daily control (White Shift)
2.PPE Rule Keeping Daily control (Yellow Shift)
TOYOTA
SPI
SPI Manual
Manual
165
Safety Pro
-Active Indicator
Pro-Active
Machine
Safety Device Function Plan & Result

Machine
Equipment condition Check Plan & Result

Method
1.Communication
2. Ergonomic Kaizen
Environment
1.5S Condition
2.Environment Feedback
TOYOTA
SPI
SPI Manual
Manual
166
Safety Pro
-Active Indicator
Pro-Active
Example of SPI control board
Man
Daily indicator
monitoring
Machine
Monthly
indicator
summary
Method
Problem
follow up &
Improvement
Environment
Man
TOYOTA
Man
Man
Man
SPI
SPI Manual
Manual
Machine
Machine
Method
Environment
167
Safety Pro
-Active Indicator
Pro-Active
TMAP-EM Contact Person
Mr. Sombat Kongkheeree
Tel.
: 02-790-6086
E-Mail : sombat_kon@tmap-em.toyota-asia.com
Ms. Nataporn Nilchuangsri
Tel.
: 02-790-6096
E-Mail : Nataporn_nil@tmap-em.toyota-asia.com
TOYOTA
SPI
SPI Manual
Manual
168

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Safety Pro

PPE Rule Keeping

Safety Device Function

Maintain & Improvement

Man Man Man Machine

Man Man Man Machine

Man Man Man Machine

Man : Good Health Condition

PPE Rule Keeping

Man : Good Health Condition

Man : Good Health Condition

Man : Good Health Condition

100 100 100 100

Remark : Not include absent person

Daily Health Check Sheet

Man : Good Health Condition

Man : Good Health Condition

Man : Good Health Condition

Man : Good Health Condition

A Add circle mark

Man : Good Health Condition

Man : Good Health Condition

Man : Good Health Condition

Man Man Man Machine

PPE Rule Keeping

Man : PPE Rule Keeping

Man : PPE Rule Keeping

Man : PPE Rule Keeping

Man : PPE Rule Keeping

Man : PPE Rule Keeping

PPE Rule Check Sheet

Man : PPE Rule Keeping

1.2) % PPE Rule Keeping

Process__________ Process__________ Process__________ Process__________ Process__________ Process__________ Process__________

No. PPE No.

II) % PPE Rule Keeping check

Revision No. / Effective Date : 1 / Jun 01, 2007

Revision No. / Effective Date : 1 / Jun 01, 2007

Total operator correct PPE rule (person)

Man : PPE Rule Keeping

Shift ___________ Month ________

No. PPE No.

Man : PPE Rule Keeping

Shift ___________ Month ________

No. PPE No.

Man : PPE Rule Keeping

No. PPE No.

Man : PPE Rule Keeping

Man : PPE Rule Keeping

Man : PPE Rule Keeping

Man Man Man Machine

PPE Rule Keeping

1.1 Model sheet

3.1 Select representative (Han)

3.1 Actual work site observation

4.1 Select audit area

4.1 Cross check

4R KYT 1) /Process HAN

KYT KEY WORD :

Revision No. / Effective Date : 1/ Jun 01, 2007

KYT KEY WORD :

Revision No. / Effective Date : 1/ Jun 01, 2007

KYT KEY WORD :

Revision No. / Effective Date : 1/ Jun 01, 2007

Process Process Process Process Process Process Process__

Shift ___ Month

Shift ___ Month

KY Ability Evaluation Yearly Record of Kumi_MC1_ Shift _Yellow_ ( _2007_ )

Shift ___ Month

Month Year