242Xe 2016 Model

Yamaha Jet Boat Manufacturing U.S.A., Inc.

YJBMTVP activity

1,Aug-11,Aug

1-Aug

8:00

10:00

13:00

15:00

17:00

Schedule of 2weeks

2-Aug 3-Aug 4-Aug 5-Aug 8-Aug 9-Aug 10-Aug 11-Aug

OpeningMeeting

Hull 1 new design

practice session

Closing

Summ

ary & Meeting

within a team

Progresscheck

GENBAreport

Remindof

plan

Hull 1 new design

practice session

PreparationProcess&

Operationcurrent

Assy 2 lineVisualize

merit

Process design

Processintegration

ofdetail design

Discussion of

after design

Designof

Kit supply

Wear house : Inventory reduction

Work designof

after process design

Streaming&

Process design

Targetshare

Process&

Operationcurrent

Assy ２ lineVisualize

merit

Process design

Processintegration

ofdetail design

AMAKUSA YMC/support

P/J LeaderGurudatt Sanil

P/J 　 Support 　AMAKUSA 　 Mr. Kayama 　

Key Word 　：　 ALL 　 YJBM Member 　Join ！！

Div. Manager Roy ReneauM.E. Mng. Stefan BroekerAsst. Div. Mng. Fred Muramatsu　

Gen. Manager Mike Fishback

YMC

ＹＰＭＴ　 TVP 　 Activity 　 organization

Production QC,QA MAINTENANCEPC

YJBM TVP Member

Branden Spicer

David Glover

Christi Hambrick

Roy Reneau

M.E.ENGINEER　　　

Bharadwaj Venkatesan

TVP Activity Organization YJBM

YMC Boat ManufacturingMemberShannon Fisher 　

PURCHASING　　　

Richard Kirkland

Monthly update to Gen Manager from PJ Manager

Cost structure(By Product)Product name : 24ft : F3F 242Ltd Se

$42,636

$720

Material$31,552

Manufacturing$8,713

Depreciation

74％

20.5％

8,22117,2093,963

Direct Labor 2,799Non-PROD. 5,822

CKD CIFLocal Parts CostRaw Material

I tem FY16 FY17 FY18Production Number 4461 3109 3169

Direct number 315 220 220

Labor Efficiency $65K $50K $125K $240K（生産性向上） 84%-->85% 85%-->86%

Accumulation from FY1686%-->87%

Accumulation from FY16

Manufacturing Improvement $220K $150K $150K $520K(製造改革） ($50/unit) ($50/unit) ($50/unit)

US Parts CD & VA/ VE $350K $250K $250K $850K( CD & VA/VE )購入品 推進 ($80/unit) ($80/unit) ($80/unit)

Purchasing --> In-house $0K $50K $200K $250K（部品の内製化） 準備期間 From MY18 model Accumulation

from FY17

$635K $500K $725K $1860K

3

2

4

1

No. Total

CIP target

Kaizen Necessity

KaizenOrientation

Necessity summary

・Investment minimum

・Build up cost competitiveness

Productivity up ×1.44 (2018)

Labor expenses

Expenses

Material

Manufacturing

CKD CIF

Local Parts Cost

Raw Material

Shortening of cycle time OEE up

Process design・Process integration

Purchase methodLocalize Material yieldQuality yield

Stock reduction・Improvement of material flow（Streaming）

Work space out

15

By Configuration to orderBy Lean-manufacturing / SCM

By 3D-Development & BOM managementBy Employee’s Culture

Way

YJBM Product Innovation

In the small boat worldNo.1 Quality & reasonable value

supported by the customer

Goal

Together we build our futureYJBM slogan

I nvestment minimum ⇒ Productivity upBuild up cost competitiveness （Including Investment ）Current condition is good ⇒ Continue the present activity

Top management interview

Necessity summary

Investment minimumCost competitiveness up

Labor efficiencyProductivity upWork space out

FY15 FY16 FY17 FY18 FY19 FY20Transfer Value $132.4 $147.3 $168.4 $187.0 $205.6 $212.5Units 4,266 4,461 5,201 6,124 6,783 6,827

