poka yoke mapping - panyapiwat
TRANSCRIPT
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Poka Yoke Mapping
Plan For Every Part
PFEP & Poka Yoke Mapping
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รายละเอยดการฝกอบรม
09.00-10.00 น. การปองกนความผดพลาด ( Error Proofing )
Poka Yoke Mapping
Workshop
13.00-16.30 น. Continuous Flow
Plan For Each Station ( PFES ) & Plan For Every Part ( PFEP )
Central Supermarket
Workshop
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Error Proof
Error Proof Mapping
การปองกนความผดพลาด
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Error Proof
คณเคยท าผดพลาดบางไหม ?
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ขอจ ากดของมนษย
• คนท างานอยางมสมาธตอเนองไดประมาณ 15 นาท • คนเราไมรสกตวหากถกแทรก เชน ระหวางท างานมคนมาเรยกท าใหลม
• หากมขวญก าลงใจด สมาธกจะด ท างานไดอยางตอเนอง
• ถามอะไรไมถกใจ หรอ มเรองกลมใจสมาธจะสน
• ขอบเขตทสายตาไปถงจะเปนขอบเขตของสมาธ หากเกนไปหรอมองไมจะ
หมดสมาธ
• การทจะใหคนงานท างานเกนขอบเขต แตใหมสมาธดๆ นนเปนไปไดยาก
• สรป ตองเขาใจจดออนคนเพอทจะใช Poka Yoke ใหถกตองมากขน
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ความนาเชอถอในตวมนษยม 5 ระดบ
ระดบท 0 : ไมมสตเลย เชน นอนหลบ อาการชก ระดบท 1 : เหมอลอย เชน เวลาเมา ลา ท างานทซ าซาก ไมมความรสกเตอน
ตวเอง ระดบท 2 : สมาธระดบธรรมดา เชน ท างานทวไป ระหวางพก ระดบท 3 : สมาธระดบปกต เชน ท างานไดอยางกระตอรอลน มสตท างานให
ด มความรสกระวงตวเองเตอนตวเองได ระดบท 4 : สมาธระดบด ท างานรบๆ ได แตมนจะตรงเกนไป
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ชนดของความผดพลาดจากมนษย
1 : ลม 2 : เขาใจผด 3 : ไมมประสบการณ 4 : แกลงท าผด 5. รางกายรบไมได เหนอยลา
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ของเสยเปนศนย 100% ตลอดเวลา
สรางสงแวดลอมการท างานทปราศจากของเสย
![Page 9: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/9.jpg)
ใชสตปญญามนสมอง ความคดสรางสรรคท างานของคณใหไมมของเสย 100% ตลอดเวลา
Poka-Yoke
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อนไหนเกลอ
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จะปองกนการผดพลาดไดอยางไร
อะไรบางทอาจกอใหเกดโอกาสในการท าผดพลาด จะปองกนมนไดอยางไร
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Does
100%
Inspection
Finds
100% of
the Rejects
100% of
the Time?
FINISHED FILES ARE THE RE-
SULT OF YEARS OF SCIENTIF-
IC STUDY COMBINED WITH
THE EXPERIENCE OF YEARS.
ใหนบตวอกษร F ในหนากระดาษน
Exercise
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ปรชญาของ Poka Yoke
• พงระลกไวเสมอคน เครองจกร และกระบวนการท างานผดพลาดได
• ขจดการตดสนใจ ประเภทกะ ประมาณ เดา ลองผดลองถก ของพนกงานออกไป
• ใชความคดแบบสรางสรรค และงายๆ ในการเอาชนะความผดพลาดขอ
มนษยและกลไก
• อยายอมรบวาสาเหตเกดจากความผดพลาดของพนกงาน
• ตงมาตรฐานของเสยเปนศนย
• ตงเปาหมายของเสยเปนศนยถอเปนความรบผดชอบของทกคน
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ค าจ ากดความของ “ความผดพลาด (Error)”
ความผดพลาดคอสงเบยงเบนใดๆไปจาก
ขบวนการทควรเปนหรอตงเปาหมายไว
ความผดพลาดคออะไร ?
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WHAT IS THE DIFFERENCE
BETWEEN
PREVENTION &
DETECTION?
