TVP KAIZEN CONTEST 2022

PRODUCTIVITY UP MODEL B5X HL

YOKOTEN TO BKA HL

KAIZEN KATSUDOU KOITO

Safety Commitment :
Always do Kiken Youchi before doing work
 2
COMPANY PROFILE
HEAD OFFICE KMC JAPAN
1. Name : PT. Indonesia Koito
2. Status : Foreign Investment (PMA)
3. Product : Automotive Lamp
4. Capital : 60 Million USD
5. Share : KOITO 90 ％ ; TOYOTSU 10 ％
6. Mass Production: March 2011
7. Location : Indotaisei Industrial Estate, Karawang
8. Employee : 1212 Persons （ End of Aug 2022 ）

PT. INDONESIA KOITO

14th/18th Affiliate of
Koito Group in the World
 3
KOITO’S CORE OF
BUSINESS
AUTOMOTIVE LIGHTING AND ACCESSORIES AIRCRAFT LIGHTING AND OTHER EQUIPMENTS
KOITO’s headlamps are high quality and reliable thanks to technologies lighting products include ceiling lights, sidewall lights, reading lights and map lights.
accumulated over many years, and are still used in a great number of cars KOITO’s cabin lighting equipment offers optimum photometric performance, illumination colors, etc. to
worldwide. improve comfort for passengers and is used in the Boeing 777, Boeing 737 and other airliners.

VALUE TO CUSTOMER
SAFETY
ENVIRONMENT
Keeping people
and automotive safe

Innovative ideas and decisive action

 4
COMPANY PROFILE

Project analysis slide 3

OUR LAMP PRODUCT YAMAHA MODEL

MATIC SPORT

RCL HEAD LAMP

NMAX (Y)
XMAX NMAX R25

Free Go R15
Soul GT

LEXI X-Ride V-ixion

Supplying headlamp products for yamaha motorcycles both

domestic and international products
 5
COMPANY PROFILE

Project analysis slide 2

GENERAL FLOW PROCESS

ALUMINIZING ASSEMBLY
INVENTORY
CHILD PART

PAINTING FINISH GOOD

INJECTION SHIPPING

WAREHOUSE YIMM
 6
PILOT PROJECT SELECTION

Project analysis slide 4

SALES PLAN ~ 2024
2R 4R
Order Volume down
SALES SHARE 2021

3500
3000
Covid 19
Impact
Semi conductor UP 4W
45%
2W
2500 Issue
30% 55%
2000
1500 3 0 %
1000
1
500 Forecast
0
2019 2020 2021 2022 2023 2024
(Pcs) YIMM HEADLIGHT MODEL
SALES SHARE COSTUMER SALES SHARE YIMM
MODEL 50000 Already Done Activity
PT. in 2020
PT.Y CLL
4% X 40000 B6H
TL 1%
46
YIMM
17% Yokotenkai
%
Based On YIMM
50% HL 30000 Project
Request (B5X HL)
82% BKA LEDHL
20000

Model Activity Part

10000
B5X Analyze 2021
B5D
0

Based On YIMM Request to Increasing Productivity,

we chose the B5X HL Model Line and BKA HL for Yokotenkai Model
 7
GENERAL SCHEDULE ACTIVITY
B5X HL SCHEDULE BKA HL SCHEDULE
Project analysis slide 4
GENERAL SCHEDULE
SCHEDULE ACTIVITY - PT INDONESIA KOITO
TVP KAIZEN YAMAHA 2021-2022
2021 2022
PLAN :

ACTUAL :
2021 2022

1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

Kick Off

EXISTING MODEL Registration Kaizen Activity

Yokotenkai Kaizen

Kaizen idea already Yokotenkai to BKA

Sept: L/O PIK  1-SEPT-2022
Proses Design
N100 N1000
NEW MODEL P4 Mass Prod
P1 DWG Issued P2 P3 Full Try
Final Contest Closing
ASM
MENTORING BY YIMM PIC 26 11 9 18 10 8 5 9

GENBA CHECK BY YIMM MANAGEMENT

TVP (Technical TV & Yokotenkai)

Final
Contest
A. Part Selection & Setting Target Activity
B. Process Flow Analyze
C. CT & OEE Analyze
D. Kaizen Idea till Implementation
E. Monitoring kaizen activity & Yokotenkai
F. CD Result Discussion
G. CD Realization
Make Planning For 2022 Activity
2021 2022
PLAN/A
Activity Items CT
MARET APRIL MEI JUNI JULI AGUSTUSSEPTEMBEROKTOBERNOPEMBERDESEMBER JANUARI FEBRUARI MARET APRIL MEI JUNI JULI AGUSTUS SEPTEMBER OKTOBER NOPEMBER DESEMBER
W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W W
w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