$132.4$147.3

$168.4$187.0

$205.6 $212.5

4,266 4,461

5,201

6,124 6,783 6,827

0

1,000

2,000

3,000

4,000

5,000

6,000

7,000

8,000

$0

$50

$100

$150

$200

$250(M) (ships)

MTP vs CapacityYJBM MTP

×1.46

Investment plan 24 Boats/day 26

(Aug)28 35

Lamination

GC

20

30

40 FY1835units/ day

(Units)

17ft 80%F4A 20%

1Shift 6:00-16:30 555min

Pulling Hole cut

Assy Pinning Assy FinishingLaketest

foamingMoldpreparation

PI Finalinsp

Linerset

$12.７M$3.0M

Production volume ×1.46 End of 2017

Current

Expansion Plan

Overall factory (Target figure)Target (Dec,2017)

Wear house

outside

Current

Process flow (Current condition)

GC(吹付)

Lamination(積層)

Pulling(離型)

Hole cut(ｻﾝﾄﾘ) assembly

(前艤装)Pinning(接着)

assembly(後艤装)

Finishing(仕上げ)

Shipment (出荷)

Lake test(浸水検査)

成形Lamination area

組立Assembly area

Linerset

(接着)

foaming(発泡)

Moldprep

(型準備)

PI(前仕上)

Finalinsp

TT 25min 600min(10h)/24ships/day

PT21min

24ft21ft19ft

HULL(ﾊﾙ )

DECK(ﾃ ｯ゙ｷ )

GC lamination linerset foaming pulling hole

cut PI assembly pinning assembly lake tast finishing finalLiner ○ ○ - - ○ ○ - - - - - -deck ○ ○ - - ○ ○ ○ - - - - -Hull ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Process

○

Liner(ﾗｲﾅｰ )

Current condition (Mar,2016)

Target (Oct, 2017)

GC(吹付)

Lamination(積層)

Pulling(離型)

Hole cut(ｻﾝﾄﾘ) assembly

(前艤装)Pinning(接着)

assembly(後艤装)

Finishing(仕上げ)

Shipment (出荷)

Lake test(浸水検査)

成形Lamination area

組立Assembly area

Linerset

(接着)

foaming(発泡)

Moldprep

(型準備)

PI(前仕上)

Finalinsp

LargerboatsSm

aller boats

24ft21ft19ft17ft

Liner(ﾗｲﾅｰ )

HULL(ﾊﾙ )

DECK(ﾃ ｯ゙ｷ )

18boats/dayTT 30.8minT-OEE 90%

T-CT 27.7min

17boats/dayTT 32.6minT-OEE 90%

T-CT 29.3min

Process Optimum Production　◆ Common Production Line　◆ No Standard Manpower per each model　◆ Multiple Pitch Process （ each Process has own speed ）　◆ In-house Equalization Production

Model TVP　◆ Production Line per model(Streaming)　◆ Standard Manpower ・ Operation per model　◆ Uniform pitch Production　◆ Production Flexibility per Market Request

Overall STEPCurrent condition Step① Target Ideal

Mar.2016 20XX

34boats/day(Jan 2018)

Dec.2017

1.?? times1.17times

Nov.2016

Space

BPD 24boats/day 28boats/day

Productivity

StreamingProcess designProductivity up

Productivity upProcess designStandardization

New design of the assembly lineBig

boatsSm

allboats

Process integration

Productivity up

Productivityup

Boats/day/Parson 0.072 0.084 ???Direct 333 333 333(+ ??)

