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KAIZEN PXP BIGPART ROLLER NEAR UP AREACURRENT FLOW AFTER FLOW
Problem: 1. Required Space for Module waiting UP Merit: 1. Redue space: 195 m22. Long distance for FL moving, sometime cause delay, mis infor 2. Reduce distance by 220 m/ trip, No mis information problems3. Double handling: Moving module in-out at Module waiting FLR 3. Eliminate double handling
DOSEN AND KAIZEN IDEACURRENT DOSEN AFTER DOSEN
KADAI MERIT
BEFORE AFTER0
20406080
100120140160 145
35
SUPPLY MODULE TIME (avg)
BEFORE AFTER0
100
200
300
400
500
600
700
800
525 525
195
0
FLR space Roller Space
MODULE WAITING UP
UP PXP BIG PART
Short distance
DEVANING PXP BIG PART ROLLER
Long distance
1 2 3 4
DEVANING PXP BIG PART ROLLER
MODULE WAITING UP
UP PXP BIG PART
1 2 3
Double Handling Muda
Very short
PAINT BUMPERSBUMPER DOLLY
PQC ROOM
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
ly
Toilet
E - Box
TBHN(seat)
All local part
vait
ing
&
Obs
erve
r
FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
PxP
sto
ck d
olly
A2
PxP
sto
ck d
olly
A2
Toilet
W/H
sto
ck c
ontr
ol b
oard
Stop &
confirm
Stop &
confirm
Stop &
confirm
Sec
urity
S top &
confirm
Sto
p &
co
nfir
m
STO
P
STO
P
STO
P
STO
P
STO
P
STO
P
Waste
RR temporary
Hose drain
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Sto
p &
co
nfir
m
So
rtin
g r
olle
r
S
D
PB1 (high usage Max=194 cases)
W part
D
Lon
g o
il ho
se s
trai
ght
Dolly bumper
Duct blow room
Fuel tank
I7I6
I5W
EIG
HT
BA
NL
AC
EA
LL
MO
DEL
I2I4
I3I1 F1
F3
I &
FF
2F
& I
I10
I9
K8
K7
K6
K1
K3
K5
K4
K2
V1
5V
14
V9
V1
3
V1
2
V1
0
V2
V4
V5
V6
V7
V8
13
IN
Cov
er c
ase
Un
pack
ing
A1C
over
cas
e U
npa
ckin
g A2
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
16
25 26 27 2829 30
CURRENT TOILET
UP
A1
G3
UP
A1
G1
UP
A1
G2
UP
A1
G1
UP
A1
G3
UP
A1
G4
UP
A2
G1
UP
A2
G1
UP
A1
G4
UP
A1
G2
UP
A2
G1
UP
A2
G2
UP
A2
G3 UP
A2
G3
KAIZEN ROOM
Cov
er c
ase
: B
um
per
Weeldisc - I
17
BatteryRoller
PB1&2
Stop &
confirm
EG A2 EG A1
Extension
Ove
r fl
ow
EG(ZA,ZB6)
EG(ZC,ZD10)
TransInnova(10)
TransFortuner(10)
EG(HB,HC6)
EG (HA 5)
AXLE - F(10)
AXLE - I(10)
Trans (HA12)
Sub axle- F (10)
EG(AU6)
EG(AS6)
TransCorolla
TransVios
EG(AZ,BE 4)
TransCamry 10
EG(VK6)
EG(VH,VJ6)
EG(AT6)
EG(AL6)
M1 & M2
D
PS1&2
Ou
tIN O
ut
IN
IN
STOP
SP2 return
IN
OUT
IN
IN
OUT
FI V KC
Bumper module(60 cases)Before 60
RK
HB
,HC
(Max
=21
)
SN
E-
ZA
,ZB
(M
ax =
14
)
SE
TR
AN
S-
HA
(Max
=5)
LD
E-
HA
(M
ax
=9)
SD
E-Z
C,Z
D (
Max
=6)
QJ
TR
AN
S-
ZA
,ZB
(Ma
x=8)
Len
gth
=1.
1)
DB
E-
AT
(M
ax
= 9
)
AT
E-
AL
(M
ax
=8)
PK
E-V
K (
Ma
x=8)
DC
E-
AU
(M
ax
=6)
DA
E-A
S (
Ma
x =
5)
PJ
E-V
H,V
J (M
ax
= 1
1)
CX
TR
AN
S-
VIO
S
ZU
(T
IRE
TU
BE
LES
S)
EP
(T
IRE
TU
BE
LES
S)
PV
(W
HE
EL
DIC
S)
M2 (A2) Max = 90 cases
Local part rack
Reserve area310A
OUT
OUT
IN
IN
OUT
OUT
IN
OUT
IN
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Wire harness area
SPS Picking Zone
T F CVIOS
T F CCORROLA
T F CCAMRY
T F CINNOVA
T F CFORTUNER
HW Room
381A Vios
Fortuner
Camry
Corrola 1.8
Corrola 2.0
Wh
eel d
isc ro
ller
loc
al pa
rtC
ap
acity
5B MODULE
ASHI MARI MODULE (40 cases)
Weight
M2 (A1) Max = 140 cases
PV
(W
HE
EL
DIC
S)
SE
AT
A2
SE
AT
A1
Sto
re
SE
AT
A2
SE
AT
A1
EM
PTY
ASHI MARI 2 (Low usage - 32 cases)
EG LOT waiting UP (24 cases)PXP SMALL MODULE
PS1(37)
Pallet
Pallet
C7
C6
C1
C3
C5
C2
C4
C12
C13
C11
C14
C15
C16
IN
C10
C9
RB
4
RB
7
RB
5
RB
8R
B10
RB
6
RB
9
IN
P x P AREA
U/P
dol
ly
PXP SMALL MODULE (56 cases)
UP LOT A1
UP LOT A2
CX
TR
AN
S-
VIO
S
Stop &
confirm
Stop &
confirm
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fire extinguish
SeatTire dolly
LO
T M
AK
ING
LA
NE
A1
Tire dollyempty
S1bS1a
Ashi MariModule
Ashi MariModule Empty
Tire A2
Seat A2EG Tire dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
EG
Tire A1
Reserve area640A
RB
1R
B2
RB
11R
B12
RB
3R
BR
BG
lass
Seat A1EG Tire dolly
Seat A1 EGTire dolly
Ashi MariEreka dolly
Ashi MariEreka dolly
C1
V1
1
V3
TMCEMPTY BOX(plastic)
PALink A
EPShaft
DDTank
PxPShaft
EJLink A
BDTank
EQShaft
VBLink A
ADTank
BUMPER DOLLY
Z1Shaft
Z2Shaft
Z3Shaft
Z4Shaft
Z5Shaft
W/H
do
lly
Axl dolly
Seat A2 EGTire dolly Axl dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
Cover case Unpacking A1
U/P
dol
ly
Project room and rest room
Tire - F
EPShaft
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Acti ve Barrier
Was
te d
olly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small WATSE 2
Ashi MariEreka dolly
WATSE 1
Waste dolly
Waste dolly
Waste dolly
Was
te d
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
Fire extinguish
Gla
ssBa
ckdo
orG
lass
Back
doo
r
Abs
ober
3 Fl
oor
Dol
ly
Sprin
g
Sprin
g
Pane
l
Pane
l
Gla
ssFr
ont
Pane
l
May
o
May
o
Gla
ss
Gla
ss
Smal
l EG
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
May
o
Trim
doo
r
Trim
doo
r
Qua
rter
Step
Smal
lEG PK EG Sm
all E
G
3 Fl
oor
Dol