I. PREPARATION
PLAN

Graps Company KPI Data

ACT

II. ACTIVITY
PLAN
STEP - 1 : Part Selection &
Setting Target Activity ACT

PLAN
STEP - 2 : Current condition
Analysis ACT

Sept ‘22 : 100% Kaizen idea already

PLAN
STEP - 3 : Process Flow
Analyze

Sept 2022
ACT

STEP - 4 : CT Analyze
PLAN
implemented & still monitoring until
Virtual Kick Off Ceremony – TVP Kaizen Contest (Champion Class)

now
ACT

PLAN

STEP - 5 : OEE Analyze

ACT

III. KAIZEN

STEP - 6 : Kaizen Idea till

PLAN
CUSTOMER EVENT : PIK EVENT :
Implementation ACT
DEVELOPMENT AUDIT I  17-DEC-2021 : DONE
STEP - 7 : Monitoring Kaizen
PLAN
1st Proto YMC  21~30 -JUN-2021 : DONE N1-N5 & N30  23-DEC-2021 : DONE
Activity & Yokotenkai
1st Proto YIMM  27 SEP~ NOV-2021 : DONE
ACT

PLAN
N100  01-APR-2022 : DONE
STEP - 8 : Result Discussion
ACT
N1 – N5  End -JAN-2022 : DONE DEVELOPMENT AUDIT II  20-MAY-2022 : DONE
PLAN ASSY CHECK  1st -FEB-2022 : DONE N100/HVPT-01  31-MAY-2022 : DONE
STEP - 9 : Realization
ACT N100/FTP  10-JUN-2022 N1000/HVPT-02  18-JUN-2022 : DONE
STEP - 10 : Evaluation of
PLAN
N1000/PILOT  05-AUG-2022 MP AUDIT  15-JUL-2022 : DONE
Repair Results & Monitoring ACT
L/O  1st –OCT-2022 L/O  1st –SEP-2022
PLAN

STEP - 11 : Standardization
ACT

PLAN
STEP - 12 : Setting the Next
Step (Yokotenkai) ACT
 8
TARGET DETERMINATION
ILUSTRATION STRUCTURE COST TARGET SETTING

1. Product Axis 2. Working Axis

Pcs/MH
Day 12
COST DOWN 10
Lead Time Productivity
PROFIT 9
10 UP 1.20x
8 Reduce
In-direct Cost
Covid
19 1
Cost Increase In-direct
7 1 DAY 8
cost 6.3% 6
Direct Cost 2 5 6
Labor cost 9,6
8.1% 4
6.3 8
MATERIAL
3 5.3 4
Material
Increase 2
2
1.4% 1
0 0
Before Target Before Target
1. Lead Time Reduction by : 2. Productivity Improvement by :
1.1 Production Small Lot by Dandory Kaizen 2.1 Balancing Job, Reduce MP
1.2 Eliminate white thread & Reduce C/T

2021-2022 2021-2022 Target Reduce Lead Time 1 Day

IF NO WITH Productivity Up
ACTIVITY ACTIVITY Increase Productivity 1.20x
 Target :
In-direct cost : ∆10% 1.10x
Direct cost : ∆10% 1.10x
Prod Up : ∆20% 1.20x
 9
PRODUCT INTRODUCTION

Project analysis slide 4

Part Explode B5X HL (XMAX)

Reflector
Extension A ( PC0G1-KP )
( PC0B-KP ) D.Alum
Inner Lens C
( AM001 )

Inner Lens A
( PC-001K )

Lens
( PC001-K )
Position HC-3
Body
( PP-01B )

Print base A,B & C

Extension B
( PC0B-KP )

Inner Lens D
( AM001 )
B5X LED HL
Part Structure Internal Process Supplier Process
Consist of 130 Parts Inner Lens B
( PC-001K )
Number of Part : Number of Part :
2 Items 128 Items
 PRODUCT SELECTION 10

B5X LED HL (General Flow Process)

Project analysis slide 4
PPIC
MRP
2x/month

PO
Delivery

R/M Injection Painting Aluminizing Assy F/G

Mcn Time Man Time Mcn Time Man Time Mcn Time Man Time Mcn Time Man Time

LENS
1 48 Sec 8 Sec 29.5 Sec 3 Sec - - - 83 Sec
1 PN
PT. KOITO

REF
1 8 SecB5X - -
1 PN 53 Sec LENS IS THE LONGEST
27.2 Sec
PROCESS
27.2 Sec
PT. KOITO

DIRECT ASSY
BODY
2
1 PN
Assy PT. NAGAI
EXT A/B

2 DIRECT ASSY
2 PN
PT. NAGAI

2 DIRECT ASSY
IN A/B

2 PN

Consist of 130 Parts PT. NAGAI

2
DIRECT ASSY
PART IN C/D

2 PN
PT.NITTOH
2
SMALL

DIRECT ASSY
1 : Internal Process
121 PN
2 : Supplier Process
 11
PROBLEM ANALYSIS
Material Information and Flow Chart Lens B5X LEDHL
SUPPLIER WH INJECTION PAINTING STORE ASSEMBLY FG CUSTOMER
MRP
2x /month