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PREVENTION DETECTION
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OUR EFFORTS SHOULD FOCUSON THE
MISTAKE STAGE
Mistake
Detect Mistake
Correct Mistake
Produce Parts
Produce Parts Detect Defect
Fix Part
Eliminate Cause
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ควบคมและตรวจสอบ
Process
Control Inspect
Process
characteristics
Product
characteristics
Level 1 : Identify cause of the defect
Level 2 : detect the defects
Level 3 : prevent the impossible error
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Find the problems Good
Wrong
To the
Client
Quality control
Production flow
Repair / Reject
Solve the problems
Avoid / Prevent
problems
To the
Client R & D
Quality control
Repair / Reject Repair / Reject
Poka Yoke
1.
2.
3.
To the Client
Control & Inspect
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WHEN A DEFECT
IS ABOUT TO OCCUR HAS OCCURRED
MISTAKE-PROOF
DEVICE
MISTAKE-PROOF DEVICE
WARNING
SIGNALS MISTAKE
IS ABOUT TO
OCCUR
CONTROL
EVEN INTENTIONAL
ERRORS ARE
IMPOSSIBLE
SHUTDOWN
OPERATIONS
STOP WHEN
DEFECT PREDICTED
WARNING SIGNALS
DEFECT HAS
OCCURRED
CONTROL
DEFECTIVE PARTS
CAN NOT PASS ON
SHUTDOWN
OPERATIONS
STOP WHEN
DEFECT DETECTED
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การปองกนความผดพลาดคออะไร?
คอระบบการปรบปรงพฒนากระบวนการ เพอลดโอกาสในการเกด ความผดพลาดและลดคาใชจายในการจดการความผดพลาดทเกดขน การปองกนความผดพลาดเปนหนงในเครองมอทมอยซงจะชวย ใหเราไปถงเปาหมายของการผลตงานอยางไมมขอบกพรอง พฒนาโดย Shigeo Shingo
ปองกนการบาดเจบของผปฏบตงาน ปองกนความผดพลาดในการผลตงาน ลดกจกรรมทไมกอใหเกดคณคาเพม ทสดของการปองกนความผดพลาด คอ เอาคนตาบอดมาท ากไมผดพลาด
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ความผดพลาดสามารถเกดขนไดเมอเงอนไขทจ าเปนของขบวนการผลตด าเนนไป อยางไมสมบรณหรอขาดหายไป
ขอบกพรอง (Defect) ทงหลายเกดขนไดโดยความผดพลาด (Error)
ไมใชความผดพลาด (Error) ทงหมดจะกอใหเกดขอบกพรอง (Defect) เสมอไป
ขบวนการถดไป ความผดพลาด ขอบกพรอง ทอาจเปนไปได ขบวนการกอนหนาน
ขนตอนในขบวนการผลตปจจบน
ค าจ ากดความของ “ความผดพลาด (Error)”
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ตวอยาง Poka Yoke ในชวตประจ าวน
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ตวอยาง Poka Yoke ในชวตประจ าวน
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ตวอยาง Poka Yoke ในชวตประจ าวน
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ตวอยาง Poka Yoke ในชวตประจ าวน
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ตวอยาง Poka Yoke ในชวตประจ าวน
![Page 28: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/28.jpg)
ตวอยาง Poka Yoke ในชวตประจ าวน
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ประเภทของความผดพลาดจากความไมระมดระวง
1. แปรรปผด 2. ประกอบผด 3. จ านวนผด 4. ประกอบไมครบ 5. เดนเครองผด 6. เตรยมงานผด 7. สงแปลกปลอมเจอปน
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ประเภทของ Poka Yoke
1. Poka Yoke จ านวน เชนเบกของตองครบ 2. Poka Yoke น าหนก เชน น าหนกไมได เครองไมท างาน เกนหรอขาด
เครองจะรอง 3. Poka Yoke ความยาว เชน สงเกนมาตรฐานจะม alarm สนเกนจะม
alarm
4. Poka Yoke รปทรง เชนลกษณะพเศษของตวชนงาน 5. Poka Yoke การประสานงานกนระหวางคนกบเครองจกร เชน ล าดบชน
ของการท างาน หากขามขนตอนเครองจกรจะไมท างาน 6. Poka Yoke ขอบเขต เชน limit ของแรงดนกาซ 7. Poka Yoke ล าดบการท างานของ WI ( Work Instruction )
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กลไก Poka Yoke
1. หากมของเสยเครองจกรจะไมแปรรป 2. หากมการปฎบตงานผดพลาด ชนงานไมสามารถเขาไปในจกได 3. หากมการท างานผดพลาด เครองจะท าการแกไขและแปรรปไดอยางถกตอง 4. คนพบของเสยของกระบวนการกอนหนา เครองจะหยดไดเองโดยอตโนมต 5. คนพบการลมท างานของกระบวนการกอนหนา เครองจะหยดท างานทนท
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ความผดพลาดและขอบกพรอง
ความผดพลาด ขอบกพรอง สภาพทท าใหเกด
ใสเกลอแทนทจะเปน น าตาล