ly
Was
te d
olly
Gla
ssFr
ont
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Qua
rter
Floo
rC
arpe
t
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
GlassR
TankFuel
Com
mon
Dol
ly
Inst
Pane
l
Tank
Fuel
Tank
Fuel
Glass quarter
Back
doo
r
Exha
ust
Back
doo
r
Exha
ust
Roof
GlassFront
PanelQuarter
Roof
Hea
dlin
ing
roof
Con
sole
box
Hea
dlin
ing
roof
Hea
dlin
ing
roof
Doo
rTL
PK E
G
PK E
G
W p
art
Cov
er c
ase
Un
pack
ing
A1C
over
cas
e U
npa
ckin
g A1
SmallEG
ViosLot Ashi Mari
CorrolaLot Ashi Mari
Ashi MariEreka dolly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small
ViosLot Ashi Mari
CorrolaLot Ashi Mari
ForturnerEG small
ForturnerEG small
CURRENT PICKING LOT
STANDBY NEXT LOT
T F
CVIO
S
T F
CC
OR
RO
LA
T F
CC
AM
RY
T F
CIN
NO
VA
T F
CF
OR
TU
NE
R
HW Temporary
Co tire & weel disc
Balancemachine
Tire - K
Wheeldisc - K
Wheeldisc - V
Wheeldisc - C
Weeldisc - F
Tire dollyempty
Co tire & weel disc
Balancemachine
For
klift
Bat
tery
EmptySlot
E-l
iftB
atte
ry
New
E-c
arB
atte
ry
Old
E-c
arB
atte
ry
EmptySlot
Wheeldisc - I
Wheeldisc - F
Tire - I Tire - C
Tire - V
EXTENDEDHW ROOM
Camry lot module
( Max=90 Cases )
Corolla lot module
( Max=90 Cases )
Fortuner lotmodule ( Max=60 Cases)
Innova lot module(Max = 50 case )
Vios lotmodule ( Max=50 Cases )
Ashi M
ariM
odule
Ashi M
ariM
odu
le Em
pty
CA
RP
ET
(Fr
/F)
Do
lly
EG
em
pty
A1
Do
lly
EG
sto
ck
A1
Tire A1EG A1
Tire A2 Axl A2
PK
EG
W p
art
PK
EG
Hea
dlin
ing
roof
Co
nsole
box
Hea
dlin
ing
roof
Hea
dlin
ing
roof
Sm
all p
art
Sm
all p
art
Sm
all p
art
Sm
all
EG
Doo
r
TL
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
Mayo
Waste
dol
ly
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Qua
rter
Flo
or
Ca
rpet
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Co
mm
on
Dol
ly
Inst
Pa
nel
Ta
nk
Fu
el
Ta
nk
Fu
el
Ba
ck d
oor
Exha
ust
SmallGlass quarter
PAINT BUMPERSBUMPER DOLLY
EMPTYBOX
PxP
UP
TIRE WAITING FOR JUNBIKI
SEAT A2Cabinet
BATTERY SHOOTER
SEAT A1
Wire harness area
SEAT A2
SEAT A1
EMPTY
Store
PQC ROOM
U/P
dolly
U/P
dolly
U/P
dolly
U/P
dolly
U/P
dolly
U/P
dolly
U/P
dolly
Waste
dol
ly
Wheel disc rollerlocal part
5B size case stock area @ FLR
Ro
ller
Dri
ve
sh
aft
- V
Dr iveshaft - C (AS)
Driveshaft - K
Driveshaft - K
E mp ry
doll y EG
E G jig
Tire dollystock 1
Tire dolly
Tire dolly
empty
Balan
ce pa
rt
Tire not
yet in STD
Balancemachine
Inst all
balance
Co tire & w eel disc
TMCEMPTY BOX(plastic)
Toilet
E-Car batterycharging
Battery charnging
Sea
t q
ualit
ychecki
ng a
rea
Seat
chec
king
tab
le Seat deffe
ct dolly
S1bS1aWATSE 1WATSE 2
Weel
dis
c - C
Tir
e - C
Tir
e - V
Weel
dis
c - V
Weel
dis
c - K
Weel
dis
c - K
Extin
guis
her
AXLE DOLLY EMPTY
AXLE DOLLY STOCK 2
SUBAXLE - FEMPTYDOLLY
E mp rydoll y EG
E xh aust F
SUBAXLE - FSTOCKDOLLY
E xh aust I
Driveshaft - F
Balan
ce pa
rt
Tire notyet in STD
Inst allbalance
Co tire & w eel disc
Wh
eel
dis
c - I
Tir
e - I
Wh
eel
dis
c - F
Tir
e - F
Driveshaft
- C (AT)
Driveshaft - C (empty)
W aste dolly
Air bottle
UPS
W aste dolly
Do
lly
UP
Balancemachine
Air bottleUPS
Tire dolly
empty
Ro
ller
Tire dollystock 2
Was
te
do
lly
4. Cover case: EG vios & Corolla
2. Jig EG I+F+cau phu, HS phu
Co
ve
r ca
se
Lo
p A
1
W eel disc tray (I)
1. EG HA & HS A2 & CAu
5. Jig HS & thanh thung (K,C,V)
Was
te
do
lly
Was
te
do
lly
W eel disc
tray (F)
W eel disc tray (C)
Tire dolly
TBHN(seat)
All local part
va
itin
g &
Ob
se
rve
r
Seat A2
Seat A1
Localpart A2
Localpart A1
C&A PART (24 CASES)
FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
S heet ( I)
PxP
sto
ck
do
lly
A2
PxP
sto
ck
do
lly
A2
PxP
sto
ck
do
lly
A1
PxP
sto
ck
do
lly
A1
A2
UP
A2
UP
A2
UP
(SP2)
Lo
ca
l
Par
t
Do
lly
LO
T M
AK
ING
LA
NE
A2
SP
2- F
(5 c
ase)
W/H
do
lly
Co
ve
r ca
se
Lo
p A
2
W aste
dolly
Co
ve
r ca
se
UP
Px
P
Toilet
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fridge
Battery dolly A1
Lo
ca
l
Par
t
Do
lly
Lo
ca
l
Par
t
Do
lly
Lo
ca
l
Par
t
Do
lly
Lo
ca
l
Par
t
Do
lly
Cabinet
OU
T
W/H
sto
ck
co
ntr
ol b
oa
rd
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
PQC & TBHN mbr waiting
Security
Stop &confirm
Stop &confirm St
op &
conf
irm
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
Waiting
S1bS1a
WATSE 1WATSE 2
RR temporary
Tire checker Vios
E - B
ox
Cove
r ca
se:
Bum
per
Cover case Unpacking A2
Tire mach
ine sp
are
EG
(AS
6)
EG
(AT6)
EG
(VK
6)
EG
(AU
6)E
G(A
L6)
EG
(AZ
,BE
4)
Tra
ns
Coro
lla
Tra
ns
Vio
s
Tra
ns
Cam
ry 1
0
EG
(VH
,VJ6)
EG
(ZA
,ZB
6)
EG
(ZC
,ZD
10)
EG
(HB
,HC
6)
Sub a
xle
- F
(10
)
Sub
tra
ns
- F
(10)
AX
LE
- F
(10)
AX
LE
- I(1
0)
Tra
ns (H
A12)
EG
(H
A 5
)T
ran
sIn
no
va(
10)
Tra
ns
Fo
rtun
er(
10)
Ste
el
Was
te
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop &confirm
Stop
&co
nfir
m
So
rtin
g r
oller
S
PS1&2
D
D
PB1 (high usage Max=194 cases)
S (80 CASES)
LO
T M
AK
ING
LA
NE
A1
Vios lotmodule ( Max=50 Cases )