① 752
PATTERN POST
② 414 ③ ④ 376
PATTERN POST PPIC ADMIN
64
⑤ 752
RESIN
IN PAINTING IN ASSEMBLY IN
INJECTION
SP 15A1 SP 11HE SP
SUPPLIER 12A20 YAMAHA
LENSA
(RESIN)
Del/Day
2.0
2,0 1.1
1.1 0.2
0.2 1.0
1,0 2.0
2.0 376 PCS

R/M IN PROCESS TotalLEAD

① TOTAL Lead Time
TIME 6.3
= 6,3 DAY
DAY F/G
2,0 DAY 2.3 DAY 2.0 DAY
(752 PCS) (865 PCS) 5 Stock Point (752 PCS)

② SEQUENCE INJECTION ④ STORE PAINTING

OEE 48 OEE CT 29.5

INJECTION STOP
CT PAINTING NG LOSS
LOSS
24%
MP 1 1.87% MP 3
OEE 73% OEE 84%

Target Kaizen Area 1 Target Kaizen Area 2

 TVP Milestone 12

Milestone Production
SUPPLIER WH INJECTION PAINTING STORE ASSEMBLY FG CUSTOMER
BENCHMARK MARCH 2021 CURRENT SITUATION
BENCHMARK

MRP
2x /month

Injection Painting Assembly  1 day Lot production PATTERN POST PATTERN POST PPIC ADMIN
752 376
 Dandori time too long 414 64
752
OEE : 73% OEE : 84% OEE : 42.7%  Productivity low RESIN
IN PAINTING IN ASSEMBLY IN
INJECTION
CT : 48 s CT : 29.5 s CT : 83 s  Over MP in Process Assembly SUPPLIER 12A20
SP 15A1 SP 11HE SP YAMAHA
LENSA
(RESIN)
MP : 1 P MP : 3 P MP : 6 P  Shortage material in process
PCS/H : 55 s PCS/H : 103 s PCS/H : 19 s 2,0 1.1 0.2 1,0 2.0
PMH : 55 s PMH : 34 s PMH : 3 s
Total ①
lead time
TOTAL LEAD TIME =6.3
6,3 DAYDays

SUPPLIER WH INJECTION PAINTING STORE ASSEMBLY FG CUSTOMER

TARGET DEC 2022 KAIZEN OF DIRECTION MRP
2x /month
TARGET

Injection Painting Assembly  Lead time reduction by 752 PATTERN POST PATTERN POST PPIC ADMIN
150 752
small lot Production 302 64
OEE : 85% OEE : 87% OEE : 70%  Dandori kaizen activity RESIN
IN PAINTING IN ASSEMBLY IN
CT : 48 CT : 29.5 s CT : 80 s  Reduce NG Rate In Painting SUPPLIER
INJECTION
12A20
SP 15A1 SP 11HE SP YAMAHA
LENSA
MP : 1 P MP : 3 P MP : 5 P  Balancing Job (RESIN)

PCS/H : 64 s PCS/H : 106 s PCS/H : 31 s  Reduce CT & MP

2,0 0.5 0.2 0.5 2.0
 Automation process in line
PMH : 64 s PMH : 35 s PMH : 6 s
Total①lead time
TOTAL LEAD TIME = 5.3
5.2 DAYDays

SUPPLIER WH INJECTION PAINTING STORE ASSEMBLY FG CUSTOMER

IDEAL 2023 - 2024 KAIZEN OF DIRECTION
MRP
2x /month

 Integrate part preparation 564 PATTERN POST PATTERN POST PPIC ADMIN
Injection Painting Assembly
IDEAL

150
to in line by Heijunka system 150 564
OEE : 90% OEE : 90% OEE : 90%  Increase OEE by automation RESIN
IN PAINTING IN ASSEMBLY IN
INJECTION
CT : 48 s CT : 29.5 s CT : 78 s system SUPPLIER 12A20
SP 15A1 SP 11HE SP YAMAHA
LENSA
(RESIN)
MP : 1 P MP : 3 P MP : 5 P
PCS/H : 68 s PCS/H : 110 s PCS/H : 42 s 1.5 0.5 0.2 0.5 1.5
PMH : 68 s PMH : 37 s PMH : 8 s
Total ①lead time
TOTAL LEAD TIME =4.2
4.2 DAYDays
 13
TVP Graphic Structure Lead Time (Loss)
Current Condition :
TV GENBA R/M STORE PAINT INJECTION PAINT F/G
LT = 6.3 days
Stock Point 5 area Target :
Qty Stock 2369 pcs LT = 5.3 days  ∆ 1.0 days
Stock Point 5 area
Qty Stock 1993 pcs Ideal:
F/G
2.0 Days LT = 4.2 days  ∆ 1.1 days
Stock Point 5 area
Qty Stock 1580 pcs
F/G
PAINT 0.2 Days 2 Days
SEQUENCE
INJECTION
1.1 Days F/G
PAINT 0.2 Days
1.5 Days
STORE PAINT SEQUENCE INJECTION
1.0 Days 0.6 Days PAINT 0.2 Days
STORE PAINT SEQUENCE INJECTION
0.5 Days 0.5 Days
STORE PAINT
0.5 Days
R/M R/M
2.0 Days 2.0 Days
R/M
1.5 Days