26boats/day 28boats/day(July 2017)

Master Plan20172016

April May July Aug SeptJune Oct Nov Dec Jan Feb Mar

Process design

Lamination area

Assembly area

April May June July

Preparation timeMove time

Shortening CT

Kit supply designKit supply Trial Kit supply Start

26boats

◆Foaming◆Lamination◆GC ◆Liner set

kaizen of Mizusumashi　Shortening CT

◆Hole cut

◆Final Assy◆Pinning

◆Deck Line

◆Hull Line

◆Final Finish◆PI

Preparation timeMove time

Non value KAIZEN

Non value KAIZEN Cure time reductionNon value KAIZEN

Non value KAIZEN

Non value KAIZEN

Additional Machine

Additional Machine

Robot Machine time 　 KAIZEN

Mizusumashi

Non value KAIZENNon value

KAIZENNon value

KAIZENNon value KAIZEN

Redesigned Layout/work

Non value KAIZENkaizen of

Mizusumashi　

Material

Target (Oct)

Warehouse Design Warehouse Layout

Training Cross training implementationCurrent Evaluation

Design strategy (Micro/Macro)

Mizusumashi

28boats34boatsJan 2018

New Assembly lineTVP design & Try

Current

Material flow Target (Dec, 2017)

GC( 吹付 )

Lamination( 積層 )

Pulling( 離型 )

Hole cut( ｻﾝﾄﾘ )

assembly( 前艤装 )

Pinning( 接着 )

assembly( 後艤装 )

Finishing( 仕上げ )

Shipment ( 出荷 )

Lake test( 浸水検査 )

成形Lamination area

組立Assembly area

Linerset

( 接着 )

foaming( 発泡 )

Moldprep

( 型準備 )

PI( 前仕上 )

Finalinsp

BigSm

all

24ft21ft19ft17ft

Liner( ﾗｲﾅｰ )

HULL( ﾊﾙ )

DECK( ﾃﾞｯｷ )

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

This time the main activities

Assembly area Basic & Detail design

How to proceed

How to “PDCAS” ① (Outline)

TVP Team

Mgmt.

ProdT.L

Prod Mgr.

ProdOper

Simulate work

sequence and

review

Review TVP

material a

Review TVP suggestions

and SOP Operator training

and changes

Mock trial,

review and final changes

Kaizen Kai(Line

through)↓

Check↓

Standardize

No Ok

Feedba

ck

Notification to

Mgmt. and

approval

Notification to TVP team and approval

End

Selecting an operatorTVP team also join

ProcessDesign

&Re-

balancing

Design new SOP

and station layout

Start

Work Area Redesign ProcessP

② Work designNo element time1 ・・・ ・・・2 ・・・ ・・・3 ・・・ ・・・・ ・・・ ・・・

Loss structure

Make a layout

ecurrent target

value

Semi-

Non-

e

Estimate reduced time

What is changed ?

current target

Before KAIZEN-KAIExplain the plan to operators ・ the aim of KAIZEN-KAI・ Estimated result If necessary, simulate the operations of some parts.

D

VTRExplanation board・ line balance sheet・ work sheet・ loss structure・ layout

・ KAIZEN operators must know the operation.・ Record a video・ Explain the aim of KAIZEN-KAI to everyone.・ Managers must take part in.

C

eCurrent Target

value

Semi-

Non-

Insp

e

reduced time

What is different from estimation ?e

decrease

increase

A Modification or an addition

KAIZEN-KAI

VTR analysis

KAIZEN-KAI

How to “PDCAS” ② (After process design)

S Make new process sheet and worksheetNew layout also

① Line re-balancing

Value Semi value

●●

Nonvalue

●●

St.1 St.2 St.3 St.4 St.1&4

Doing

Process design

Hull 1Hull 2Hull 3Hull 4

Deck 1 Deck 2Deck 3Deck 4

Pin

Lake

FF3

FF1

FF4 FI

F assy 1F assy 2F assy 3F assy 4

PIPI

FF 2

Hull 1Hull 2 Hull 3Hull 4

Deck 1 Deck 2 Deck 3Deck 4

Pin

Lake

FF3

FF1

FF4 FI

F assy 1F assy 2F assy 3

PIPI

FF2

Big

Small

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

24ft21ft

19ft17ft

This time

Material flow Target (Dec, 2017)

GC(吹付)

Lamination(積層)

Pulling(離型)

Hole cut(ｻﾝﾄﾘ) assembly

(前艤装)Pinning(接着)

assembly(後艤装)

Finishing(仕上げ)

Shipment (出荷)

Lake test(浸水検査)

成形Lamination area

組立Assembly area

Linerset

(接着)

foaming(発泡)