W part
C V K
M2
DM1 & M2
M2 (REVISE)
PB1&2
Long oil hose straight
Lon
g o
il h
os
e st
raig
ht
Check sheet
8. Jig EG Camry, AS, thanh thung
Dolly bumper
Duct blow room
Fu
el ta
nk
Tire dollystock 1
Tire dollystock 2
AXLE DOLLY STOCK 1
BATTERY OVER
IN
SP
2- I (5
case
)
P allet
P allet
RK
HB
,HC
(M
ax=21
)
PJ
E-V
H,V
J (M
ax
= 1
1)
SD
E-Z
C,Z
D (M
ax =
6)
PK
E-V
K (
Max=
8)
DB
E- A
T (M
ax =
9)
DC
E-
AU
(Max
=6)
QJ
TR
AN
S- Z
A,Z
B(M
ax=
8) L
eng
th =
1.1)
SE
TR
AN
S- H
A (M
ax=5)
PS1(37)
W aste
dolly
I7I6
I5W
EIG
HT
BA
NL
AC
EA
LL M
OD
EL
I2I4
I3I1 F1
F3
I &
FF
2F
& I
I10
I9M
OU
LDIN
GK
-I K8
K7
K6
K1
K3
K5
K4
K2
C10
C12
C13
C11
C9
C14
C15
C16
C8
C7
C6
C1
C3
C5
C4
C2
V16
V15
V14
V9
V11
V13
V12
V10
V2
V4
V5
V3
V1
V6
V7
V8
P x P AREAS = 600 m2
A1
UP
A1
UP
A1
UP
A1
UP
1314
PV
AIR
CO
ND
ITIO
NE
R(V
) (M
ax
=16)
EI P
AN
EL C
OR
OLLA
(Max=14)
SN
E- Z
A,Z
B (M
ax =
14)
LD
E- H
A (M
ax=9)
AT E
- A
L (
Max=8)
DA
E-A
S (M
ax =
5)
PV
Tir
e V
J, V
K (
Max
= 2
6)
PV
Flo
or
car
pet
VJ,
VK
(M
ax=
16)
Innova lot module(Max = 75 case )
Fortuner lotmodule ( Max=180 Cases)
Camry lot module
( Max=70 Cases )Corolla lot module
( Max=50 Cases )
PA
WH
EE
L D
ISC
VH
(M
ax=6)
PV
FL
OO
R C
AR
PE
T V
H (M
ax=
6)
ENGIN PART (F)
ENGIN PART (I)
IN
OUT
IN
OUT
IN
IN IN IN
Ou
t
Ou
t
Ou
t
Ou
t
Cover case
S1b S1a WATSE 1 WATSE 2
Waste
dol
ly
Waste
dol
ly
Co
ver
case Un
packin
g A
1Co
ver
case Un
packin
g A
1Co
ver
case Un
packin
g A
2Co
ver
case Un
packin
g A
1
Panel
Quarter
Roof
Ba
ck d
oor
Exha
ust
Ta
nk
Fu
el
Gla
ss
Fro
nt
Co
mm
on
Dol
ly
Trim
door
Trim
door
Qua
rter
Ste
p
Sm
all
EG
PK
EG Sm
all
EG
3 F
loor
Dol
ly
Gla
ss
Ba
ckdo
or
Fra
me
Fra
me
Be
am
Gla
ss
Ba
ck d
oor
Ab
sobe
r
3 F
loor
Dol
ly
Sp
ring
Be
amSp
ring
Pa
nel
Pa
nel
Gla
ss
Fro
nt
Pa
nel
Mayo
Mayo
Gla
ss
Gla
ss
Roof
GlassFront
GlassR
Small
Sm
all
EG
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
Localpart A1
Localpart A2
15 16
17 18 1921 22
2320 2425 26 27 28
29 30E-Box
RB
4R
B5
RB
6
RB
7R
B8
RB
9
RB
10
RB
1R
B2
RB
11
RB
12
RB
3R
BR
BG
las
s
Ov
er f
low
Batterycharging
BatterychargingEx-box
W/H
do
lly
W/H
do
lly
SPS Picking Zone
E/GUP
Tire
B-lane
No. of part = 355
F
Bumper moduleall model ( 60 cases)
I
OVER MODULE
EM PT Y B OX
Local part area
OVER FLOW
PS2 (32) EG LOT WAITING FOR JUNBIKIUN-FINISHED CASE PB2 (low usage 48) OVER PXP
WA
TS
E 1
WA
TS
E 2
Lo
ca
l
pa
rt A
1
Lo
ca
l
pa
rt A
1
EG A2 Seat A2
Seat A1
Tir
e d
olly
em
pty
A1
Tir
e d
olly
sto
ck
A1
Do
lly
EG
sto
ck
A2
Do
lly
EG
em
pty
A2
Tir
e d
olly
em
pty
A2
Tir
e d
olly
sto
ck
A2
Battery dolly A2
MUDA SPACE:
- 195 m2 - 5 FLR used to store module waiting UP
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
REDUCE SPACE
UP BIG PART NEAR ELECAR SUPPLY DOSENI. HEAVY JOB REDUCTION:
CURRENT METHOD AFTER FLOW
Problem: 1. Long distance from picking area to standby area Merit: 1. Eliminate double handling2. Heavy job push E/G, Trans dolly to standby area 2. Reduce Heavy job (Supply by Elecar)
CURRENT DOSEN AFTER DOSEN
MERIT
PAINT BUMPERSBUMPER DOLLY
PQC ROOM
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
ly
Toilet
E - Box
TBHN(seat)
All local part
vait
ing
&
Obs
erve
r
FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
PxP
sto
ck d
olly
A2
PxP
sto
ck d
olly
A2
Toilet
W/H
sto
ck c
ontr
ol b
oard
S top &
confirm
S top &
confirm
S top &
confirm
Sec
urity
S top &
confirm
Sto
p &
co
nfir
m
STO
P
STO
P
STO
P
STO
P
STO
P
STO
P
Waste
RR temporary
Hose drain
S top &
confirm
S top &
confirm
S top &
confirm
S top &
confirm
Sto
p &
co
nfir
m
So
rtin
g r
olle
r
S
D
PB1 (high usage Max=194 cases)
W part
D
Lon
g o
il ho
se s
trai
ght
Dolly bumper
Duct blow room
Fuel tank
I7I6
I5W
EIG
HT
BA
NL
AC
EA
LL M
OD
EL
I2I4
I3I1 F1
F3
I & F
F2
F &
II1
0I9
K8
K7
K6
K1
K3
K5
K4
K2
V1
5V
14
V9
V1
3
V1
2
V1
0
V2
V4
V5
V6
V7
V8
13
IN
Cov
er c
ase
Unpa
ckin
g A1
Cov
er c
ase
Unpa
ckin
g A2
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
16
25 26 27 2829 30
CURRENT TOILET
UP
A1
G3
UP
A1
G1
UP
A1
G2
UP
A1
G1
UP
A1
G3
UP
A1
G4
UP
A2
G1
UP
A2
G1
UP
A1
G4
UP
A1
G2
UP
A2
G1
UP
A2
G2
UP
A2
G3 UP
A2
G3
KAIZEN ROOM
Cov
er c
ase
: B
um
per
Weeldisc - I
17
BatteryRoller
PB1&2
S top &
confirm
EG A2 EG A1
Extension
Ove
r fl
ow
EG(ZA,ZB6)
EG(ZC,ZD10)
TransInnova(10)
TransFortuner(10)
EG(HB,HC6)
EG (HA 5)
AXLE - F(10)
AXLE - I(10)
Trans (HA12)
Sub axle- F (10)
EG(AU6)
EG(AS6)
TransCorolla
TransVios
EG(AZ,BE 4)
TransCamry 10
EG(VK6)
EG(VH,VJ6)
EG(AT6)
EG(AL6)
M1 & M2
D
PS1&2
Out
IN Out
IN
IN
STOP
SP2 return
IN
OUT
IN
IN
OUT
FI V KC
Bumper module(60 cases)Before 60
RK
HB
,HC
(Max
=21)
SN
E- Z
A,Z
B (M
ax =
14)
SE
TRA
NS
- H
A (M
ax=5
)
LD
E- H
A (
Max
=9)
SD
E-Z
C,Z
D (M
ax =
6)
QJ
TRA
NS
- ZA
,ZB
(Max
=8) L
engt
h =1
.1)
DB
E- A
T (M
ax =
9)
AT
E- A
L (M
ax=8
)
PK
E-V
K (M
ax=8
)
DC
E- A
U (
Max
=6)
DA
E-A
S (M
ax =
5)
PJ
E-V
H,V
J (M
ax =
11)
CX
TRA
NS
- VI
OS