Current Condition TARGET IDEAL

(2021Y March) (2022Y Dec) (2023 - 2024Y)

 14
Material Information Flow Chart
MIFC BEFORE
SUPPLIER WH INJECTION STORE PAINTING STORE PAINTING ASSEMBLY FG CUSTOMER

1 day lot production PPIC ADMIN MRP

PATTERN POST 2x /month

1. Dandori Time too long 1 day Sequence 1 day Store PATTERN POST
57.7 Minute production capacity needed

RESIN IN IN
INJECTION PAINTING ASSEMBLY IN
SP 15A1 SP 11HE SP YAMAHA
SUPPLIER 12A20
(RESIN)
Model A Model B Model C

MIFC AFTER
SUPPLIER WH INJECTION STORE PAINTING STORE PAINTING ASSEMBLY FG CUSTOMER

0,5 day Small lot production PPIC ADMIN MRP

PATTERN POST 2x /month

1. Dandori Kaizen 0,5 day Sequence 0,5 day Store PATTERN POST
57.7  40 Minute production capacity needed

RESIN IN IN
INJECTION PAINTING ASSEMBLY IN
SP 15A1 SP 11HE SP YAMAHA
SUPPLIER 12A20
(RESIN)
Model Model Model Model Model Model
A B C A B C
 Activity Kaizen 15

1.1 Kaizen Dandori

Minute STEP KAIZEN DANDORI

70.0
UCHI ADJUST SOTO IMPROVEMENT POINT
Target 40’ 1. Preheat Mold (Uchi) : 19.0 min
60.0
2. Purging material : 6.2 min
4.2
3. Cleaning Mold (Uchi) : 8.0 min
50.0
4.2 4. Adjustment mode & anti rush : 3.6 min
7.4 5. Other Process : 20.9 min
40.0 7.4
Total dandori time : 57.7 min

30.0
57.7
53.5
46.1
20.0 39.1 37.0
1. Preaheat 2. Purging 3. Cleaning 4. Adjustment
10.0 Mold material mold Anti Rush

0.0
STEP-0 UCHI => SOTO STEP-1 STEP-2 PROBABILITY

1. STEP 0 = MENDATA SELURUH ELEMEN KERJA MAN POWER

2. STEP 1 = MEMISAHKAN ANTARA UCHI , SOTO DAN ADJUSMENT 5. Others Process
3. STEP 2 = MEMINDAHKAN UCHI/ADJUSMENT KE SOTO
 Activity Kaizen 16

BEFORE AFTER
ALL DANDORI PROCESS DO AT UCHI DANDORI MOVE UCHI DANDORI TO SOTO DANDORI & REDUCE UCHI DANDORI
1 2
1 2
Purging Every
dandori Purging every
(Different Materials dandori
in 1 MC) (same Materials in
Loss 6.2 Min Preheating do outside 1 MC)
Preheat mold (Uchi) Waiting Preheat19 min  12 min Reduce 4.2 Min
temp Loss 19 Min Reduce 7 Min
3 4
3 4
Cleaning Every
dandori
Loss 8 Min Tablet anti rust
every dandory
Effect Anti rust Process Effect tablet anti rust
Until 6 Shoot No Cleaning 3 Shoot OK 1.6 min
Loss 3.6 Min Reduce 8 Min Reduce 2.0 Min

PROBLEM POINT Effect of the KAIZEN Reduce

1. Preheat Mold (Uchi) : 19.0 min 1. Preheat Mold (Uchi) : 12.0 min 7.0 min
2. Purging material : 6.2 min 2. Purging material : 2.0 min 4.2 min
3. Cleaning Mold (Uchi) : 8.0 min 3. Cleaning Mold (Soto) : 0 min 8.0 min
4. Adjustment & anti rush (Spray) : 3.6 min 4. Adjustment & anti rust (Tablet) : 1.6 min 2.0 min
5. Other Process : 20.9 min 5. Other Process : 20.9 min -
Total dandori time : 57.7 min Total dandori time : 36,5 min △21.2 min
 Monitoring & Result 17

1 Dandori Time 2 Lead Time B5X HL

Current Condition :
Dandori Time 57.7  36.5 minute LT = 6.3 days
Stock Point 5 area Management Target :
Reduce △21.2 minute (45%) LT = 5.2 days  ∆ 1.1 days
Qty Stock 2369 pcs
minute
Stock Point 5 area
Day
Qty Stock 1993 pcs
57.7 F/G
2.0 Days

