SECOND SESSION

CHARTING/
STANDARD
OPERATION

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 SESSION OBJECTIVES
SESSION OBJECTIVES

(1) TO RECORD AND ANALYSE INFORMATION

ABOUT A PROCESS WITH A VIEW TO
ELIMINATING WASTE(MUDA).

(2) TO PREPARE A "STANDARD OPERATIONS"

THAT MEETS THE REQUIREMENTS OF THE

PROJECT OBJECTIVE.

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 66 TOOLS
TOOLS FOR
FOR KAIZEN
KAIZEN

1. PROCESS CHART
2. "TABLE OF PRODUCTION CAPACITY
3. "STANDARD OPERATIONS ROUTINE
SHEET"
4. "STANDARD OPERATIONS BULLETIN"
5. "MANUAL ON WORK DIRECTIONS
6. PERFORMANCE ANALYSIS BOARD

060616 VPC/MI


1999 10 15

66 Tools
Tools for
for Kaizen
Kaizen

17111 24060







1006 940

MI-1764 3
25 2810060"1006
DR-2424 3 21 241000
30" 1198 1

1. PROCESS CHART TP-1101 3

(1/1) 5
11 141000
30"

5 5760

2052 11

2. "TABLE OF PRODUCTION CAPACITY

1711-24060

3. "STANDARD OPERATIONS ROUTINE

/
T /



1764
25

SHEET"
2424
21

1101

11







/

4. "STANDARD OPERATIONS BULLETIN"

5. "MANUAL ON WORK DIRECTIONS

1764

2424

2424

12

/
18

1101

6. PERFORMANCE ANALYSIS BOARD

1101 30 NM-18

1764


/
NM-12

DR


NM-13

TP

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 Performance analysis board Date dd/mm

plan actual difference

Time Op. time Reasons of delay
cumulative cumulative cumulative
83 65 18 Shortage of
8:10 9:00 0.83
83 65 18 parts
100 83 17 Defective of
9:00 10:00 1.0 183 148 35 length

10:00 11:00 100 102 2

1.0 283 250 33
100 80 20 Defective of
11:00 12:00 1.0 383 330 53 plating

12:45 14:00 125 89 36

1.25
508 419 89

14:00 15:00 100 100 0

1.0
608 519 89
100 37 63
15:00 16:00 1.0 A machine trouble
708 556 152

16:00 16:50 83 90 7
0.83 791 646 145

Total 791 645 -145

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 STANDARD OPERATIONS
STANDARD OPERATIONS

CONSISTS OF THREE ELEMENTS:

(1) CYCLE TIME :
-REQUIRED TIME TO PRODUCE ONE UNIT.
(2) WORK SEQUENCE:
-ORDER IN WHICH REPETITIVE JOB CAN
BE DONE.
(3) STANDARD STOCK ON HAND:
-MINIMUM AMOUNT OF STOCK ON HAND
REQUIRED TO CONTINUE REPETITIVE
OPERATION.
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 STANDARD OPERATIONS
STANDARD OPERATIONS
(1) cycle time
(3) Standard
stock on
hand

(2) work sequence

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 CHARTING METHODS
CHARTING METHODS

MANUAL WORK;

MACHINE WORKING;

WALKING;

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 WORK COMBINATION
WORK COMBINATION
BETWEEN OPERATORS
BETWEEN OPERATORS AND
AND
MACHINES
MACHINES
BASIC RULES
COMPLETION
TIME

30 SECONDS 1 MINUTE 1'

30"

30 SECONDS 10 SECONDS

1 MINUTE 1'
20"
30 SECONDS

1 MINUTE 1'
00"
MANUAL OPERATION
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MACHINE PROCESSING
Process chart Name of Product Role for Printing Division Nikkan Role Plant Date 01/03/01 Drawn
by

Storage of Inspection
Raw material raw materials Transportation Waiting Processing Batching Storage of F.G

Quantity Appearance Both

Process Flow Chart

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Raw materials

Take up raw material

walking
processing

processing Set work

walking

checking
Inspection

Place finished good

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Finished goods storage
Sequence of process

Process 1: Surface processing Process 3: Tapping

Process 2: Drilling Process 4: Quality checking

(Measurement of diameter)

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 TABLE OF
TABLE OF PRODUCTION
PRODUCTION CAPACITY
CAPACITY

- USED TO DETERMINE CAPACITY OF THE

PROCESS.
- EACH PART AND EACH OPERATION INVOLVED
IN MAKING PRODUCT MUST BE SHOWN.