ZU
(TIR
E T
UB
ELE
SS
)
EP
(TIR
E T
UB
ELE
SS
)
PV
(WH
EE
L D
ICS
)
M2 (A2) Max = 90 cases
Local part rack
Reserve area310A
OUT
OUT
IN
IN
OUT
OUT
IN
OUT
IN
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Wire harness area
SPS Picking Zone
T F CVIOS
T F CCORROLA
T F CCAMRY
T F CINNOVA
T F CFORTUNER
HW Room
381A Vios
Fortuner
Camry
Corrola 1.8
Corrola 2.0
Wh
eel disc ro
llerlo
cal part
Cap
acity
5B MODULE
ASHI MARI MODULE (40 cases)
Weight
M2 (A1) Max = 140 cases
PV
(WH
EE
L D
ICS
)
SE
AT
A2
SE
AT
A1
Sto
re
SE
AT
A2
SE
AT
A1
EM
PTY
ASHI MARI 2 (Low usage - 32 cases)
EG LOT waiting UP (24 cases)PXP SMALL MODULE
PS1(37)
Pallet
Pallet
C7
C6
C1
C3
C5
C2
C4
C12
C13
C11
C14
C15
C16
IN
C10
C9
RB
4
RB
7
RB
5
RB
8R
B10
RB
6
RB
9
IN
P x P AREA
U/P
dol
ly
PXP SMALL MODULE (56 cases)
UP LOT A1
UP LOT A2
CX
TRA
NS
- VI
OS
Stop &
confirm
Stop &
confirm
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fire extinguish
SeatTire dolly
LO
T M
AK
ING
LA
NE
A1
Tire dollyempty
S1bS1a
Ashi MariModule
Ashi MariModule Empty
Tire A2
Seat A2EG Tire dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
EG
Tire A1
Reserve area640A
RB
1R
B2
RB
11R
B12
RB
3R
BR
BG
lass
Seat A1EG Tire dolly
Seat A1 EGTire dolly
Ashi MariEreka dolly
Ashi MariEreka dolly
C1
V1
1
V3
TMCEMPTY BOX(plastic)
PALink A
EPShaft
DDTank
PxPShaft
EJLink A
BDTank
EQShaft
VBLink A
ADTank
BUMPER DOLLY
Z1Shaft
Z2Shaft
Z3Shaft
Z4Shaft
Z5Shaft
W/H
do
lly
Axl dolly
Seat A2 EGTire dolly Axl dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
Cover case Unpacking A1
U/P
dol
ly
Project room and rest room
Tire - F
EPShaft
S top &
confirm
Stop &
confirm
S top &
confirm
S top &
confirm
Acti ve Barrier
Was
te d
olly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small WATSE 2
Ashi MariEreka dolly
WATSE 1
Waste dolly
Waste dolly
Waste dolly
Was
te d
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
Fire extinguish
Gla
ssBa
ckdo
orG
lass
Back
doo
r
Abs
ober
3 Fl
oor
Dol
ly
Sprin
g
Sprin
g
Pane
l
Pane
l
Gla
ssFr
ont
Pane
l
May
o
May
o
Gla
ss
Gla
ss
Smal
l EG
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
May
o
Trim
doo
r
Trim
doo
r
Qua
rter
Step
Smal
lEG PK EG Sm
all E
G
3 Fl
oor
Dol
ly
Was
te d
olly
Gla
ssFr
ont
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Qua
rter
Floo
rC
arpe
t
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
GlassR
TankFuel
Com
mon
Dol
ly
Inst
Pane
l
Tank
Fuel
Tank
Fuel
Glass quarter
Back
doo
r
Exha
ust
Back
doo
r
Exha
ust
Roof
GlassFront
PanelQuarter
Roof
Hea
dlin
ing
roof
Con
sole
box
Hea
dlin
ing
roof
Hea
dlin
ing
roof
Doo
rTL
PK E
G
PK E
G
W p
art
Cov
er c
ase
Unpa
ckin
g A1
Cov
er c
ase
Unpa
ckin
g A1
SmallEG
ViosLot Ashi Mari
CorrolaLot Ashi Mari
Ashi MariEreka dolly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small
ViosLot Ashi Mari
CorrolaLot Ashi Mari
ForturnerEG small
ForturnerEG small
CURRENT PICKING LOT
STANDBY NEXT LOT
T F
CVIO
S
T F
CC
OR
RO
LA
T F
CC
AM
RY
T F
CIN
NO
VA
T F
CF
OR
TU
NE
R
HW Temporary
Co tire & weel disc
Balancemachine
Tire - K
Wheeldisc - K
Wheeldisc - V
Wheeldisc - C
Weeldisc - F
Tire dollyempty
Co tire & weel disc
Balancemachine
For
klift
Bat
tery
EmptySlot
E-l
iftB
atte
ry
New
E-c
arB
atte
ry
Old
E-c
arB
atte
ry
EmptySlot
Wheeldisc - I
Wheeldisc - F
Tire - I Tire - C
Tire - V
EXTENDEDHW ROOM
Camry lot module
( Max=90 Cases )
Corolla lot module
( Max=90 Cases )
Fortuner lotmodule ( Max=60 Cases)
Innova lot module(Max = 50 case )
Vios lotmodule ( Max=50 Cases )
Ash
i Mari
Mod
uleA
shi M
ariM
odu
le Em
pty
UP,PICKING E/G,
TRANSSTAND BY ASSY LINE
1 unit
Delivery
1 2
Heavy Job: Eliminate double handling
80m
UNPACKINGASHI MARI ASSY LINE
1 units
Elecar
1 unit
1 3
Supply by Ereka
3 2
AXLETIRSEAE/Gashimari
CA
RP
ET(
Fr/
F)
Do
lly
EG
em
pty
A1
Do
lly
EG
sto
ck
A1
Tire A1EG A1
Tire A2 Axl A2
PK E
G
W p
art
PK E
G
Hea
dlin
ing ro
of
Cons
ole
box
Hea
dlin
ing ro
of
Hea
dlin
ing ro
of
Smal
l par
t
Smal
l par
t
Smal
l par
t
Smal
l EG
Doo
r
TL
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
May
o
Was
te d
olly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Qua
rter
Floo
rCa
rpet
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Inst
Pane
l
Tank
Fuel
Tank
Fuel
Back
doo
r
Exha
ust
SmallGlass quarter
PAINT BUMPERSBUMPER DOLLY
EMPTYBOX
PxP
UP
TIRE WAITING FOR JUNBIKI
SEAT A2Cabinet
BATTERY SHOOTER
SEAT A1
Wire harness area
SEAT A2
SEAT A1
EMPTY
Store
PQC ROOM
U/P
doll
yU
/P d
olly
U/P
doll
yU
/P d
olly
U/P
doll
yU
/P d
olly
U/P
doll
y
Was
te d
olly
Wheel disc rollerlocal part
5B size case stock area @ FLR
Ro
ller
Dri
ve
shaf
t -
V
Driveshaft - C (AS)
Driveshaft - K
Driveshaft - K
Emprydoll y EG
EG jig
Tire dollystock 1
Tire dolly
Tire dollyempty
Ba
lan
ce pa
rt
Tire
not
yet in S
TD
Balancemachine
Installbalance
Co tire & weel disc
TMC
EMPTY BOX
(plastic)
Toilet
E-Car batterycharging
Battery charnging