มเกลอในกาแฟ •ทบรรจเหมอนกน
•ความเมอยลาของพนกงาน •อานหนงสอหรอท าอยางอน อยดวย
การก าหนด ความเรวของเครองผด
ชนสวนตาง ๆทผลต ไมไดตามขอก าหนด
• WI เขยนไวไมสมบรณ
• P/N เหมอนกนมาก • การฝกอบรมผปฏบตงาน
• ความยากในการใชเครอง
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Build a Culture of Stopping to Fix Problem, to Get Quality Right the First Time
Error-proofing
Problem solving
Response system
Building culture of stopping to fix problem
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Error Proof – Response System
Team members are empowered to stop machines or the entire production line if a problem occurs. Mistake-proof devices ensure that defects will be caught and corrected before unacceptable products are produced.
Response system Error – proofing (poka yoke)
Approach for operators:
Preventative
If trouble, Stop!
If defective don’t pass
Immediate response from support areas
Approach for machines:
A mistake-proofing system prevents errors and defects
Stop line when defects are detected or machines break down
STOP
Trouble!
Poka-yoke
STOP
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การปองกนความผดพลาด : ชนดของความผดพลาด
1. Processing omissions: การท างานขามขนตอน
2. Processing errors: การไมท างานตามขนตอนมาตรฐานการท างาน
3. Error in setting up the work piece: ใชเครองมอไมถกตองหรอ ปรบแตงเครองมอไมตรงกบผลตภณฑทก าลงท า
4. Missing parts: ใสชนงานทตองการในการประกอบ/เชอมไมครบ
5. Improper part/item: ใสชนงานทไมถกตองเขาไปในการประกอบ
ความผดพลาด (Error) 10 ประการทสามารถใช Error Proofing ชวยในการแกไขหรอก าจดใหหมดไป
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6. Processing wrong workpiece: ท างานทไมตองการใช
7. Operations errors: ท างานไมตรงตามขอก าหนดปจจบน ซงอาจเกดจากการใช Spec ทไมถกตอง (ผด Revision)
8. Adjustment, measurement, dimension errors: ความผดพลาดจากการปรบแตง,ทดสอบเครองหรอวดขนาดชนงานจากการกระท า ของผสงมอบงาน(supplier)
9. Errors in equipment maintenance or repair: ขอบกพรองจากการซอมหรอเปลยนชนสวนของเครองมอไมถกตอง
10. Error in preparation of consumables: การเตรยมตวในการผลตไมถกตองเชน Tool ทออกแบบไมเหมาะกบการท างาน, อณหภม ท Set ไมถกตอง
การปองกนความผดพลาด : ชนดของความผดพลาด
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หลกการใชลดความนาจะเปน ในการเกดความผดพลาดของคนมดงน
การปองกนความผดพลาดจากคน
1. ท าใหเหนไดชดเจนดวยตา 2. ระบคนรบผดชอบ 3. จดหากลไกการใหขอมลปอนกลบเขาไปในการควบคม 4. จดท าขอจ ากดของเครองมอการปฏบตงาน
จ ากดดวยวตถ
จ ากดดวยการเรยนร 5. จดท าเปนมาตรฐาน
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Types of Mistake- Proof Devices
• Guide/reference/interference rod or pin*
• Alarm*
• Limit switch/ microswitch*
• Counter*
• Checklist*
• Template
• Odd-part-out method
• Sequence restriction
• Standardize and solve
• Critical condition indicator
• Stopper/gate
• Sensor
• Detect delivery chute
* Most commonly used
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40
ท าใหเหนไดดวยสายตา
มปายบอก
ใชเสยงเตอนใหชดเจน
เปานกหวด
ใสเครองหมาย/สญญานเตอนของการหยดการท างาน
การท าใหพนกงานเหน สมผส รบรสภาพของการท างาน, ขอมลปอนกลบการท างาน และผลกระทบจากการปฏบตงานของแตละคน
![Page 40: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/40.jpg)
41
จดท าขอจ ากด
จ ากดดวยลกษณะวตถ
จ ากดดวยการเรยนร
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42 42
Error Proofing Devices (1)
Work-Piece
Platform
Locating Pins
Locating Pins
เพอใหมนใจไดวาชนงานวางถกต าแหนง
![Page 42: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/42.jpg)
43 43
Profiler Cutting Wheel
offset is fixed
Template Work-Piece
Error Proofing Devices (2)
Templates
เพอใหมนใจไดวาชนงานถกท าตามตนแบบไมมผดเพยน
![Page 43: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/43.jpg)
44 44
Error Proofing Devices (3)
Limit Switches
เพอใหมนใจไดวาความลกในการตดหรอเจาะไดขนาดทสม าเสมอ