COMPLETION TIME:
TOOL CHANGE TIME = CHANGE TIME / NO. OF UNITS
CAPACITY = AVAILABLE TIME / TIME REQUIRED PER PIECE

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 TABLEOF
TABLE OFPRODUCTION
PRODUCTIONCAPACITY
CAPACITY
(BYPARTS,
(BY PARTS,BY
BYPROCESS)
PROCESS)

DATE / / PAGE

SECTION GROUP SNAME
FLOORFOREMAN ITEMNO TYPE
CHIEF
PART DAILYRE

QUIREMENT

BASICTIME TOOLEXCHANGE MANUAL

OPERATIONS
WORK MACHINE MANUAL MACHINE PRODUCTION NOTE
NAMEOFTHEPROCESS COMPLETION EXCHANGE EXCHANGE CAPACITY
SEQUENCE NUMBER OPERATION PROCESSING MACHINE
TIME UNIT TIME
TIME TIME PROCESSING

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TOTAL

 CALCULATION OF
CALCULATION OF THE
THE
PRODUCTION
PRODUCTION
CAPACITY
CAPACITY

PRODUCTION DAILY OPERATING TIME

CAPACITY = COMPLETION TIME/PC + TOOL CHANGING TIME/PCS

10 6 9 / 8

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 EXAMPLE 1
PART: "KE INTAKE MANIFOLD"
ITEM NO: "17111-24060"
PROCESS: "MACHINING OF BOOSTER SURFACE"
PROCESSING TOOL CHANGE
OPERATIONS: SEQUENCE: TIME: TIME:

MATERIAL

(1)MILLING OF SURFACE MI1764 3" 25"

1'00" 1000 PCS

(2)DRILLING OF HOLE DR2424 3" 21"

30" 1000 PCS

(3)TAPPING OF HOLE TP1101 3" 11"

30" 1000 PCS

(4)CHECKING OF HOLE DIA. QUALITY CHECK 5"

FINISHED GOODS
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EXAMPLE
1 -

REQUIRED QUANTITY / MONTH = 41360

22 WORKING DAYS PER MONTH
2 SHIFTS PER DAY
OPERATING TIME PER SHIFT = 470 Min.
(AVAILABLE TIME)

QUANTITY DAY =
OR QUANTITY SHIFT =
060616 VPC/MI
 EXAMPLE 1
TABLE OF PRODUCTION CAPACITY
(BY PARTS, BY PROCESS)
DATE 8/ JULY/'90 PAGE

SECTION GROUP SNAME

CHIEF
FLOORFOREMAN
PART INTAKEMANIFOLD
ITEMNO

TYPE
KE
DAILYRE

QUIREMENT 940/
BASICTIME TOOLEXCHANGE MANUAL
OPERATIO
WORK MACHINE MANUAL MACHINE PRODUCTION NOTE
NAMEOFTHEPROCESS
SEQUENCE NUMBER OPERATION PROCESSING COMPLETION EXCHANGE EXCHANGE CAPACITY MACHINE
TIME UNIT TIME PROCESSI
TIME TIME

1 - 1764 3 25 28 100 1 00

2 - 2424 3 21 24 1,000 30

3 - 1101 3 11 14 1,000 30

4 QUALITY11 - 5 - 5 - -

060616 TOTAL 14 VPC/MI

STANDARD OPERATIONS
STANDARD OPERATIONS ROUTINE
ROUTINE SHEET
SHEET

THIS SHEET IS THE TOOL FOR

(1) THE DETERMINE OF WORK COMBINATION

AND WORK SEQUENCE WITHIN THE
CONSTRAINT OF THE CYCLE TIME

(2) THIS SHEET ALSO SHOWS THE WORK

SEQUENCE BY OPERATORS AND BY
MACHINES IN TERMS OF THE
PROGRESSING TIME.