Moldprep

(型準備)

PI(前仕上)

Finalinsp

BigSm

all

24ft21ft19ft17ft

Liner(ﾗｲﾅｰ )

HULL(ﾊﾙ )

DECK(ﾃ ｯ゙ｷ )

Hull line new design(Basic)

0

5

10

15

20

25

30

35

Station 1 Station 2 Station 3 Station 4 Station 5 Station 6 Station 7 Station 8

Tim

e (M

in)

Hull Stations

Hull Line- Current Time Analysis (242 ltd S)

Operator 1 Operator 2 Operator 3

21 min

27.130.2 30.4

27.226.525.5

26.426.0

9.8

4.2

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

Station 1 Station 2 Station 3 Station 4

Tim

e (M

in)

Hull Stations

Hull Line-LARGE: Future Analysis

Operator 1 Operator 2 Operator 3

27.5 min

CURRENT MIX LINE

24.5

7.6

24.7

21.1

25.826.6

16.6

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

Station 1 Station 2 Station 3 Station 4Ti

me

(Min

)

Hull Stations

Hull Line-Small With Floating Operator (6 Operators)

Operator 1 Operator 2 Floating Operator

27.5 min

SPLIT LINE

24 Boats

34 Boats

KAIZEN NEEDED

Total Operators 16

Mizusumashi 0

Total Stations (floor space) 8

Total Operators 15

Mizusumashi 1

Total Stations (floor space) 4

Number of operators same in

split line with higher productivity

& less stations

Big Line9 operators

Small Line6 operatorsPro

ducti

vity

Up

+0.5min

+0.5min

1, Standard Work Combination Worksheet

2, Required parts list

New Hull 1 New design(Detail) Big line

New Hull 1 New design(Detail) Big line

Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty Parts name Parts # Qty Parts name Part # Qty Parts name Part # Qty Parts name Part # Qty1 Succpler Drain F0R-U2287-00 1 CARPET-12,11,10,9 F3F-U398G-D-00 1 MOTOR MOUNTS 68N-44517-00 8 I NTAKE SCREEN F2J -U72B7-00 1 J OI NT HOSE ASSY 6AP-Y125J 02 22 J OI NT PI PE F2D-U883E-00 2 GLUE Q-5200 10229 BOLTS M8-1.25X40MM 90119-08857 16 I NTAKE SCREEN F2J -U72B7-10 1 GROMMETS F1C-U136D-10 44 MANHOLE ASSY F0R-U7608-00 2 CABLES, REVERSE F2D-U149C-00 2 SPACER F1C-U72C0-01 8 DI E CAST PLATE F3F-U273B-01 2 DRAI N PLUG ASSY BLACK F2J -U2280-00 15 PLEXUS/ACTI VATOR 10151 234.3ML CABLES, THROTTLE F1T-U7252-33 2 SHI MS 10MM GDO-U7249-00-10 BOLT 90101-06SA2 6 WASHER 90201-06809 66 PLEXUS/ADHESI VE 10152 234.3ML ANCHOR STOPPER F3F-U166D-00 1 SHI MS 5MM GDO-U7249-00-5 SCREW 90111-08832 14 WASHER 90201-15SA1 47 # 10 WASHER 90204-15S00 8 COCKPI T DRAI N F1B-62241-00 2 BOSTI C BLACK 10212 SCREW 90111-08833 8 WASHER 90209-12SB6 108 BOLT HH M8X3 90101-08802 8 WATER PI LOT F2C-U753B-01 2 ACTI VATOR 10167 1 SCREW 90149-12SD1 10 CLAMP HOSE 90450-27801 29 PLAI N WASHER 90201-1800 8 NUT F2C-U2733-00 2 MI XI NG TUBE SMP-SM 1 SCREW 90167-08S10 2 CABLE TI E 90464-44801 10

