KAIZEN PXP BIGPART ROLLER NEAR UP AREA

CURRENT FLOW
1

AFTER FLOW

4
Short
distance

MODULE
WAITING UP

UP PXP BIG
PART

MODULE
WAITING UP

UP PXP
PART

Long
distance
PXP BIG PART
ROLLER

DEVANING

Problem:

Double
Handling
Muda

1. Required Space for Module waiting UP

2. Long distance for FL moving, sometime cause delay, mis infor
3. Double handling: Moving module in-out at Module waiting FLR

DEVANING

Merit:

1. Redue space: 195 m2

2. Reduce distance by 220 m/ trip, No mis information proble
3. Eliminate double handling

DOSEN AND KAIZEN IDEA

CURRENT DOSEN

AFTER DOSEN

KADAI

MERIT
REDUCE SPACE

MUDA SPACE:
- 195 m2
- 5 FLR used to
store module
waiting UP

Very short

PXP BIG PART

ROLLER

LONG DISTANCE:
- Appx 220 m additional
moving / module
- Appx 80 second muda /
module

MIS
INFORMATION:
- FL member was far
away => high risk of
mis information =>
Can cause delay

800

FLR space

Roller Space

700
600

400
300
200

145

140

195

500

SUPPLY MODULE TIME (a

160
120
100
80

525

525

60

35

40

100

20

0
BEFORE

AFTER

BEFORE

AFTER

P PXP BIG
PART

roblems

E (avg)

35

TER

UP BIG PART NEAR ELECAR SUPPLY DOSEN

I. HEAVY JOB REDUCTION:
AFTER FLOW

CURRENT METHOD
80m

1
UP,
PICKING E/G,
TRANS

1 unit

STAND BY

Member push
dolly

1 unit
Delivery

UNPACKING
ASHI MARI

ASSY LINE

Heavy Job: Eliminate double handling

Problem:

1
1 units
Elecar

Supply by
Ereka

STAND BY

1 unit

ASSY

Heavy Job: Eliminate by using Elecar

1. Long distance from picking area to standby area

2. Heavy job push E/G, Trans dolly to standby area

Merit:

CURRENT DOSEN
ASSY
LINE

1. Eliminate double handling

2. Reduce Heavy job (Supply by Elecar)
AFTER DOSEN

ASSY
LINE
3

1 unit

2
3
1

10 units

MERIT
m

70
60
50
40
30
20
10
0

Push EG dolly
65

100
80

Push Tire dolly

80

60
40
2

20

0
BEFORE

AFTER

BEFORE

AFTER

LECAR SUPPLY DOSEN

AFTER FLOW

ASSY LINE

AFTER DOSEN

MERIT
100
80

Push Tire dolly

80

60
40
20

0
BEFORE

AFTER

ASHI MARI ELIMINATE DOUBLE HANDLING & HEAVY JOB REDUCTION

I. HEAVY JOB REDUCTION:
AFTER FLOW

CURRENT METHOD
1

UNPACKING
ASHI MARI

2
10 units

STAND BY

Heavy Job: Eliminate double handling

Problem:

800m

1 unit

1 unit

Picking

Delivery

UNPACKING
ASHI MARI

ASSY LINE

Heavy Job: Eliminate double handling

1. Very heavy job impact to member's health.

2. Double handling heavy process

1
1 units
Pickin
g

Supply by
Ereka

STANDBY
AREA

CURRENT DOSEN

1. Eliminate double handling

2. Reduce Heavy job (Supply by Elecar)
AFTER DOSEN

ASSY
LINE

ASSY LINE

ASSY

MIX LOT
ASHI MARI

Heavy Job: No
double handling

Merit:

1 unit

1 unit

1 unit
1 unit

10 units
10 units

MERIT
100

HEAVY MOVING DISTANCE (10 unit)

90

100

80

80

60

60

40

40
15

20
0

Push dolly (1 unit)

85

17

20
0

BEFORE

AFTER

BEFORE

AFTER

ANDLING & HEAVY JOB REDUCTION

AFTER FLOW

ASSY LINE

AFTER DOSEN

MERIT
100

Push dolly (1 unit)

85

80
60
40
17

20
0
BEFORE

AFTER

BEFORE PXP BIG PART MODULE SUPPLY

I. PART FLOW

Vios

Corrola

Camry

Innova

Forturne
r

II. OPERATION

Vios
BUMPER
UNPACKING

Unfinished
Location

Lot 1
Lot 2
Lot 3
Vios

BUMPER
UNPACKING

Lot 1

Unfinishe
d
Location

Lot 2
Lot 3

1 SIDE OPERATION WITH ROLLERS => MUDA MOVING JOB

PART MODULE SUPPLY

BUMPER ROLLER
I. CAPACITY

Vios

Corrola

Camry

Innova

Forturne
r

II. OPERATION

BUMPER
UNPACKING

250

REDUCE MUDA JOB

Moving other
lot

200
150

Vios
OUT

100

Moving
required lot

100
50

0
110

80

0
BEFORE

Lot 1
Lot 2
Lot 3

180
160

AFTER

REDUCE SPACE BUT

INCREASE CAPACITY
132.24

Capacity
Space

140

IN 120
100

75

80

2 SIDE OPERATION WITH ROLLERS

=> NO MUDA MOVING JOB

20

60
40

60

80

0
BEFORE

AFTER

ROLLER

250

REDUCE MUDA JOB

Moving other
lot

200
150

100

Moving
required lot

100
50

0
110

80

0
BEFORE

180
160

AFTER

REDUCE SPACE BUT

INCREASE CAPACITY
132.24

Capacity
Space

140
120
100

75

80

20

120
100
80
60

60
40

140

60

80

40
20

0
BEFORE

AFTER

Model
V
C
K
F
I

Capacity
Line Lane Stack Cases
1
4
4
16
1
4
4
16
1
4
4
16
1
4
4
16
1
4
4
16
Total
80

MERIT:
REDUCE MUDA MOVING JOB

MOVING TI BEFORE AFTER

Moving requ
110
80
Moving othe
100
0

Space
Capacity

BEFORE AFTER
132.24
75
60
80

BEFORE AFTER
Roller Spac
525
525
FLR space
195
0
BEFORE AFTER
SUPPLY MOD
145
35

BEFORE AFTER
HEAVY MOVI
90
15
BEFORE AFTER
Push dolly (
85
17
BEFORE AFTER
Push EG dol
65

BEFORE AFTER
Push Tire do
80

75