PAINT 0.2 Days F/G

INTERNAL PROCESS
BEFORE 2.3 DAYS
2 Days
40.0 INJECTION
36.5

AFTER 1.2 DAYS

1.1 Days
PAINT 0.2 Days
STORE PAINT INJECTION
1.0 Days 0.5 Days
STORE PAINT
0.5 Days

R/M R/M
2.0 Days 2.0 Days

BEFORE TARGET ACHIEVE BEFORE ACHIEVEMENT

TV GENBA R/M STORE PAINT INJECTION PAINT F/G

 2. TVP Working Axis Analysis 18

2.1 Assembly Line B5X HL LINE ASSY 11HE FINISH

U Line
Target
(Commonize) 6
5 4
OEE 90% With 6 MP 1 2 3

MP NEEDS :  CT : 421/78
Stop Loss TT : 5.4 MP START
39%
Loss Actual : 6MP
Genba
57.30% Yamazumi Line 11HE
120
Line Balance 84%
Over MP
100
Speed Loss
18,3 % 6” 83 1.7” 82
80
09 12
TT : 78”
Ballance Loss 6.54% 3.5” 66 2.6” 69
Shortage material 17 02 09 6.4” 13 1.3” 61
58
OEE = 42.7 %

Non Value 3.65% 60

in Painting 03 08
Check 2.72 %
25
32 42
Semi
40 35
Value 44
TV 55
Genba 19.8% 20
29.67% 35
Line Balance 25 22 22
Value 84% < Std 90%
00
09
9.6%
MP1 MP2 MP3 MP4 MP5 MP6
Man Waiting Check Non Value Semi Value Value
 2. TVP Working Axis Analysis 19

AREA PROBLEM Issue IDEA TARGET

Target Line Balance

1. Balance Loss Line balance 84% Balancing Job
90%
2. Over MP Reduce CT
Reduce 6MP  5MP
ASSY

3. Stop Loss Shortage Material from Reduce NG Lens Stop Loss 50%
Painting 39%  19.5%

4. Quality Loss NG Rate Thread Reduce NG Rate Reduce NG Rate 50%

PAINT (NG Rate High) common line : 1.97% Thread 1.97%  0.98%
 2. TVP Working Axis Analysis 20

Balance Loss, Over MP & Stop Loss Kaizen Activity

Layout 11HE Before Yamazumi 11HE Before
Balancing
MP Before : 6 MP
Challenge reduce MP  CT : 421”
Sec
100
90 83 82
80
4 68 69 7 78"
70 6
6 5
4 60 6 4 58 61
2 4 5 6
1 3 50 3 5 5
40 3 3 4 4
30 4 2 3 3
20 2 3 2 2
2 1 2
10 1 1 1 1 1
0
Line Balance 84% MP1 MP2 MP3 MP4 MP5 MP6

Layout 11HE After Yamazumi 11HE After

MP After : 5 MP
Sec
92 96  CT : 421”
100
82
90 74 77 1 3 T/T : 78"
80 4 7
MP5 MP4 70 6 2 5
6
5 6 6
60
4 4 5
2
5
4
50
3
Still have
5 3MP C/T Over from T/T
4
4
1 3 40 3 3
30 4 2 3
20 2 3 2 2
2 1
MP3 10 1 1 1 1
0
MP1 MP2 MP3
MP3 MP4
MP4 MP5
MP5 MP6
 Activity Kaizen 21

MP3 BEFORE AFTER

Conector Assy (Check by Visual) Change Methode connector check (PUSH-PULL-PUSH)
Install : 5” Install : 4”
Check : 5” Check : 2”
Others : 82” Others : 82”

Total C/T : 92” Total CT : 88”

Baratsuki High Reduce C/T : 4”

Visual check (potential unlocking point)
PUSH PULL PUSH

One Process,One Check

Demerit : Merit :
Methode Install the Connector (potential Unlocking) must check Re-training MP related to standard / Installation method changed
several times to make sure it is locked according to OPL (PUSH-PULL-PUSH) check only one times

MP 3 C/T : 92”  C/T : 88”(∆4 second)

 Activity Kaizen 22

MP4 BEFORE AFTER

Aiming M/C doing by Manual Change manual M/C to Auto M/C

NO Temachi Aiming MC/T

machine automation : 15”
MC
the B5X HL model because it
Adj. Screw unstable will be discontinued it cannot be
Aiming
Temachi MC settings
implemented and will be
implemented by yokoten to the
Self nut BKA HL model
SWITCH ONLY
PUSH Reflector

Manual Aiming Auto Aiming

Walking : 13” Walking : 11”
VW : 18” VW : 3”
Other : 57” Other : 57”
PUSH &
HOLD
Total C/T : 88” SWITCH Total C/T : 71”
ONLY
Reduce C/T : 17”
Demerit : Merit :
The aiming process time becomes long The aiming setting process is just switch ON the m/c,

MP 4 C/T : 88” C/T : 71”(∆17 second)

 Activity Kaizen 23

MP5 BEFORE AFTER

Body Assy Process layout is too wide Relayout Child Part position (compact line)
Install : 13” Install : 10”
Walking : 6” Walking : 2”
Others : 63” Others : 63
Many steps
Total CT : 82” Total CT : 75”
Reduce CT : 7”