10 COVER EXHAUST VALVE F1C-U751G-00 2 GASKET F2C-U7564-00 2 SCREW 90167-08S12 4 WASHER LOCK 92990-06100 611 PACKI NG F1S-U7525-01 2 DRAI N PLUG F2J -U2280-00 2 SCREW 90167-10S12 8 NYLON NUT LOCK 95780-08300 412 SEAL PACKI NG F1U-U7747-01 1 DRAI N, 2 SHOWER F2A-U2242-00 1 SCREW 90169-10SA1 12 BULKHEAD 3 CARPETED F3F-BHD3-00 113 DRAI N, BODY 3 F1W-U224E-00 2 DRAI N FLOOR ASSY F2D-U2290-00 1 SCREW 90169-12SA8 4 BULKHEAD 4 CARPETED W/SHOWER PUMP F3F-BHD4-10 114 TRANSDUCER F2D-U8K1W-01 1 PACKI NG 7 F2D-U266F-10 1 BULKHEAD 5 CARPETED F3F-BHD5-10 118 THRU HULL EXHAUST F3F-U7565-00 2 BOSTI C 10212 1.75 BULKHEAD 6 CARPETED F3F-BHD6-10 119 THRU HULL 3/4X90 DEG WHT GP1-U2290-00 1 ACTI VATOR 10167 1 BULKHEAD COMP VI NYL F3F-BHDCOMP-10 120 THRU HULL 3/4 BLACK GP1-U7616-10 1 STEERI NG CABLE ASSY F3F-U1470-00 1 BI LGE PUMP ASSY F3F-BPASY-00 121 THRU HULL BLACK GP1-U7616-10 1 DUCT I NTAKE F3F-U72B6-00 1 WATER TANK ASSY F3F-WTASY-00 122 RUDDER ASSY F3F-STRAY-00 1 DUCT I NTAKE F3F-U72B6-10 123 WASHER PLAI N 5/16 90201-15SA1 4 MI XI NG TUBE SMP-SM 124 NYLON NUT M8-1025 95780-08300 4 SEAL PI PE 30/CABLE CONN ASSY EU0-61435-00 225 BODY/CH PT OF EU0-6727-00 EU0-61436-00 226 PACKI NG C/CH PT OF EU0-67267-00 EU0-61438-00 227 WASHER 30/CH PT OF EU0-61446-00 EU0-61446-00 228 STOPPER EU0-61486-00 22930313233343536

St.2Hull

OP3-1St.1

OP1 OP2

2 4 6 8 10 12 14 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 501 Move Boat 16 162 Apply silicone to drain plug assy 46 463 Install water pilots 31 314 lay carpet out for installation 56 565 Retrieve ladder 19 196 Wipe down sides with alcohol 40 407 Drill plug hole-If nessessary 36 368 Install floor drain 22 229 Remove yellow plug tops 87 87

10 Wipe down hull 58 5811 Install anchor stopper 47 4712 Clean trash out of hull 37 3713 Vacuum out hull 121 12114 Install carpet/glue 673 67315 Cut excess edges of carpet inside hull 109 10916 Take to trash 13 1317 Replace ladder 13 1318 Lay cables in Hull 105 10519 Remove edges @ bow of hull carpet 44 44202122

Name & Date: Shannon Fisher 8/3/2016 UMTotal 1573 1573 MIN

TOTAL26.22 OPERATOR 2

602

# MANUAL TASK TIME

AUTO RUN TIME

SUB TOTAL FOR REF.

TIME ( draw red vertical line at tact time ) Each block = 2 minutes

YJBM Standard Work Combination Worksheet

Process Name Hull Assembly TAKT TIME 28 OP

Standard Work

PartList

Operator 3 @ Hull 1 Operator 3 @ Hull 4

Travel from Hull1 to Hull4 ea. cycle

Operator 1 Work Area Operator 2 Work Area

New Hull 1 Configuration @ 28 min pitch time Reduce Muda (eliminate waste movement) Balance work based on task precedence Zone work areas and avoid overlap

12.7 15.79.1

10.28.9

3.2

3.6 1.6

2.3

0.0

5.0

10.0

15.0

20.0

25.0

30.0

Operator 1 Operator 2 Operator 3

Tim

e (S

ec)

Hull 1 Operators

Gemba Summary

Value Semi Value Inspection Non value Preparation

New Hull 1 New design(Detail) Big line

Hull 1 new design practice session

1, Result2, Found3, The following actions necessary

Mock Practice Result

Total Time: 28.13 Minutes (excluding stops)

Hull 1: SOP Practice

Mock Practice Review

Work Area Operator Body/Motion Time & Misc.