Sea
t qu
alit
yc
he
ckin
g a
rea
Se
atc
hec
kin
g ta
ble S
ea
t deffe
ct dolly
S1bS1aWATSE 1WATSE 2
We
eld
isc
- C
Tir
e -
CT
ire
- V
We
eld
isc
- V
We
eld
isc
- K
We
eld
isc
- K
Ex
tin
guis
her
AXLE DOLLY EMPTY
AXLE DOLLY STOCK 2
SUBAXLE - FEMPTYDOLLY
Emprydoll y EG
Exhaust F
SUBAXLE - FSTOCKDOLLY
Exhaust I
Driveshaft - F
Ba
lan
ce pa
rt
Tire notyet in STD
Installbalance
Co tire & weel disc
Wh
eel
dis
c -
I
Tir
e -
I
Wh
eel
dis
c -
F
Tir
e -
F
Driveshaft - C (AT)
Driveshaft - C (empty)
Waste dolly
Air bottle
UPS
Waste dolly
Do
lly
UP
Balancemachine
Air bottleUPS
Tire dollyempty
Ro
ller
Tire dollystock 2
Was
te d
oll
y
4. Cover case: EG vios & Corolla
2. Jig EG I+F+cau phu, HS phu
Co
ve
r ca
se
Lo
p A
1
Weel disc tray (I)
1. EG HA & HS A2 & CAu
5. Jig HS & thanh thung (K,C,V)
Was
te d
oll
y
Was
te d
olly
Weel disc tray (F)
Weel disc tray (C)
Tire dolly
TBHN(seat)
All local part
va
itin
g &
Ob
serv
er
Seat A2
Seat A1
Localpart A2
Localpart A1
C&A PART (24 CASES)FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
Sheet ( I)
PxP
sto
ck d
oll
y A
2
PxP
sto
ck d
oll
y A
2
PxP
sto
ck d
oll
y A
1
PxP
sto
ck d
oll
y A
1
A2
UP
A2
UP
A2
UP
(SP
2)
Lo
cal
Par
tD
oll
y
LO
T M
AK
ING
LA
NE
A2
SP
2- F (5
cas
e)
W/H
do
lly
Co
ve
r ca
se
Lo
p A
2
Waste dolly
Co
ve
r ca
se
UP
Px
P
Toilet
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fridge
Battery
dolly A1
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Cabinet
OU
T
W/H
sto
ck
co
ntr
ol b
oar
d
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
PQC & TBHN mbr waiting
Se
curity
Stop &
confirm
Sto
p &c
onfirm S
top
&c
onfi
rm
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
Waiting
S1bS1a
WATSE 1WATSE 2
RR temporary
Tire checker Vios
E -
Bo
x
Co
ver
cas
e: B
um
per
Cover case Unpacking A2
Tire
ma
chine
spare
EG
(AS
6)
EG
(AT
6)E
G(V
K6)
EG
(AU
6)E
G(A
L6)
EG
(AZ
,BE
4)
Tra
ns
Co
roll
a
Tra
ns
Vio
s
Tra
ns
Ca
mry
10
EG
(VH
,VJ
6)
EG
(ZA
,ZB
6)
EG
(ZC
,ZD
10)
EG
(HB
,HC
6)
Su
b a
xle
- F
(10
)
Su
b t
ran
s -
F(1
0)
AX
LE
- F
(10)
AX
LE
- I
(10
)
Tra
ns
(H
A1
2)
EG
(H
A 5
)T
ran
sIn
no
va(
10)
Tra
ns
Fo
rtu
ne
r(10
)
Ste
el
Was
te
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Sto
p &
con
firm
So
rtin
g r
olle
r
S
PS1&2
D
D
PB1 (high usage Max=194 cases)
S (80 CASES)
LO
T M
AK
ING
LA
NE
A1
Vios lotmodule ( Max=50 Cases )
W part
C V K
M2
DM1 & M2
M2 (REVISE)
PB1&2
Long oil hose straight
Lon
g o
il h
ose
str
aigh
t
Check sheet
8. Jig EG Camry, AS, thanh thung
Dolly bumper
Duct blow room
Fu
el tank
Tire dollystock 1
Tire dollystock 2
AXLE DOLLY STOCK 1
BATTERY OVER
IN
SP
2- I (5 ca
se)
Pallet
Pallet
RK
HB
,HC
(M
ax=
21)
PJ
E-V
H,V
J (M
ax
= 1
1)
SD
E-Z
C,Z
D (
Max
=6)
PK
E-V
K (
Max
=8
)
DB
E-
AT
(M
ax =
9)
DC
E-
AU
(Max
=6)
QJ
TRA
NS
- ZA
,ZB
(Ma
x=8)
Le
ngth
=1.
1)
SE
TR
AN
S- H
A (
Max
=5
)
PS1(37)
Waste dolly
I7I6
I5W
EIG
HTB
AN
LAC
EA
LL M
OD
EL
I2I4
I3I1 F1
F3
I &
FF
2F
& I
I10
I9M
OU
LDIN
GK
-I K8
K7
K6
K1
K3
K5
K4
K2
C10
C12
C13
C11
C9
C14
C15
C16
C8
C7
C6
C1
C3
C5
C4
C2
V16
V15
V14
V9
V11
V13
V12
V10
V2
V4
V5
V3
V1
V6
V7
V8
P x P AREAS = 600 m2
A1
UP
A1
UP
A1
UP
A1
UP
1314
PV
AIR
CO
ND
ITIO
NE
R(V
) (M
ax
=16)
EI
PA
NE
L C
OR
OL
LA
(Ma
x=1
4)
SN
E-
ZA
,ZB
(M
ax
= 1
4)
LD
E-
HA
(M
ax=
9)
AT
E-
AL
(M
ax
=8)
DA
E-A
S (
Max
=5)
PV
Tir
e V
J, V
K (
Ma
x =
26)
PV
Flo
or
car
pet
VJ,
VK
(M
ax=
16)
Innova lot module(Max = 75 case )
Fortuner lotmodule ( Max=180 Cases)
Camry lot module
( Max=70 Cases )Corolla lot module
( Max=50 Cases )
PA
WH
EE
L D
ISC
VH
(M
ax=
6)
PV
FL
OO
R C
AR
PE
T V
H (
Max
=6
)
ENGIN PART (F)
ENGIN PART (I)
IN
OUT
IN
OUT
IN
IN IN IN
Ou
t
Ou
t
Ou
t
Ou
t
Cover case
S1b S1a WATSE 1 WATSE 2
Was
te d
olly
Was
te d
olly
Cove
r ca
se U
npac
king
A1Co
ver
case
Unp
ackin
g A1
Cove
r ca
se U
npac
king
A2Co
ver
case
Unp
ackin
g A1
PanelQuarter
Roof
Back
doo
r
Exha
ust
Tank
Fuel
Gla
ssFr
ont
Com
mon
Dol
ly
Trim
doo
r
Trim
doo
r
Qua
rter
Step
Smal
lEG PK EG Sm
all E
G
3 Fl
oor
Dol
ly
Gla
ssBa
ckdo
or
Fram
e
Fram
e
Beam
Gla
ssBa
ck d
oor
Abso
ber
3 Fl
oor
Dol
ly
Sprin
g
Beam
Sprin
g
Pane
l
Pane
l
Gla
ssFr
ont
Pane
l
May
o
May
o
Gla
ss
Gla
ss
Roof
GlassFront
GlassR
Small
Smal
l EG
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
Localpart A1
Localpart A2
15 16
17 18 1921 22
2320 2425 26 27 28
29 30E-Box
RB
4R
B5
RB
6
RB
7R
B8
RB
9
RB
10
RB
1R
B2
RB
11R
B12
RB
3R
BR
BG
lass
Ove
r flo
w
Batterycharging
Batterycharging
Ex-box
W/H
do
lly
W/H
do
lly
SPS Picking Zone
E/GUP
Tire
B-lane
No. of part = 355
F
Bumper moduleall model ( 60 cases)
I
OVER MODULE
EMPTY BOX
Local part area
OVER FLOW
PS2 (32) EG LOT WAITING FOR JUNBIKIUN-FINISHED CASE PB2 (low usage 48) OVER PXP
WA
TSE
1W
AT
SE 2
Lo
cal
pa
rt A
1
Lo
cal
pa
rt A
1
EG A2 Seat A2
Seat A1
Tir
e d
olly
em
pty
A1
Tir
e d
olly
sto
ck
A1
Do
lly
EG
sto
ck
A2
Do
lly
EG
em
pty
A2
Tir
e d
olly
em
pty
A2
Tir
e d
