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Kobetsu Kaizen

Kobetsu Kaizen

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Published by Rik Chattopadhyay

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Published by: Rik Chattopadhyay on Oct 28, 2012
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12/04/2012

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1
 Implementation Manual - 4Kobetsu Kaizen
 
Qs. 1 What is the role of KK sub-committee ?
KK sub-committee has a team of upto 7-8 members in a large company representingthe heads of different departments and the chairman is usually the Plant Head. Thecommittee has following roles:Recording, categorizing and analysing 16 losses(except break down and defect loss)machine-wise, department-wise, unit-wise and company-wise: Calculation/Analysis of OEE and set targets for minimizing/eliminating each loss. Insome cases, companies are also including specific losses that affect their business. Inother words the formula for OEE may be different at different stages of TPM in acompany and specific to the constraints a company may haveBased on business need, set priorities on losses and projects looking at resourceconstraints.Selecting Kaizen themes based on losses, setting targets and assigning teams to takeresponsibility for each identified project.: Identify bottleneck areas, fix targets and set priorities: Launching of project teams with pilot projectsHelping all support functions to arrive at the Loss vs. cost matrix and the P,Q,C,D,S,Mmeasures.Identifying aim and scope of KK, training requirement and guiding the facilitators tofocus losses on company performance.Knowledge sharing through horizontal deployment activitiesDevelop the Master plan for KK and track progress of Kaizens and OEEMotivate people to do Kaizens.Giving inputs to the education and training pillar for training matrix development.Working in close co-ordination with other sub-committees for achieving the PQCDSMtargets. This committee will meet at least once a week or month for the abovementioned points.
 
 
2 
Qs. 2 Which losses to be addressed by KK ?
KK pillar deals only with those losses that cannot be handled by any other pillar. All16 losses have to be considered by the KK committee and make up the loss structurefor the company. (Losses due to defect/rework losses through Quality Maintenance,failure losses through Planned Maintenance).Next, the KK sub-committee will identify the priorities and assign project teams towork on specific losses on different machines and areas.Remaining losses will have to be addressed by KK sub-committee. Usually, theyaddress the following losses:Each company has to make up their list and collect data. The highest losses will be thepriority for the KK pillar. In some companies this list may be different. This is only anexample:Loss no. 2: Set-upLoss no. 3: Tool changeLoss no. 4: Start-up lossLoss no. 5: Minor stoppagesLoss no. 6: Reduced speedLoss no. 9: Management LossLoss no. 10: Operating motion lossLoss no. 11: Line organization lossLoss no. 13: Measurement and adjustment lossLoss no. 15: Tools, jigs and consumables lossLoss no. 16: Yield loss.Major three losses can be prioritized in each area to start the work.
Qs. 3 What is the role of operators in Kobetsu Kaizen ?
Be a member in small groups/circles and participate in circle meetings.Improve and sustain 1 ‘s’ and 2 ‘s’ to eliminate search time losses.Identify losses by identifying abnormalities.
 
 
3 E.g. SET_UP time reduction: operators take part in the study of videos taken duringset-up activity. They discuss, give ideas and contribute for Kaizen developments infixing, eliminating and reducing elements in setting.E.g. Reduction of tool change time. Operators detect and inform the early wearing outof tools, and contribute to extending their tool-life.Provide inputs for quantifying management losses.Operators to maintain results by following standards built up by PM and JH pillarswhich includes generating OPL’s.They must assist the KK team to make trials and implement Kaizens when proposedby all pillars.
Qs. 4 What training is required for doing KK ?
Training to cover:- Training on 16 losses- Calculating costs- Why-why analysis- PM analysis- Machine structure/Principle of working- SMED and setup reduction training- Tool technology- 3Ms(Muri, Muda, Mura)- FMEA, FTA, and other analytical techniques- OJT, OPL- Industrial engineering and JIT concepts- Poka Yoke/fail-safing- QC tools and story board- Training operators to collect data.

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