Wash Adj2

Fix MC
er
Chutter
Chutter NO Steps
Fix Adj1 Body Fix MC Body
Was Adj2

Fix Adj1
Reduce Space 1 m

2 meter 1 meter
Demerit : Merit :
Part storage is on the side with out of reach, resulting in a lot of steps, Small parts storage area is in front making it easy to take & install to the
long CT and a lot of space jig

MP 5 CT : 82”  CT : 75”(∆7 second)

Space: 2 meter  1 meter (∆ 1 meter)
 Monitoring & Result 24

1 MP LINE ASSY 11HE  CT LINE 11HE 2 YAMAZUMI LINE 11HE

MP Second Check NVW VW i-Reguler Job Baratsuki Takt Time
second Total Activity Reduce 120 120
7 6MP  5MP 430 CT in MP3, MP4, MP5 & 110 Line Balance 84% up to 97.6% C/T < T/T 110
420 else
100 100
410 90 72 76 74 73 75 TT : 78” 90
0,65 0,83 0,62 2,53
6 400 80 0,52 80
390 70 70
421” ▲51” 60
Achieve Target 60
▲1 MP 380
50 50
5 6 370
40 40
360 30 30
5 370”
350 20 20
4 340 10 10
BEFORE ACHIEVEMENT BEFORE ACHIEVE
ACHIEVEMENT 0 0
CT MCT CT MCT CT MCT CT MCT CT MCT
MP-1 MP-2 MP-3 MP-4 MP-5 MP6

3 PRODUCTIVITY 4 OEE LINE 11HE

12
Pcs/MH UP 1.21x %
100

10 90 UP 33% Target OEE 90%

80
Gap 14 Level UP
8 70
47.3
60
6
9.6 9.7 50
8
4
40
76%
30

2 20 42.7%
10
0 0
BEFORE TARGET ACHIEVEMENT BEFORE AFTER
ACHIEVEMENT
 2. TVP Working Axis Analysis 25

Quality Loss Kaizen Activity In Painting Line

Structure Loss Graph Point Of Occurance Legend :
Paretto NG Lens March ‘21
No Thread Potencial Thread
%
2.50%

Thread : 1,97 %
High Stop Loss 1.97%
2.00%
Assy 39%, due to
NG Loss Painting

1.50% Benang Seigen Test

The potential for NG white thread
is from uniforms, conveyor, hand
1.00% covers and filter material
0.84%
0.72% 1. Uniform 2. Conveyor 3. Hand cover 4. Filter

0.50% 0.44%
0.34%
0.24%

0.01%
0.00%
Thread Cat Dot Scratch Finger Crater Paint
over thin

Painting Assy
 Activity Kaizen 26

BEFORE AFTER
Potencial Thread Problem Countermeasure thread problem
Uniform Uniform
STA NDA RISA SI PENGGUNA A N A PD

1 1
DEPT PA RT PROCESS
A REA CL EA N ROOM PA INTING

A L AT PEL INDUNG DIRI

operator does not use K ac am at a Saf et y re-training operator to use of

anti-static clothes when Mas k er Res p i r at o r
Si n g l e Cat r i d g e
standard Safety device in the
entering the clean room clean room area
Pak ai an A n t i St at i c

Han d Co v er

area Sar u n g Ta n g an
L at ex

Sep at u K er j a

A PD WA J IB DIGUNA K A N DI A REA K ERJ A

HSE DEPT & HSE O F F ICER

2 Conveyor Conveyor
2
The thread fibers from the Conveyor thread fibers are
conveyor stick to the part cleaned by hot jets

3 Hand Cover 3 Replacing hand cover

Hand cover stringy and materials with anti-static
there is no expiration date cloth and doing periodic
replacements

4 Filter airsuply 4 Filter airsuply

Painting clean room Painting clean room area is
area is not installed installed with a Dust trap
with a dust trap Dust Trap (4 partitions) for easy cleaning

Floor Dust Trap

5 5
Painting clean room Painting clean room area is
area is not installed installed with a Dust trap
Floor with a dust trap Dust Trap
 Monitoring & Result 27

1 NG Rate Painting 2 Structure Loss Graph

NG Loss Painting
March Y21 Before 1.87%  After 0.39%
1.97% Reduce △1.48%
650 Pcs 1.93
550
1.82
1.63
NG
1.75 Rate thread %
1.43 Grafik Structure loss Graph
450 1.97%  0.59%
1.25
350 1.01 100% Loss
250 0.78
0.59
Reduce △70%
0.75 Loss Stop Loss Genba
Stop Loss 8%

150 Genba 14.11% 8.45% NG Loss

0.25 90% 15.8% 0.39 %
50 NG Loss
Non Value
Q1- Q2- Q3- Q4- Q1- Q2- Q3- Q1- Q2- Q3- Q4- Q1- Q2- Q3- 1.87% 10.17%
Y21 Y21 Y21 Y21 Y22 Y22 Y22 Y21 Y21 Y21 Y21 Y22 Y22 Y22 80% Ballance Loss 11.23%
Check 10.17%

