L|AN AllLlCAJlON8 lN

VANu|ACJuklNG
DoIloltloo
Joo uoIloltloo oI looo roucctloo stoous Ior.
!us| roduce, wbo| is required by |be cus|omer|"
- Obno
A ollosooy oI oo ootorrlso clulo to rocossos
wlto lollzou wosto.
A oooooot systo orllootou oo too 1ooooso
woy oI uolo bcslooss.
locrooso oI oIIlcloocy 8 stoouorulzotloos by
cootlococs lrovooots.
lrlory lcroso oI Looo
V %o iden|i|y ond eIimino|e
wos|e (mudo) ond
so|is|y cus|omer needs
o| |be Iowes| ossibIe
cos| wi|b considero|ion
ond resec| |or bumoni|y
o| emIoyees
Cooroctorlstlcs oI looo I
QUALITY
DELIVERY COSTS
Reduction
of
Scrap
Rework
Tests
PPM values
Failures
Reduction of
nvestments
Quality costs
Service costs
Shift bonus
Over time pay
Material costs
Reduction of
Delivery time
Throughput time
Raw, semi (WP)
& finished materials
Lot size
Improvement of
OEE
|ssooco oI Looo
lts ob|octlvos ls to otllso
V Cost
V Ocollty
Vuollvory
wollo lrovlo soIoty.
Jo oot tols ob|octlvo , lt trlos to olllooto toroo |oy
socrcos oI loss Iro too oorotlo systo
V A8J|
V vAklAlLlJ
V lN|L|xllLlJ.
Waste
UnLvenness
Cverburden
AcLlvlLles LhaL do noL
add value
workload LhaL ls
noL balanced
work LhaL creaLes burden for Lhe
Leam members or processes
Picture Source Toyota Motor Company Australia
%yes o| MUDA (wos|es)
Decrease in MUDA results
in cost reduction
HIBA BF BYER PRBBX.
IXYEXTBRY WAITIXB TRAXSPBRT PRBIESSIXB HBTIBX REPAIR
Waste of Over Production
,8te of !nventory
,8te of Waiting
,8te of Transport
,8te of Processing
,8te of Notion
,8te of Repair
vorloblllty
In raw maicrial ,varialiliiy can lcad
io roduciion
of dcfcciivc aris or io cquimcni
failurcs.
In slills, ii can lcad io roduciiviiy
losscs or roccss loiilc nccl iIai
rolong lcad iimcs.
VarIabIIIty Is any devIatIon Irom
tbe standard tbat detracts Irom tbe
quaIIty oI servIce or product
deIIvered to tbe customer.
loIlolblllty
Inflcililiiy is any larricr io
mcciing cIanging cusiomcr
rcquircmcnis iIai can lc
ovcrcomc wiiIoui incurring cira
ordinary cosi.
TOYOTA AIMS AT FLEXIBILITY
Llo|s botwooo too toroo ob|octlvos oou too toroo socrcos
oI loss.
|lllootlo wosto ools to roucco cost.
|lllootlo vorloblllty lrovos gcollty
|lllootlo loIlolblllty lrovos uollvory
Looo roroo ouurossos oll toroo socrcos oI loss
slcltoooocsly.
No ottor wooro tooy lot bo Iocou wltolo too
oroolsotloo.
Jroultloool 's leon
Jroultloool
Loo ulstooco,
|coctloool
Vlou, l, Iow
Low
8oolstlcotou
lcso, lloooou, No
lovollo
l bo slzo
Low
Looo
8oort ulstooco,
Ilow orlootou
8yocoroolzou,
soll, ooy
ulo
8llo
lcll, lovollo
|l|O
ulo
ean Coal
Customer Focus: Highest Quality, Lowest Cost, Shortest Lead
Time by continually eliminating Nuda
]!T ]idoka
Standardization
Stability
Teamwork and
!nvolvement
Flexible, motivated
team members
continually seeking a
better way
!|% (IuII) - A IiIIor o| %I8
Doo't roucco sootolo coloss too ccstoor oos
oruorou lt.
Lovol uooou so toot wor| oy rocoou sootoly
torocooct too loot.
Llo| oll rocossos to ccstoor uooou toroco sllo
vlscol tools (collou |ooboos}.
Vollzo too Ilolblllty oI oolo oou ocoloory.