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STANDARD
STANDARD OPERATIONS
OPERATIONS ROUTINE
ROUTINE SHEET
SHEET

USED TO SHOW RELATIONSHIP BETWEEN

WORK SEQUENCE, NET OPERATION TIME,
AND CYCLE TIME.
WORK SEQUENCE IS THE ORDER IN WHICH
INDIVIDUAL OPERATIONS ARE CARRIED
OUT.
NET OPERATION TIME IS THE ACTUAL TIME
IT TAKES TO COMPLETE THE OPERATION.

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 CALCULATION OF
CALCULATION OF CYCLE
CYCLE
TIME
TIME

CYCLE TIME OPERATING TIME

= REQUIRED QUANTITY

OPERATING TIME PER DAY

OPERATING TIME PER SHIFT
REQUIRED QUANTITY / DAY OR
REQUIRED QUANTITY

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EXAMPLE
1

Processing sequence:
MI1764 DR2424 TP1101 QUALITY CHECK

Machine Layout:

MATERIAL MI1764
DR2424

FINISHED PRODUCT QUALITY CHECK TP1101

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STANDARD
STANDARD OPERATIONS
OPERATIONS BULLETIN
BULLETIN

- DIAGRAM THAT DISPLAYS THE WORK SEQUENCE,

WORKPLACE LAYOUT, AND OPERATING DIRECTION.

- SHOWS SAFETY CAUTIONS, QUALITY CHECKS, AND

STANDARD STOCK ON HAND.
- DISPLAYED AT WORK STATION THEN SUPERVISOR
CAN QUICKLY UNDERSTAND IF THE OPERATOR IS
CARRING OUT THE OPERATIONS IN ACCORDANCE
WITH THE STANDARD OPERATIONS.

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 SEQUENCE FOR
WRITING

STANDARD OPERATIONS BULLETIN DATE / /

FROM -THE START OF OPERATION 7

WORK CONTENT
TO -THE END OF OPERATION 1
QUALITY CHECK

SAFETY CAUTION
2 LAY OUT
STANDARD STOCK
ON HAND
MACHINE NUMBER
NUMBER OF
STANDARD STOCK
ON HAND
3 SAFETY MARK
CYCLE TIME
QUALITY MARK
6
4
NET OPERATING
TIME WORK SEQUENCE
OPERATOR
NUMBER

5 STANDARD STOCK ON HAND

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DEFINITION OF STANDARD STOCK ON
HAND

THE MINIMUM NUMBER OF WORKS THAT

EACH PROCESS HAS
THE OPERATOR CAN CONTINUE
REPETITIVELY TO COMPLETE ONE WORK
CYCLE

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BASIC RULES FOR STANDARD STOCK ON
HAND

PRODUCTION LINE TYPE #OF S.O.H

SAME
OPERATOR DIRECTION
DIRECTION 0
VS.
PROCESSING OPPOSITE
DIRECTION DIRECTION 1
CHUTE SHOULD BE USED.

AUTOMATIC
AUTOMATIC
MACHINING MACHINE 1
VS. MANUAL
MANUAL OPERATION OPERATION 0
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 STANDARD STOCK ON
HAND
EXAMPLE #1
PROCESSING SEQUENCE

A1 A2

2 3
MATERIAL FINISHED PRODUCT
A A
1 4
M/C OPERATION TYPE S.S.O.H
A1 DRILLING AUTOMATIC 1
A2 TAPPING AUTOMATIC 1
TOTAL 2
060616
NOTE: PROCESSING SEQUENCE & WORKVPC/MI
DIRECTION ARE THE SAME
 STANDARD STOCK ON
HAND
EXAMPLE #2
B B
MATERIAL 1 5 FINISHED PRODUCT

