STEP 1 ADDDRESSING THE HOOK DESIGN PROBLEM

PROBLEM: During rear side bolster installation, the hook protruding from the back breaks often.

As Doug OBSERVATION: Similar engineering design is present in Tsutsumi plant and it had not reported the problem. Also modifying the relevant
tool would cost KFS about $50,000.

Friesen, What SOLUTION: Bring 2-3 personals from the Tsutsumi plant to observe the work here and identify the reason for breakage. A small workshop
or training can be arranged for the seat installation workers conducted by the Tsutsumi employees.

would you do STEP 2: CROSS-THREADING INCIDENCES

to address the PROBLEM: When a team member shot a bolt at an angle, cross-threading happens.
SOLUTION: Team leaders can fix this problem online within 30 seconds with a re-tapping tool.

seat problem STEP 3: WRONG SEAT ASSEMBLY PROBLEMS

PROBLEM: Special delivery of seat orders were done twice a day but KFS sometimes sent the wrong seat assemblies
SOLUTION: Some POKA-YOKE can be tried to be implemented in the seat reorder system so that there is no chance of wrong delivery of
seats

Where would
I would focus my attention as Doug Friesen to reduce the defects in the seat assembly because it is just a waste of
you focus energy and time during manufacturing, where after the assembly the seats again need to be inspected and
rectified leading to extra time waste.
your Hence the root cause for these defects must be analyzed as the first priority which would lead to less defective
attention and seat manufacturing.

solution
efforts?