NaN
N NaN NaN NaN NaN NaN NaN NaN 70%
G Non Value
16.84%

OEE = 91.6 %
49568
P 51329 51660. 45712 51551. 51051. 64403. 51442 60%
r 66666 33333 33333 5 Aug Y22

OEE = 84 %
o 66667 33333 33333
0.59%
d 50%
u
k Check 22.45 %
s 40% TV
i Semi Value
Genba
610
T 610 610 610 610 610 610 610 71.21% 71.21%
a 30%
r
g
e 20% TV
Genba Semi Value
t 33.68%
33.68%
1.93
% 1.82 1.63 1.43 1.01 0.78 0.59 N.aN
10% Man Man
N
G
0%
BEFORE ACHIEVEMENT
Painting
 TVP Summary Result 28

SUMMARY RESULT B5X KAIZEN

LEAD TIME OEE ASSY PRODUCTIVITY
Current Condition : % Stop Loss 39%  12%
LT = 6.3 days
Ahievement :
Reduce △69% Productivity 8  9.7
Pcs/M.H
Stock Point 5 area LT = 5.2 days  ∆ 1.1 days Up 1.21x
Qty Stock 2369 pcs Stock Point 5 area
Qty Stock 1580 pcs 9.6 9.7
F/G
2.0 Days
8
PAINT 0.2 Days
F/G F/G
2.0 Days 2.0 Days
INJECTION
1.1 Days
PAINT 0.2 Days
INJECTION PAINT 0.2 Days
STORE PAINT 0.6 Days INJECTION
1.0 Days STORE PAINT 0.5 Days
STORE PAINT
0.5 Days 0.5 Days

R/M R/M
R/M
2.0 Days 2.0 Days
2.0 Days

BEFORE TARGET ACHIEVEMENT BEFORE ACHIEVEMENT

TV GENBA R/M STORE PAINT INJECTION PAINT F/G BEFORE TARGET ACHIEVEMENT

COST REDUCTION B5X HL

Effect of
Process Item Kaizen Before After Price Volume Total/Years
Kaizen
Injection Dandori time 57,7 min 36,5 min 4.2 H/day -70 72000 5.040.000

OEE 73% 91% △ 18%

Painting NG rate Lens 1.97% 0.59% 1.38% -125 72000 9.000.000

Assembling
OEE

 CT Process
IDR 83,736,000 /Years
84%

421 Sec
92%

370 Sec
△ 8%

51 second
YOKOTEN
BKA HL
-738 72000 53.136.000
MP 6 5 1 MP

OEE 42.7% 76% △ 33.3%

Demand Vynile Use No Use 1 Pcs - 150 72000 10.800.000

CT Process 8 second - 80 72000 5.760.000

Total 83.736.000
 BKA Yokotenkai 29

B5X LED HL Part Comparation with manual Process

Current Model Next Model
PART NAME REMARKS
B5X LEDHL BKA LEDHL
BODY 1 1
REFLECTOR*
ADJUSTING SCREW 1 4 3 more parts

WAVE WASHER 1 4 3 more parts

PUSH ON FIX 1 4 3 more parts

All Process already Yokoten to BKA HL PIVOT 2 2

PRINT BASE ASSY B 1 1
LENS*
10 more parts
REFLECTOR ASSY 8 18

* : Internal Process Koito EXTENSION ASSY 8 5

LENS 1 1 already Yokotenkai
BKA LED HL PROTECTOR 2 2
CAP ASSY 2 2
SEALANT 50 gr 50 gr
REFLECTOR*

PAN HEAD TAP SCREW 16 30 14 MORE PART

Kaizen MC BKA HL
QTY 40
LENS* 2 TOTAL PART 34 74 MORE PART Target
CUSTOMER : YIMM
1 450”
MODEL
PIK L/O
:
:
BKA LED HL
OCT 2022
∑CT (CURRENT) 370” 480” GAP 110”
MAIN LINE : 11HE
 30
BKA Activity Kaizen
1 BEFORE AFTER
Screw Tightening PCB to BODY by Manual Process Screw Tightening using Auto Machine
The screw tightening process for BKA LEDHL is more than
the previous model process (B5X LEDHL).
1. B5X LED HL BECAUSE IT WILL BE DISCONTINUOUS SO THERE IS
ITEM B5X BKA REMARKS
NO AUTOMATION
TAPING CORD ASSY = 1
PAN HEAD TAP SCREW PCB B TO BODY= 14
(WITH MANUAL 8 pcs 14 pcs REF ASSY = 2
BODY ASSY = 5 2. BKA LED HL DONE AUTOMATION
PROCESS) INNERLENS ASSY = 4
LENS ASSY = 4

Screw driver 1. B5X LEDHL IF TIGHTENING Tightening MC Total 46 second

PROCESS BY MANUAL SCREW
DRIVER

RESULT : 8 x 4 sec = 32 sec

2. BKA LED HL IF TIGHTENING

PROCESS BY MANUAL SCREW
DRIVER
Baratsuki
High RESULT : 14 x 4 sec = 56 sec

C/T 56 sec  C/T 46 sec (Δ10 second)