2 3 4
B1 B2 B3
PROCESSING SEQUENCE
M/C OPERATION TYPE S.S.O.H
B1 TESTING MANUAL 0
B2 BLANKING AUTOMATIC 1
B3 PIERCING AUTOMATIC 1
TOTAL 2
060616
NOTE: PROCESSING SEQUENCE & WORKVPC/MI
DIRECTION ARE THE SAME
 STANDARD STOCK ON
HAND
EXAMPLE #3
PROCESSING
SEQUENCE
A1 A2

7 6
A A
MATERIAL 1 5 FINISHED
B PRODUCT
B
2 3 4
B1 B2 B3
PROCESSING
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SEQUENCE
 STANDARD STOCK ON
HAND
EXAMPLE #3
M/C OPERATION TYPE DIRECTION S.S.O.H

B1 TESTING MANUAL SAME 0

B2 BLANKING AUTOMATIC SAME 1
B3 PIERCING AUTOMATIC SAME 1
A2 TAPPING AUTOMATIC OPPOSITE 2
A1 DRILLING AUTOMATIC OPPOSITE 2

TOTAL 6

060616 VPC/MI
 EXERCISE #1
PREPRARE THESE CHARTS FROM THE FOLLOWING
FORMATION:

(1) COMPLETE A "TABLE OF PRODUCTION CAPACITY"

(2) DETERMINE THE CYCLE TIME FOR THIS MANUFACTURING LINE
(3) PREPARE A "STANDARD OPERATIONS ROUTINE SHEET"
(4) PREPARE A "STANDARD OPERATIONS BULLETIN"

PARTS: "8 INCH PINION"

NAME OF THE PROCESS: MACHINE NUMBER
1. ROUGH MACHINING GC-614
2. CHAMFERING CH-228
3. FINISHING CUT GC-1444
4. FINISHING CUT GC-1445
5. DIAMETER MEASUREMENT TS-1100
060616 VPC/MI
EXERCISE #1
NOTE:
-2 SHIFTS PER DAY
-OPERATING TIME = 7 HRS 50 MIN.PER SHIFT
-EACH MACHINE processes 1 work AT A TIME
-WALKING TIME to and BETWEEN MACHINES = 2"
-TAKING MATERIAL/PLACING PRODUCT=1" PER EACH ITEM
-DAILY REQUIRED QUANTITY =1226 PIECES PER DAY
PROCESSING SEQUENCE:
GC614 GH228 GC1444 GC1445 TS1100

MACHINE LAYOUT

GH228 GC614
MATERIAL
GC1444
FINISHED PRODUCT
GC1445 TS1100
060616 VPC/MI
EXERCISE
#1

TIME
STUDY:

MANUAL MACHINE COMPLETION EXCHANGE EXCHANGE

OPERATION PROCESSING TIME UNIT TIME
SEC. SEC. SEC. UNITS SEC.

GC614 5 38 43 300 150

GH228 6 7 13 2000 60

GC1444 6 38 44 300 150

GC1445 6 30 36 300 150

TS1100 7 3 10 - -

060616 VPC/MI
MANUAL ON
MANUAL ON WORK
WORK DIRECTIONS
DIRECTIONS

- USED BY SUPERVISOR AS BASIS

FOR INSTRUCT OPERATORS
DEPEND ON STANDARD
OPERATIONS.
- SHOWS CRITICAL AREAS OF
OPERATION, SAFTY & QUALITY.
- SHOWS CORRECT ARRANGEMENT
OF MACHINES.
060616 VPC/MI
 SEQUENCE FOR
WRITING

MANUAL ON WORK DIRECTIONS DATE / / PAGE

REQUIRED UNITS/ GROUP SNAME
ITEMNO
QUANTITY
PROCESS OPERATOR

NAMEOFITEM
NUMBER
QUALITY CRITICALAREAS NET
WORKCONTENT OPERATING
CHECK GAUGE RIGHT WRONG SAFTY EASEINOPERATION TIME
MIN SEC

SAMEASSTANDARD MANUAL+WALKING
OPERATIONSROUTINE SAMEASSTANDARD
SHEET OPERATIONSROUTINE
SHEET

060616 VPC/MI