olly
sto
ck
A2
Battery
dolly A2
ASSY LINE
10 units
1 unit
ASSY LINE
1 unit
Member push dolly
Heavy Job: Eliminate by using Elecar
STAND BY
1
2
3
1
3
2
BEFORE AFTER0
10203040506070 65
2
Push EG dolly
BEFORE AFTER0
102030405060708090 80
3
Push Tire dolly m m
ASHI MARI ELIMINATE DOUBLE HANDLING & HEAVY JOB REDUCTIONI. HEAVY JOB REDUCTION:
CURRENT METHOD AFTER FLOW
Problem: 1. Very heavy job impact to member's health. Merit: 1. Eliminate double handling2. Double handling heavy process 2. Reduce Heavy job (Supply by Elecar)
CURRENT DOSEN AFTER DOSEN
MERIT
UNPACKINGASHI MARI STAND BY ASSY LINE
10 units 1 unit 1 unit
Picking Delivery
1 2 4
Heavy Job: Eliminate double handling
800m
UNPACKINGASHI MARI ASSY LINE
1 units
Picking
STANDBY AREA
1 unit
1 3
Supply by Ereka
MIX LOT ASHI MARI
32
Heavy Job: Eliminate double handling
AXLETIRSEAE/Gashimari
Heavy Job: No double handling
CA
RP
ET(
Fr/
F)
Do
lly
EG
em
pty
A1
Do
lly
EG
sto
ck
A1
Tire A1EG A1
Tire A2 Axl A2
PK E
G
W p
art
PK E
G
Hea
dlin
ing ro
of
Cons
ole
box
Hea
dlin
ing ro
of
Hea
dlin
ing ro
of
Smal
l par
t
Smal
l par
t
Smal
l par
t
Smal
l EG
Doo
r
TL
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
May
o
Was
te d
olly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Qua
rter
Floo
rCa
rpet
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Inst
Pane
l
Tank
Fuel
Tank
Fuel
Back
doo
r
Exha
ust
SmallGlass quarter
PAINT BUMPERSBUMPER DOLLY
EMPTYBOX
PxP
UP
TIRE WAITING FOR JUNBIKI
SEAT A2Cabinet
BATTERY SHOOTER
SEAT A1
Wire harness area
SEAT A2
SEAT A1
EMPTY
Store
PQC ROOM
U/P
doll
yU
/P d
olly
U/P
doll
yU
/P d
olly
U/P
doll
yU
/P d
olly
U/P
doll
y
Was
te d
olly
Wheel disc rollerlocal part
5B size case stock area @ FLR
Ro
ller
Dri
ve
shaf
t -
V
Driveshaft - C (AS)
Driveshaft - K
Driveshaft - K
Emprydoll y EG
EG jig
Tire dollystock 1
Tire dolly
Tire dollyempty
Ba
lan
ce pa
rt
Tire
not
yet in S
TD
Balancemachine
Installbalance
Co tire & weel disc
TMC
EMPTY BOX
(plastic)
Toilet
E-Car batterycharging
Battery charnging
Sea
t qu
alit
yc
he
ckin
g a
rea
Se
atc
hec
kin
g ta
ble S
ea
t deffe
ct dolly
S1bS1aWATSE 1WATSE 2
We
eld
isc
- C
Tir
e -
CT
ire
- V
We
eld
isc
- V
We
eld
isc
- K
We
eld
isc
- K
Ex
tin
guis
her
AXLE DOLLY EMPTY
AXLE DOLLY STOCK 2
SUBAXLE - FEMPTYDOLLY
Emprydoll y EG
Exhaust F
SUBAXLE - FSTOCKDOLLY
Exhaust I
Driveshaft - F
Ba
lan
ce pa
rt
Tire notyet in STD
Installbalance
Co tire & weel disc
Wh
eel
dis
c -
I
Tir
e -
I
Wh
eel
dis
c -
F
Tir
e -
F
Driveshaft - C (AT)
Driveshaft - C (empty)
Waste dolly
Air bottle
UPS
Waste dolly
Do
lly
UP
Balancemachine
Air bottleUPS
Tire dollyempty
Ro
ller
Tire dollystock 2
Was
te d
oll
y
4. Cover case: EG vios & Corolla
2. Jig EG I+F+cau phu, HS phu
Co
ve
r ca
se
Lo
p A
1
Weel disc tray (I)
1. EG HA & HS A2 & CAu
5. Jig HS & thanh thung (K,C,V)
Was
te d
oll
y
Was
te d
olly
Weel disc tray (F)
Weel disc tray (C)
Tire dolly
TBHN(seat)
All local part
va
itin
g &
Ob
serv
er
Seat A2
Seat A1
Localpart A2
Localpart A1
C&A PART (24 CASES)FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
Sheet ( I)
PxP
sto
ck d
oll
y A
2
PxP
sto
ck d
oll
y A
2
PxP
sto
ck d
oll
y A
1
PxP
sto
ck d
oll
y A
1
A2
UP
A2
UP
A2
UP
(SP
2)
Lo
cal
Par
tD
oll
y
LO
T M
AK
ING
LA
NE
A2
SP
2- F (5
cas
e)
W/H
do
lly
Co
ve
r ca
se
Lo
p A
2
Waste dolly
Co
ve
r ca
se
UP
Px
P
Toilet
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fridge
Battery
dolly A1
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Lo
cal
Par
tD
oll
y
Cabinet
OU
T
W/H
sto
ck
co
ntr
ol b
oar
d
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
PQC & TBHN mbr waiting
Se
curity
Stop &
confirm
Sto
p &c
onfirm S
top
&c
onfi
rm
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
ST
OP
Waiting
S1bS1a
WATSE 1WATSE 2
RR temporary
Tire checker Vios
E -
Bo
x
Co
ver
cas
e: B
um
per
Cover case Unpacking A2
Tire
ma
chine
spare
EG
(AS
6)
EG
(AT
6)E
G(V
K6)
EG
(AU
6)E
G(A
L6)
EG
(AZ
,BE
4)
Tra
ns
Co
roll
a
Tra
ns
Vio
s
Tra
ns
Ca
mry
10
EG
(VH
,VJ
6)
EG
(ZA
,ZB
6)
EG
(ZC
,ZD
10)
EG
(HB
,HC
6)
Su
b a
xle
- F
(10
)
Su
b t
ran
s -
F(1
0)
AX
LE
- F
(10)
AX
LE
- I
(10
)
Tra
ns
(H
A1
2)
EG
(H
A 5
)T
ran
sIn
no
va(
10)
Tra
ns
Fo
rtu
ne
r(10
)
Ste
el
Was
te
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Stop &
confirm
Sto
p &
con
firm
So
rtin
g r
olle
r
S
PS1&2
D
D
PB1 (high usage Max=194 cases)
S (80 CASES)
LO
T M
AK
ING
LA
NE
A1
Vios lotmodule ( Max=50 Cases )
W part
C V K
M2
DM1 & M2
M2 (REVISE)
PB1&2
Long oil hose straight
Lon
g o
il h
ose
str
aigh
t
Check sheet
8. Jig EG Camry, AS, thanh thung
Dolly bumper
Duct blow room
Fu
el tank
Tire dollystock 1
Tire dollystock 2
AXLE DOLLY STOCK 1
BATTERY OVER
IN
SP
2- I (5 ca
se)
Pallet
Pallet
RK
HB
,HC
(M
ax=
21)
PJ
E-V
H,V
J (M
ax
= 1
1)
SD
E-Z
C,Z
D (
Max
=6)
PK
E-V
K (
Max
=8
)
DB
E-
AT
(M
ax =
9)
DC
E-
AU
(Max
=6)
QJ
TRA
NS
- ZA
,ZB
(Ma
x=8)
Le
ngth
=1.