Cutting Tool
Work-Piece
Limit Switches
![Page 44: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/44.jpg)
45 45
Critical Condition Indicator
บงชวาคาของตวแปรตางอยในขอบเขตทก าหนด
Error Proofing Devices (4)
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Guide/Reference/ Interference Rod
Rods Rod Clearance Area
Example:
![Page 46: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/46.jpg)
Alarms
Fire Alarm
Car Alarm
Christmas Tree lights on machine
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Limit Switch or Microswitch
The grooved edges of two sides of the work pieces are
used as guides for setting up the plates correctly. A limit
switch is mounted on the jig and interlocked with the start
switch so it is impossible to start the drill press if the side
plate is set in the wrong position. Defects due to defective
holes are completely eliminated.
Example:
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49
An indicator that keeps track of the number of:
parts, turns, strokes, output, or abnormalities.
Can be mechanical or electronic.
8 4
Counter
Example:
![Page 49: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/49.jpg)
50
Checklist
• Preflight pilot
checklist
• “To Do” lists
• Inspection checklists
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51
Made of sheet metal. Has configuration to
guarantee accurate positioning.
0 +1
2
3
-
456
5
4
3
21
BASIC
-1
-2+5
+4
+3
+2 +1
Template
Example:
![Page 51: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/51.jpg)
52
Supply only the correct number of parts.
When the operation is complete there
should be no left over parts or shortages.
ASSEMBLY
DETAILS
Odd Part Out
Example:
![Page 52: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/52.jpg)
Sequence Restriction
Example
A new “first-in, first-out” rack was developed that dispenses the tapes
only in the proper order for testing. When one tape is removed for
use, the next tape slides down, ready for use. When a tape has been
used, the inspector places it in the top of the rack, where it remains in
the correct order. Errors in the testing sequence are completely
eliminated.
![Page 53: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/53.jpg)
Standardize and Solve
Example
The containers are packed on a scale. If there are too
few gears in a box, it will not weigh enough, and the
omission is detected.
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55
Critical Condition Indicator
Min
Max
Normal
Pressure
Pressure
Gauge
Normal Direction of
Motor Rotation
Normal Direction of Fluid
Circulation
Oil Tank Cap
Mobil DTE 25
Max
Min
Sight Glass
Normal
Fluid Level
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56
Sensor
Tempilabel Temperature
Monitor ®
77° C 82° C 88° C 93° C
A N
o. 4
A-1
70
/77
170° F 180° F 190° F 200° F
Center Turns Black at Rating Shown So.
Pla
infield
, N
J, U
.S.A
.
Example
![Page 56: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/56.jpg)
Delivery (Detect) Chute
Example
Using the fact that the unwelded bushing is missing the shaft,
a mechanical sorter was developed to remove the faulty
parts from the transport line.
sorting arm
chute
good items unwelded
bushings
sorting arm
from automatic welding machine
chute
retrieval bin
to next
process
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58
EXAMPLE OF SOLUTION OTHER THAN DEVICE
REDESIGN
MUST TALK WITH THE
DESIGN ENGINEER AND
LET THEM KNOW THAT THE
PROBLEM CAN BE SOLVED
BY REDESIGNING THE
PARTS, TOOL, OR MACHINE
PART # ELIMINATED
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Successful Mistake- Proof Devices
You should be able to answer yes to all of these:
• Is it safe to use?
