Factory Concept:

SHORTER GREEN
LEAD TIME COMPANY

1. OPTIMUM TEMPERATURE
1.MIERUKA
2. GREEN AREA
2. ZERO MUDA 3. ERGONOMIC WORK SPACE
4. ANTI POLUTION FACILITY
CONCEPT DESIGN:
A. SHORTER LEAD TIME
1. MIERUKA:
- Factory operations visible from garden office (OHBEYA)
- Centralized Supplier receiving area. (Inventory Mieruka)
- Centralized and close located small part store for easy control and short
distance to production lines. (Inventory Mieruka)

2. ZERO MUDA:
- Straight process flow to minimize manufacturing lead time.
- Combine machining line to distribute man power allocation
- Small production lot and frequent withdrawal to keep store at minimum quantity
- Time efficiency by putting canteen area close with factory lines
- Different supply receiving and customer delivery route to minimize traffic.
- Quick response time by putting all operation related departments at the first floor.
CONCEPT DESIGN:
B. QUALITY
1. BUILD IN QUALITY EACH PROCESS
- JIDOKA implementations in new assembling line
- Production Man power develop quality concern by training, etc...
- Management Gemba to build culture and quality awareness of employee
- Speed quality problem information and 5 why analysis to solve every quality
problem
- Quality reward identification to improve employee pride by each line

2. FOLLOW STANDARDIZE WORK:

- Develop the understanding of standardized work of Group Leader, Foreman,
Section Head and Manager by training and practice at operations
- Completed and validate all Standardized work each production line
- MANAGEMENT GEMBA to build awareness in standardized work
implementations with consistently.
CONCEPT DESIGN:
B. GREEN COMPANY
- High factory ceiling to keep in-room temperature low to promote comfortable working
environment. (Especially casting area)
- Garden area to promote comfortable working environment.
- World class waste water treatment compliance with government regulation.
- 60:40 ratio for building and open space in factory area.
- No Forklift zone inside factory (except at shipping area).
- Ergonomic work space (all new facilities max height 150 cm)
1. Salary Increase
2. Profit Increase
3. Order from Customer Increase
4. Competency increase
5. Shorter Lead Time