22249473 Training of Japanese Manufacturing Tools

8/8/2019 22249473 Training of Japanese Manufacturing Tools

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Prepared by:Prepared by: Obaid BilgaramiObaid BilgaramiManager CoordinationManager Coordination


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The most Pragmatic, Down-To-Earth andProcess Oriented Manufacturing Approaches.

More focused on Process Improvement(New Manufacturing Vision).

Effective Efficiency Optimizing Approach

(Not Efficiency Maximizing Approach).Stepping stone top other manufacturing

standards, i-e; Lean, ISO 9000, TS 16949,etc.


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Kaizen

5S.

GembaGenchi Genbutsu

Obeya

Poka YokeJidoka

Andon

Kanban/Pull System

Muda, Mura, Muri

HeijunkaFIFO

Takt Time


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A combination of two Japanese words:Kai = Change & Zen = Better

i-e;Change for Better

Kaizen Cycle (Good Better Best)

Kaizen Mind

Kaizen Procedure

Before/ After Approach


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Seiri (Sorting)

Seiton (Setting)

Seiso (Sweeping)

Seiketsu (Standardizing)

Shitsuke (Sustaining)


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The word literally means The Place wheretruth can be found and refers to The Place

Where the Activity is happening like CrimeScene, Play Ground, Production Floor, etc..

The availability of Incharges, i-e;

Production, QC, Maintenance at floor toensure system effectiveness and FactualAnalysis of Problem if occurs.


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The word literally means Go See foryourself referring to the Gemba Attitude, i-

e; instead of depending on hearsay,reports, summary charts, or any docs, getout and visit the place where actually the

problem occurs.This attitude enables an effective and

most appropriate decisions based on On

the Spot Analysis.


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The word literally means Big Room andrefers to The room where reports/ results/

Summaries & Performances are displayedfor Management Perusal.

The Management holds meeting to

evaluate the Deptt. Performance/Issues,Activities Status and propose rationaldecisions.


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The word literally means Mistake Proof and refers to Any device, limits or system

installed at operations to ensure zerodefect/ error/ mistake.

The Zero Defect Target can only be

achieved if the abnormality is stopped at itsplace of origin, this is what poka yoke for.


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The word literally means Automation orIntelligent System and refers to Machine

to be built/added with devices or limitsensors to stop in case of an abnormality.

This system is to ensure fast, effective

and reliable means of production toeliminate inadvertent errors, negligence,maintenance failure like Poka Yoke.


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The word literally means Paper Lantern and refers to status-display station or a

system to notify management,maintenance, and other workers of a qualityor process problem.

This is another example of Jidoka toeliminate the error/ defect at its place of origin with Problem Identification at

machines


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The word literally means Visual Card andrefers to Kanban is a signaling system to

trigger action. In kanban, cards are used tosignal the need for an item from InventoryStock or suppliers .

It is based on Pull System and also refersto JIT System which is another hallmark of Japanese Manufacturing System.


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The word literally means Level andrefers to a system of production

smoothing/ leveling designed to achieve amore even and consistent flow of work .

It is based on study of processes

sequence and their flow on machines toimplement best possible line balancing, i-e; also called Chain Production.


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Muda (Waste)1.Over-production

2.Motion (of operator or machine)3. Waiting (of operator or machine)4.Conveyance5.Processing itself 6.Inventory

7.Correction (rework)

Muri (Overburden)

Mura (Inconsistency)


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The German word literally means Clock and refers maximum time allowed to

produce a product .Takt Time is defined as:

T= T a/ T dWhere:

Ta = Net Available Time to Work eg. [minutes of work / day]Td = Total demand (Customer Demand) eg. [unitsproduced / day]T = TAKT Time eg. [minutes of work / unit produced]


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It stands for First In First Out and refersto the inventory system where what comes

in first is handled first, what comes in nextwaits until the first is finished .

An effective way of Inventory Management

to ensure smooth flow of inventory with datewise traceability to avoid stock fromdeterioration and going abnormally excess

and also en effective tool of JIT/Pull System.


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Kaizen = Change for Better

5S. = Work DisciplineGemba = Activity Place

Genchi Genbutsu = Go & See The Problem

Obeya = Monitoring Room

Poka Yoke = Mistake Proofing

Jidoka = Automization

Andon = Visual Control

Kanban/Pull System = Signal for Production

Muda, Mura, Muri = Waste/Unevenness/Overburden

Heijunka = Line Balancing

FIFO = First In First Out

Takt Time = Production Time


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Japanese Management Tools begins withsimple Kaizens and results into an Industry

with Work Inducing Environment, OptimallyEffective Production with Zero Defect Ratioand Efficient Utilization of Machines & Manpower and ultimately with continual

upward trend of profitability and downwardtrend of losses.


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Thank You

Documents

22249473 Training of Japanese Manufacturing Tools