 31
BKA Activity Kaizen

Project analysis slide 4

2

Sliding cover Lighting M/C by Manual

BEFORE AFTER
Sliding cover Lighting M/C by Auto
Ｎｏ WORK ELEMENT PROCESS CYCLE TIME
Ｎｏ WORK ELEMENT PROCESS CYCLE TIME
1 PICK & PUT ASSY UNITS ON THE LIGHTING JIG 5
1 PICK & PUT ASSY UNITS ON THE LIGHTING JIG 5 2 INSTALLING THE CONNECTOR CORD ASSY TO THE UNIT ASSY 3
2 INSTALLING THE CONNECTOR CORD ASSY TO THE UNIT ASSY 3 3 SWITCH MC 1
3 SWITCH MC 1 SWIPE THE COVER TO THE MOST LEFT, ADJUST THE RIGHT
SWIPE THE COVER TO THE MOST LEFT, ADJUST THE RIGHT
4 6
4 8 LO-BEAM
LO-BEAM 5 SWITCH MC 1
5 SWITCH MC 1 6 SWIPE THE COVER TO THE RIGHT, ADJUST LO-BEAM LEFT 4
6 SWIPE THE COVER TO THE RIGHT, ADJUST LO-BEAM LEFT 5 7 SWITCH MC 1
7 SWITCH MC 1 8 COVER RIGHT-LEFT OPEN, HI-BEAM CHECK 5
▲ 9s
8 SWIPE THE COVER TO THE RIGHT, CHECK THE HI-BEAM 8 TOTAL 26”
TOTAL 32” Sliding Cover Auto : 15 sec
Sliding Cover manual : 21 sec
Sl
id
in
g

Auto
Temachi Sl
id
in
g
Picture : Desain Jig Lighting BKA LEDHL
Picture : Desain jig Lighting Before

Demerit Merit
The Lighting Check process when Lo-Beam verification has to be closed and opened The Lighting Check process when Lo-Beam verification must be closed and
on one of the Reflectors, is currently still being carried out by the Operator manually. opened on one of the Reflectors, for LEDHL BKA is done automatically.

CT 32 sec  CT 26 sec (Δ 6 second)

 BKA Kaizen Proposal 32

BEFORE AFTER
BKA using plastic packaging BKA plastic less proposal

Low Cost
Green Enviro

Finish Good
Visual Check Plastic packaging Put in Box Visual Check Put in Box
NO Plastic packaging

NVW : 47” CT Vinyl Process : 7” NVW : 40” Reduce CT : 7”

V.Check : 26” Check : 26”
Walking : 9” Walking : 9”

Total CT : 82” Total CT : 75”

Demerit : Merit :
Plastic Packaging produces plastic waste reduce plastic waste & go green concept

CT : 82”  CT : 75”(∆7 second)

 33
BKA Kaizen Result
BKA HL Reduce ƩCT BKA HL Productivity Up
second Pcs/MH
500 8.2
Reduce Target
△16 sec Reduce 8 Pcs/MH
480 △23 sec 8
UP △1.05x

7.8 UP △1.04x
460 Target
450 sec
7.6
440 480 7.9
464 457
7.4 7.8
420
7.2 7.5

400 7
BKA BEFORE BKA KAIZEN BKA PACKAGING BKA BEFORE BKA KAIZEN BKA PACKAGING
PROPOSAL PROPOSAL

ƩCT Before 480 sec  After 464 sec Productivity Before 7.5  After 7.8 Pcs/MH
(Reduce 16 sec) (Up 1.04x)

IT STILL NOT ACHIEVE TARGET, WE WILL DO NEXT KAIZEN

ACTIVITY FOR ACHIEVE TARGET
 34
Cost Reduction B5X HL & BKA HL
B5X HL Kaizen

Process Item Kaizen Before After Effect of Kaizen Price Volume Total/Years

Injection Dandori time 57,7 min 36,5 min 4.2 H/day -70 72000 5.040.000

OEE 73% 91% △ 18%

Painting NG rate Lens 1.97% 0.59% 1.38% -125 72000 9.000.000

OEE 84% 92% △ 8%

Assembling  CT Process 421 Sec 370 Sec 51 sec

-738 72000 53.136.000
MP 6 5 1 MP

OEE 42.7% 76% △ 33.3%

Demand Vynile Use No Use 1 Pcs - 150 72000 10.800.000

CT Process 8 sec - 80 72000 5.760.000

Total 83.736.000

BKA HL Kaizen
Model Item Kaizen Before After Effect of Kaizen Price Volume Total/Years

BKA HL  CT Process 480 Sec 464 Sec 16 sec -1120 62.400 69.888.000

PT.INDONESIA KOITO IDR 153,624,000 /Years

PT.INDONESIA KOITO
K A I Z E N K AT S U D O U KO I T O

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