Operator 1

• Op 3 setup adhesive mix on table instead of boat

• Portable mini table for tool setup and under boat work

• Check operator 3 sequence for adhesive mix

• Review Bostic application/cleaning process for improvement

Operator 2

• Fix vacuum, battery stand and other accessory fixed in station layout

• Review mounting plate installation in hull 1 for operator ease (cover)

• Check different tool for alcohol based cleaning (mop)

• Review Hull dolly design for stability

• Review carpet installation time and SOP

• Starboard drain holes and floor drains not done correctly (Hole cut issue)

Operator 3• Fix operator motion

and work area• Review SOP and

communication method

Hull 1: Video Check Items & Operator Feedback

Future Action After Mock Practice

• Separate test area for kaizen simulation and training

• Mimic layout with portable work stations and equipment for realistic results

• Employee scheduling for kaizen practice and training (regular work hours or over-time)

• Immediate leadership creation (TL, CL and floater) and training for future

• Kaizen design review by production and TVP members once a week

Suggestions For Future

New Design Review Process

Design

•TVP performs time –studies and evaluates current condition•New design of stations proposed

Review 1

•New process basic design sent to leadership (Managers, Supervisors, Group Leaders, Team leaders) for 1st review

Operator Selection

•1st draft standard work developed by TVP (detailed design)•Management and TVP discuss on standard work, operator selection and equipment for support (Once a week)

Review 2

•TVP and production (GL, TL and some operators) review new design material and make final changes (once a week)

•Decide training days with management and proceed for kaizen simulation in the next week

Finalize

•Review all processes and implement additional kaizen ideas •Finalize work standard and update in overall workforce training agenda

Future(Deployment plan)

How to “PDCAS” ① (Outline)

TVP Team

Mgmt.

ProdT.L

Prod Mgr.

ProdOper

Simulate work

sequence and

review

Review TVP

material

Review TVP suggestions

and SOP Operator training

and changes

Mock trial,

review and final changes

Kaizen Kai(Line

through)↓

Check↓

Standardize

No Ok

Feedba

ck

Notification to

Mgmt. and

approval

Notification to TVP team and approval

End

Selecting an operatorTVP team also join

ProcessDesign

&Re-

balancing

Design new SOP

and station layout

Start

Each station 5 weeks Line through 2 weeks

Deployment planNew design deployment plan

1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4WHull DESI GN

St1St2St3St4

ThroughDeck DESI GN

S1St2St3St4

ThroughFA DESI GN

PinningSt1St2St3St4

ThroughDESI GN

FF/FI St1St2St3St4St5

Through

Done

Big

DecOngoing Not yet

Aug Sept Oct Nov

2 Month 1 Line1 Line all station Kaizen completion , then next design

10~14 Months

Parts supplynew design

Assembly area material flow

Small

Big

H DSt.4

H DSt.3

H DSt.2

H DSt.1

H H

H D H D H D H D H H

WIPH H

D D

H H

D D

D DDD

HELMS INSERT

Hole cut

Hole cut

Large

smallWIP WIP

kitunit

1cycle26min

Kit parts

Going round 6min +

Paying out4min×4

Stowing4min+ =

Check the boat

Check the boat

WIP2boats buffer

28min×2=56min

Kit 2boats buffer

28min×2=56min

HH D D

H

D

H

D

Warehouse & Sub assembly

WarehouseSub & Kit

(Small line)

Sub & kit(Big line)

Assembly line

Image

Split lineSynchronized with the assembly

2sets buffer28min×2=56min

Kit supply

3.Paying out : detail

H D

H D

H D H D The nextempty

At work

1min1min

Classify the parts into the kit to be able to carry onetime, and design the dolly4.Kit design