• Prevents reoccurrence?
• Inexpensive?
• Simple to use?
• Easy to implement?
• Durable?
• Easy to maintain?
• Does not hinder operator?
• Gives prompt feedback?
• Gives prompt action (prevention)?
• Has the right people’s input?
• Reliable—does not give false signals?
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60
Exercise: Mistake Proofing
• Step 1: Read the “Before Improvement” section for the
mistake proofing scenario assigned to your team.
• Step 2: Work with your team members to identify
potential mistake-proofing applications for each problem
assigned.
• Step 3: In the “After Improvement” section, describe the
mistake-proofing device that you feel would over come
the problem. Include sketches. Prove as many devices
as possible during the allotted time frame.
• Step 4: Prepare a presentation of you team’s ideas.
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Description of Process: Small sign plaques are mounted on a panel.
Before Improvement:
Although the workers were careful when
mounting the plaques, defects occurred
because it was possible to mount them
upside down.
After Improvement:
Process: Mounting small plaques on a panel Problem: Plaques mounted upside down
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Description of Process: Small sign plaques are mounted on a panel.
Before Improvement:
Although the workers were careful when
mounting the plaques, defects occurred
because it was possible to mount them
upside down.
After Improvement:
Process: Mounting small plaques on a panel Problem: Plaques mounted upside down
![Page 62: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/62.jpg)
Description of Process: Molded items are milled in an automatic machine and delivered to
the next process via a chute.
Before Improvement:
If an unmilled part came through the chute,
the next machine shut down abnormally and
could be damaged.
After Improvement:
Process: Milling molded items Problem: Unprocessed items
Exercise: Mistake Proofing
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Description of Process: Molded items are milled in an automatic machine and delivered to
the next process via a chute.
Before Improvement:
If an unmilled part came through the chute,
the next machine shut down abnormally and
could be damaged.
After Improvement:
Process: Milling molded items Problem: Unprocessed items
Exercise: Mistake Proofing
![Page 64: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/64.jpg)
Description of Process: A chassis was placed in a jig for machining.
Before Improvement:
It was possible to insert the chassis
in the jig backwards. Correct
operation depended on the worker’s
vigilance.
After Improvement:
Process: Processing chassis Problem: Chassis set backwards in jig
Exercise: Mistake Proofing
![Page 65: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/65.jpg)
Description of Process: A chassis was placed in a jig for machining.
Before Improvement:
It was possible to insert the chassis
in the jig backwards. Correct
operation depended on the worker’s
vigilance.
After Improvement:
Process: Processing chassis Problem: Chassis set backwards in jig
Exercise: Mistake Proofing
![Page 66: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/66.jpg)
Description of Process: Four mounting holes are drilled in many different
types of plates. The holes are all equally spaced in one dimension, but are
spaced differently along the other axis, depending on the size of the plate.
Before Improvement:
The holes were drilled with a four-
spindle drill press, which required
setup for each different type of plate.
When the number of types of plates
increased, time required for setup
increased as well, and setup errors
increased in incorrectly drilled holes.
After Improvement:
Process: Drilling a variety of
different work pieces
Problem: Errors made during setup for
different work pieces
Exercise: Mistake Proofing
![Page 67: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/67.jpg)
Description of Process: Four mounting holes are drilled in many different
types of plates. The holes are all equally spaced in one dimension, but are
spaced differently along the other axis, depending on the size of the plate.
Before Improvement:
The holes were drilled with a four-
spindle drill press, which required
setup for each different type of plate.
When the number of types of plates
increased, time required for setup
increased as well, and setup errors
increased in incorrectly drilled holes.
After Improvement:
Process: Drilling a variety of
different work pieces
Problem: Errors made during setup for
different work pieces
Exercise: Mistake Proofing
A new method for drilling the mounting
plates was developed that makes setup
operations unnecessary and completely
eliminates defects in hole spacing. A
two-spindle drill press is set to the
constant hole spacing used in all the
plates. A stop block is located on the
drill press table in line with the spindles,
and the jigs for the different plates now
have notches at each hole position. The
block fits into the notch in the jig as
each plate is fed in. It is now possible to
continuously feed the work pieces and
position them accurately.