Cootlococs Ilow
!|% (IuII) -Iroduc|ion
lovootory Arrlvos wlto Nocossory uolts lo Nocossory
Ocootltlos ot too Nocossory Jlo
lcll 8ysto. koloolso Votorlols os usou
V Ccstoor Drlvos lroucctloo Dooou
Auototloo to Cooolo lroucctloo Ocootltlos
8wlIt Cooooovor 8ot-c Jlo
8oortooou Loou Jlos to lloot oou |lool Ccstoor
Lovol Dooou
wbo| Does !|DOkA meon
Actootloo wlto ocoo tocco.
Jooro ls oo roo to o|o uoIocts
lt ls oocossory to sooroto ocoo |ob Iro ocoloo
|ob
cllu lo Ocollty
AbnormoIi|y Con|roI - !idoko
Auuross |cotloos loulotoly
DoIocts oro oot lossou Aloo
Acolovlo 1luo|o.
V Creo|e 8|ondordizo|ion - lroblos oro ooslly
rocoolzou
V |ncreose Irequency - Jloly ulscovory oI gcollty
lsscos, rolocooot otorlols sooo Iollow
AbnormoIi|y Monoqemen| (Ioko-Yoke)
8llo low-cost uovlcos toot oltoor uotoct oboorol sltcotloos boIoro tooy occcr, or
ooco tooy occcr, sto too lloo to rovoot uoIocts.
nnovations that Detect Abnormalities
Failsafe Devices
Mistake Proofing
Help Create a Defect-Free Product or
Process
8toouorulzou or|
key Ioin|s:
Irocedures
%ok| %ime (A s|ondord |ime wi|b wbicb one ou|u| bos |o be
mode.)
L||ec|ive oero|inq ||mc[Costomcr dcmoad pcr s|lt
Consis|ency
8ene|i|s o| 8|ondordized work:
Irocess 8|obiIi|y
CIeor 8|or| ond 8|o Ioin|s
leorninq ond %roininq
koizen ond emIoyee invoIvemen|
|mroved moroIe & roduc|ivi|y
|| 8|ondord work is no| |oIIowed
uosoIo
Voro uoIoct
Loss oIIlcloot
kolzoo lo l solIt coclu bo uls-lrovooot to
oootoor solIt
DlIIlcclt to luootlIy oboorolltlos = coooot solvo
root cocso lo tloly oooor
kolzoo (Cootlococs lrovooot}
l. 8oll locroootol lrovooots
2. lovolvooot oI oll oolo
3. Cootlococs oIIort
=. lDCA
lcroso oI kolzoo
l. lrovo gcollty.
2. koucco costs.
3. 8oortoolo loou tlo.
=. lrovo soIoty.
5. lrovo wor| oblllty.
kolzoo lrocoss - lDCA
!dea/Kaizen
!dentification
P!
nalyze Work
Process
DO
Recommendation
CHECK
!mproved
Standardized
Procedure(s)
CT
Continuous
Cycle
8|obiIi|y - %be 58 8ys|em
A clooo, woll A clooo, woll- -oruorou wor|loco toot tol|s to yoc ls oruorou wor|loco toot tol|s to yoc ls
too Iocouotloo oI lrovooot. too Iocouotloo oI lrovooot.
]apanese Term English Translation Definition
Seiri Sort
Clearly separate necessary items from
unnecessary, abandon the unnecessary.
Seiton
Straighten/Set !n
Order
Neatly arrange and identify things for ease
of use.
Seiso Scrub/Shine
Always maintain tidiness and cleanliness.
Regularly scheduled cleanups.
Sediketsu Standardize
Constantly maintain the 3S' mentioned
above.
Shitsuke Sustain
Create vehicles to enforce the above rules.
An antomated gnide ehicle (ACV) deliers assemIl, line parts to a worLstation
when the parts are needed.
lrouccts 8 ollcotloo oI Looo lo
oocIoctcrlo
n fleiIle mannfactnring enironments. where operators assemIle
components with parts snpplied I, parts Iins. a simple indicator is
illnminated to alert stocLing personnel to refill the Iins Iefore parts are
depleted. Keeping Iins stocLed with parts withont the need of the
operator to leae the station to retriee and refill improes prodnctiit,.
!,7983850.943
As parts file ont of a iIrator, feeder Iowl to a cone,ing rail. the, mnst Ie
inspected Iefore the, are fed to the net stage of pacLaging or placement in
additional finished components. Jeeder Iowls are effectie in parts orientation. Int
withont additional inspection deices or components the, do not proide a means to
sort parts that hae minor flaws or defects that conld create proIlems or lead to
additional scrapped prodnct later in the mannfactnring process.
JuANk Ou