※AMAKUSA parts supply example

Picking list

pinning

Under 27ft over 27ft Fisherman’s

AMAKUSA 2’nd plantwarehouse

D H

Pick parts according to the list

Hardware kit

Parts rack

Pay out on the day before

Parts supply

Supply list

・ Local parts・ CKD

Inventory reduction

LakeTest

Deck

Hull

Final FinishInspection & Repair

Warehouse

Kit Cut

Lamination

Liner

Small Parts

Deck

Hull

Deck

HullVARTM

Gel-coat

Tooling shop

R&D

Mold storage

Gel-coat, Lamination, Liner set Hole-cut, PI, WIP Assembly (Test) Final Finish

1day 1day 1day

D : Material flow & stock

boat

Hull

Deck

Sub Assy

AssemblyMold preparation

Gel-coat

Trimming & Hole-cut

Finish product storage

Pinning

10-15 days

Finishproduct

Engine storage

Wear house inventory

We are waiting mail from UT

Analysis data & KAIZEN idea by UT student

Each shopProductivity up

Pitch time of each shop (F3F) 　

STEP1 : 28boats/dayTarget : 34boats/day

Done Done

Next Lamination area

Comparison of assembly design

Category,1 Category,2

Mix 1 line Streaming 2 lines

Q

DInvestment

Inventory space

Production plan

C

Direct OP

Indirect OP

Expenses

New model 〇 ◎

Summary・ 34boats/day・ After design

Final summaryYJBM Soga san

Mix one line(34boats/day)

Split line(34boats/day)

PI

Hull 1Hull 2Hull 3Hull 4Hull 5Hull 6

Pin

Lake

FI 1

WIP

Deck 1Deck 2Deck 3Deck 4Deck 5Deck 6Deck 7Deck 8

FF 1FF 2FF 3FF 4

FI 2FI 3FI 4FI 5

F assy 1F assy 2F assy 3F assy 4F assy 5

34boats/dayTT 　 15.8min

T-OEE 90%T-CT 14.0min

Hull 8Hull 7 F assy 6

F assy 7F assy 8

Process design & Layout

Layout Layout

F assy 9

PIPI

PI

Hull 1Hull 2Hull 3Hull 4

Deck 1 Deck 2Deck 3Deck 4

Pin

Lake

FF 3

FF 1

FF 4 FI

F assy 1F assy 2F assy 3F assy 4

PIPI

FF 2

Hull 1Hull 2Hull 3Hull 4

Deck 1 Deck 2 Deck 3Deck 4

Pin

Lake

FF 3

FF 1

FF 4 FI

F assy 1F assy 2F assy 3

PIPI

FF 2

24ft21ft

19ft17ft

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

17boats/dayTT 　 31.7min

T-OEE 90%T-CT 28.0min

YJBM

CurrentOption C

■ Line Balance

Option AOption B

24ft:136H21ft:121H19ft: 95H17ft : 85H

41H

10H

15H

If we expand the Plant1 and produce at 2 lines, we may raise productivity.

Option A Option B Option CProduction 35 BPD 35 BPD 30 BPDSmall Parts Outsourcing In house In house

組立部分のみにして詳細を見える化

FF

FA

Assy

FFFA

Assy

Lamination

YJBM

Focus operator loss (Hull line)

24ft21ft19ft17ft

Mix 1 line Streaming 2 line

24ft21ft

17ft19ft

Balanceloss

Loss by mix line

Non value

14min

St.1 St.2

St.1

St.1

St.2

St.2

St.3 St.4 St.5 St.6 St.7 St.8

Total №.of station 8Total №.of operator 17+1

28min

28min

St.3

St.3 St.4

St.4

Total №.of station 8Total №.of operator 15+1

Hull line

Hull line

Hull line

St.1&4

St.2&4

24 ・ 21ft

Price$40,000 Price

$30,000

LaborLabor

24 ・ 21ft 19 ・ 17ft

Price$40,000 Price

$30,000

LaborLabor

Profit up

Focus cost

↓ Reduce

Labor costs are the same of the large boat and a small boat

Build up the cost by theoretical value design

19 ・ 17ft

Mix 1 line Streaming 2 lineYJBM

Focus QualityYJBM

End