1)
SE
TR
AN
S- H
A (
Max
=5
)
PS1(37)
Waste dolly
I7I6
I5W
EIG
HTB
AN
LAC
EA
LL M
OD
EL
I2I4
I3I1 F1
F3
I &
FF
2F
& I
I10
I9M
OU
LDIN
GK
-I K8
K7
K6
K1
K3
K5
K4
K2
C10
C12
C13
C11
C9
C14
C15
C16
C8
C7
C6
C1
C3
C5
C4
C2
V16
V15
V14
V9
V11
V13
V12
V10
V2
V4
V5
V3
V1
V6
V7
V8
P x P AREAS = 600 m2
A1
UP
A1
UP
A1
UP
A1
UP
1314
PV
AIR
CO
ND
ITIO
NE
R(V
) (M
ax
=16)
EI
PA
NE
L C
OR
OL
LA
(Ma
x=1
4)
SN
E-
ZA
,ZB
(M
ax
= 1
4)
LD
E-
HA
(M
ax=
9)
AT
E-
AL
(M
ax
=8)
DA
E-A
S (
Max
=5)
PV
Tir
e V
J, V
K (
Ma
x =
26)
PV
Flo
or
car
pet
VJ,
VK
(M
ax=
16)
Innova lot module(Max = 75 case )
Fortuner lotmodule ( Max=180 Cases)
Camry lot module
( Max=70 Cases )Corolla lot module
( Max=50 Cases )
PA
WH
EE
L D
ISC
VH
(M
ax=
6)
PV
FL
OO
R C
AR
PE
T V
H (
Max
=6
)
ENGIN PART (F)
ENGIN PART (I)
IN
OUT
IN
OUT
IN
IN IN IN
Ou
t
Ou
t
Ou
t
Ou
t
Cover case
S1b S1a WATSE 1 WATSE 2
Was
te d
olly
Was
te d
olly
Cove
r ca
se U
npac
king
A1Co
ver
case
Unp
ackin
g A1
Cove
r ca
se U
npac
king
A2Co
ver
case
Unp
ackin
g A1
PanelQuarter
Roof
Back
doo
r
Exha
ust
Tank
Fuel
Gla
ssFr
ont
Com
mon
Dol
ly
Trim
doo
r
Trim
doo
r
Qua
rter
Step
Smal
lEG PK EG Sm
all E
G
3 Fl
oor
Dol
ly
Gla
ssBa
ckdo
or
Fram
e
Fram
e
Beam
Gla
ssBa
ck d
oor
Abso
ber
3 Fl
oor
Dol
ly
Sprin
g
Beam
Sprin
g
Pane
l
Pane
l
Gla
ssFr
ont
Pane
l
May
o
May
o
Gla
ss
Gla
ss
Roof
GlassFront
GlassR
Small
Smal
l EG
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
Localpart A1
Localpart A2
15 16
17 18 1921 22
2320 2425 26 27 28
29 30E-Box
RB
4R
B5
RB
6
RB
7R
B8
RB
9
RB
10
RB
1R
B2
RB
11R
B12
RB
3R
BR
BG
lass
Ove
r flo
w
Batterycharging
Batterycharging
Ex-box
W/H
do
lly
W/H
do
lly
SPS Picking Zone
E/GUP
Tire
B-lane
No. of part = 355
F
Bumper moduleall model ( 60 cases)
I
OVER MODULE
EMPTY BOX
Local part area
OVER FLOW
PS2 (32) EG LOT WAITING FOR JUNBIKIUN-FINISHED CASE PB2 (low usage 48) OVER PXP
WA
TSE
1W
AT
SE 2
Lo
cal
pa
rt A
1
Lo
cal
pa
rt A
1
EG A2 Seat A2
Seat A1
Tir
e d
olly
em
pty
A1
Tir
e d
olly
sto
ck
A1
Do
lly
EG
sto
ck
A2
Do
lly
EG
em
pty
A2
Tir
e d
olly
em
pty
A2
Tir
e d
olly
sto
ck
A2
Battery
dolly A2
ASSY LINE
10 units
1 unit
PAINT BUMPERSBUMPER DOLLY
PQC ROOM
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
lyU
/P d
olly
U/P
dol
ly
Toilet
E - Box
TBHN(seat)
All local part
vait
ing
&
Obs
erve
r
FR bumper (B)
FR bumber (A)
FR bumper dolly
RR bumper dolly
Assembly part dolly
RR bumper (B)
RR bumber (A)
UP BUMPER
PxP
sto
ck d
olly
A2
PxP
sto
ck d
olly
A2
Toilet
W/H
sto
ck c
ontr
ol b
oard
S top &
confirm
S top &
confirm
S top &
confirm
Sec
urity
S top &
confirm
Sto
p &
co
nfir
m
STO
P
STO
P
STO
P
STO
P
STO
P
STO
P
Waste
RR temporary
Hose drain
S top &
confirm
S top &
confirm
S top &
confirm
S top &
confirm
Sto
p &
co
nfir
m
So
rtin
g r
olle
r
S
D
PB1 (high usage Max=194 cases)
W part
D
Lon
g o
il ho
se s
trai
ght
Dolly bumper
Duct blow room
Fuel tank
I7I6
I5W
EIG
HT
BA
NL
AC
EA
LL M
OD
EL
I2I4
I3I1 F1
F3
I & F
F2
F &
II1
0I9
K8
K7
K6
K1
K3
K5
K4
K2
V1
5V
14
V9
V1
3
V1
2
V1
0
V2
V4
V5
V6
V7
V8
13
IN
Cov
er c
ase
Unpa
ckin
g A1
Cov
er c
ase
Unpa
ckin
g A2
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
3 FloorDolly
16
25 26 27 2829 30
CURRENT TOILET
UP
A1
G3
UP
A1
G1
UP
A1
G2
UP
A1
G1
UP
A1
G3
UP
A1
G4
UP
A2
G1
UP
A2
G1
UP
A1
G4
UP
A1
G2
UP
A2
G1
UP
A2
G2
UP
A2
G3 UP
A2
G3
KAIZEN ROOM
Cov
er c
ase
: B
um
per
Weeldisc - I
17
BatteryRoller
PB1&2
S top &
confirm
EG A2 EG A1
Extension
Ove
r fl
ow
EG(ZA,ZB6)
EG(ZC,ZD10)
TransInnova(10)
TransFortuner(10)
EG(HB,HC6)
EG (HA 5)
AXLE - F(10)
AXLE - I(10)
Trans (HA12)
Sub axle- F (10)
EG(AU6)
EG(AS6)
TransCorolla
TransVios
EG(AZ,BE 4)
TransCamry 10
EG(VK6)
EG(VH,VJ6)
EG(AT6)
EG(AL6)
M1 & M2
D
PS1&2
Out
IN Out
IN
IN
STOP
SP2 return
IN
OUT
IN
IN
OUT
FI V KC
Bumper module(60 cases)Before 60
RK
HB
,HC
(Max
=21)
SN
E- Z
A,Z
B (M
ax =
14)
SE
TRA
NS
- H
A (M
ax=5
)
LD
E- H
A (
Max
=9)
SD
E-Z
C,Z
D (M
ax =
6)
QJ
TRA
NS
- ZA
,ZB
(Max
=8) L
engt
h =1
.1)
DB
E- A
T (M
ax =
9)
AT
E- A
L (M
ax=8
)
PK
E-V
K (M
ax=8
)
DC
E- A
U (
Max
=6)
DA
E-A
S (M
ax =
5)
PJ
E-V
H,V
J (M
ax =
11)
CX
TRA
NS
- VI
OS
ZU
(TIR
E T
UB
ELE
SS
)
EP
(TIR
E T
UB
ELE
SS
)
PV
(WH
EE
L D
ICS
)
M2 (A2) Max = 90 cases
Local part rack
Reserve area310A
OUT
OUT
IN
IN
OUT
OUT
IN
OUT
IN
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Wire harness area
SPS Picking Zone
T F CVIOS
T F CCORROLA
T F CCAMRY
T F CINNOVA
T F CFORTUNER
HW Room
381A Vios
Fortuner
Camry
Corrola 1.8
Corrola 2.0
Wh
eel disc ro
llerlo
cal part
Cap
acity
5B MODULE
ASHI MARI MODULE (40 cases)
Weight
M2 (A1) Max = 140 cases
PV
(WH
EE
L D
ICS
)
SE
AT
A2
SE
AT
A1
Sto
re
SE
AT
A2
SE
AT
A1
EM
PTY
ASHI MARI 2 (Low usage - 32 cases)
EG LOT waiting UP (24 cases)PXP SMALL MODULE
PS1(37)
Pallet
Pallet
C7
C6
C1
C3
C5
C2
C4
C12
C13
C11
C14
C15
C16
IN
C10
C9
RB
4
RB
7
RB
5
RB
8R
B10
RB
6
RB
9
IN
P x P AREA
U/P
dol
ly
PXP SMALL MODULE (56 cases)
UP LOT A1
UP LOT A2
CX
TRA
NS
- VI
OS
Stop &
confirm
Stop &
confirm
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
W/H
do
lly
Fire extinguish
SeatTire dolly
LO
T M
AK
ING
LA
NE
A1
Tire dollyempty
S1bS1a
Ashi MariModule
Ashi MariModule Empty
Tire A2
Seat A2EG Tire dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
EG
Tire A1
Reserve area640A
RB
1R
B2
RB
11R
B12
RB
3R
BR
BG
lass
Seat A1EG Tire dolly
Seat A1 EGTire dolly
Ashi MariEreka dolly
Ashi MariEreka dolly
C1
V1
1
V3
TMCEMPTY BOX(plastic)
PALink A
EPShaft
DDTank
PxPShaft
EJLink A
BDTank
EQShaft
VBLink A
ADTank
BUMPER DOLLY
Z1Shaft
Z2Shaft
Z3Shaft
Z4Shaft
Z5Shaft
W/H
do
lly
Axl dolly
Seat A2 EGTire dolly Axl dolly
1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu 1. EG HA & HS A2 & CAu
Cover case Unpacking A1
U/P
dol
ly
Project room and rest room
Tire - F
EPShaft
S top &
confirm
Stop &
confirm
S top &
confirm
S top &
confirm
Acti ve Barrier
Was
te d
olly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small WATSE 2
Ashi MariEreka dolly
WATSE 1
Waste dolly
Waste dolly
Waste dolly
Was
te d
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
3 Fl
oor
Dol
ly3
Floo
rD
olly
Fire extinguish
Gla
ssBa
ckdo
orG
lass
Back
doo
r
Abs
ober
3 Fl
oor
Dol
ly
Sprin
g
Sprin
g
Pane
l
Pane
l
Gla
ssFr
ont
Pane
l
May
o
May
o
Gla
ss
Gla
ss
Smal
l EG
UP1
-1
UP1
-1
UP1
-2
UP2
-1
UP2
-2
UP3
-1
U4
May
o
Trim
doo
r
Trim
doo
r
Qua
rter
Step
Smal
lEG PK EG Sm
all E
G
3 Fl
oor
Dol
ly
Was
te d
olly
Gla
ssFr
ont
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
Qua
rter
Floo
rC
arpe
t
Com
mon
Dol
ly
Com
mon
Dol
ly
Com
mon
Dol
ly
GlassR
TankFuel
Com
mon
Dol
ly
Inst
Pane
l
Tank
Fuel
Tank
Fuel
Glass quarter
Back
doo
r
Exha
ust
Back
doo
r
Exha
ust
Roof
GlassFront
PanelQuarter
Roof
Hea
dlin
ing
roof
Con
sole
box
Hea
dlin
ing
roof
Hea
dlin
ing
roof
Doo
rTL
PK E
G
PK E
G
W p
art
Cov
er c
ase
Unpa
ckin
g A1
Cov
er c
ase
Unpa
ckin
g A1
SmallEG
ViosLot Ashi Mari
CorrolaLot Ashi Mari
Ashi MariEreka dolly
CamryLot Ashi Mari
CamryLot Ashi Mari
CorrolaLot Ashi Mari
ViosLot Ashi Mari
I nnovaEG small
ViosLot Ashi Mari
CorrolaLot Ashi Mari
ForturnerEG small
ForturnerEG small
CURRENT PICKING LOT
STANDBY NEXT LOT
T F
CVIO
S
T F
CC
OR
RO
LA
T F
CC
AM
RY
T F
CIN
NO
VA
T F
CF
OR
TU
NE
R
HW Temporary
Co tire & weel disc
Balancemachine
Tire - K
Wheeldisc - K
Wheeldisc - V
Wheeldisc - C
Weeldisc - F
Tire dollyempty
Co tire & weel disc
Balancemachine
For
klift
Bat
tery
EmptySlot
E-l
iftB
atte
ry
New
E-c
arB
atte
ry
Old
E-c
arB
atte
ry
EmptySlot
Wheeldisc - I
Wheeldisc - F
Tire - I Tire - C
Tire - V
EXTENDEDHW ROOM
Camry lot module
( Max=90 Cases )
Corolla lot module
( Max=90 Cases )
Fortuner lotmodule ( Max=60 Cases)
Innova lot module(Max = 50 case )
Vios lotmodule ( Max=50 Cases )
Ash
i Mari
Mod
uleA
shi M
ariM
odu
le Em
pty
ASSY LINE
10 units
1 unit
1 unit
BEFORE AFTER0
102030405060708090
100 90
15
HEAVY MOVING DISTANCE (10 unit)
BEFORE AFTER0
102030405060708090 85
17
Push dolly (1 unit)m m
BEFORE PXP BIG PART MODULE SUPPLY
I. PART FLOW
II. OPERATION
Vios Corrola Camry Innova Forturner
Lot 1
Lot 2Lot 3
Vios Unfinished Location
Vios Unfinished Location
Lot 1 Lot 2Lot 3
BUMPER UNPACKING
BUMPER UNPACKING
1 SIDE OPERATION WITH ROLLERS => MUDA MOVING JOB
Model Line Lane Stack CasesV 1 3 4 12C 1 3 4 12K 1 3 4 12F 1 3 4 12I 1 3 4 12
60
Capacity
Total
BUMPER ROLLER
I. CAPACITY
II. OPERATION
Vios Corrola Camry Innova Forturner
Lot 1
Lot 2Lot 3
OUT
Vios
IN
2 SIDE OPERATION WITH ROLLERS => NO MUDA MOVING JOB
BUMPER UNPACKING
BEFORE AFTER0
50
100
150
200
250
11080
100
0
Moving other lot
Moving required lot
BEFORE AFTER0
20
40
60
80
100
120
140
160
180
0
20
40
60
80
100
120
140
6080
132.24
75
Capacity
Space
REDUCE SPACE BUT INCREASE CAPACITY
REDUCE MUDA JOB
Model Line Lane Stack CasesV 1 4 4 16C 1 4 4 16K 1 4 4 16F 1 4 4 16I 1 4 4 16
80
Capacity
Total
CapacityModel Line Lane Stack Cases
V 1 4 4 16C 1 4 4 16K 1 4 4 16F 1 4 4 16I 1 4 4 16
Total 80
MERIT:REDUCE MUDA MOVING JOB
MOVING TBEFORE AFTERMoving req 110 80Moving oth 100 0
BEFORE AFTERSpace 132.24 75Capacity 60 80
BEFORE AFTERRoller Spac 525 525FLR space 195 0
75BEFORE AFTER
SUPPLY MO 145 35
BEFORE AFTERHEAVY MOV 90 15
BEFORE AFTERPush dolly 85 17
BEFORE AFTERPush EG dol 65 2
BEFORE AFTERPush Tire d 80 3