![Page 68: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/68.jpg)
Description of Process: Four mounting holes are drilled in many different types of plates. The holes are
all equally spaced in one dimension, but are spaced differently along the other axis, depending on the size
of the plate.
Before Improvement: After Improvement:
Process: Drilling a variety of
different work pieces
Problem: Errors made during setup for
different work pieces
Exercise: Mistake Proofing
![Page 69: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/69.jpg)
Description of Process: Cables of many different sizes and colors are wired to a multipoint terminal
board.
Before Improvement:
The workers followed a diagram mounted over
the terminal board. Defects occurred because of
misunderstandings, mix-ups, or oversights made
when workers looked from the diagram to the
wiring work.
After Improvement:
Process: Wiring terminal boards Problem: Wiring errors
Exercise: Mistake Proofing
![Page 70: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/70.jpg)
Description of Process: Cables of many different sizes and colors are wired to a multipoint terminal
board.
Before Improvement:
The workers followed a diagram mounted over
the terminal board. Defects occurred because of
misunderstandings, mix-ups, or oversights made
when workers looked from the diagram to the
wiring work.
After Improvement:
Process: Wiring terminal boards Problem: Wiring errors
Exercise: Mistake Proofing
A wiring template was made that slides between the
rows of terminals on the board. Samples of the
correct wire for each terminal are attached to the
template, and the worker can tell at a glance which
terminal to connect with a particular wire.
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72
Front Seat Process Flow
1 2
Receive Part from supplier
Incoming Inspection
3 Picking all parts
Load frame structure to
build pallet/Install silencer 4
5
6
Install back's foam to frame structure
Close out trim to Front Back
8 Install front cushion +
pan to frame structure 7
Load Cushion Foam to Pan
Close out trim to Cushion
10
9
11
12
Install plastic part
Install buckle Head Rest Sub-assembly
Install Head Rest
14 Steam
14 Final Inspection
15 Functional Checking
Plastic bag covering
16 Loading to Shipping Rack
17
18
Dock Audit
Ship to Customer
13 Install SAB
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Opn#1
Load frame
Ergonomic
Lifter
Opn#2
Install B/F
Opn#3
Close Out
Cushion
Sub-Assy
Opn#4
Install Cushion
M8 X 2
Opn#5
Install Cushion
M8 X 2
Opn#6
Install Plastic
Opn#7
Install H/R
Arm Rest H/R
Sub-Assy
Opn#9
Steam
Opn#11
Final Inspect
Ergonomic
Lifter
Poka Yoke Mapping :
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74
Poka Yoke Mapping :
Operation
Description #1 #2 #3 #4 #5 #6 #7 # 8 #9 #10 #11 Rwk C/S H/R
Monitor
Touch Screen Monitor
Bar Code Scanner
Bar Code Printer
LPS Software
Poka Yoke Lighting
PLC Program + Wiring
ToolNet
Prevent for wrong part
Prevent for no torque
Prevent for wrong bolt
As of Aug 13’2009
Off-Line
![Page 74: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/74.jpg)
75
Poka Yoke Mapping Exercise
1 2
Receive Part from supplier
Incoming Inspection
3 Picking all parts
Load frame structure to
build pallet/Install silencer 4
5
6
Install back's foam to frame structure
Close out trim to Front Back
8 Install front cushion +
pan to frame structure 7
Load Cushion Foam to Pan
Close out trim to Cushion
10
9
11
12
Install plastic part
Install buckle Head Rest Sub-assembly
Install Head Rest
14 Steam
14 Final Inspection
15 Functional Checking
Plastic bag covering
16 Loading to Shipping Rack
17
18
Dock Audit
Ship to Customer
13 Install SAB
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76
System Architecture
Three Tier Architecture
Application Business Logic
D/B
Server
D/B Management Software
SQL or Oracle
Helios 17”
Thin Client
For all scanners E
T
H
E
R
N
E
T
N
E
T
W
O
R
K
Automated Equipment (e.g. PLC’s)
Robotics
Data Collection (e.g. Barcode/RF Readers)
Atlas Copco
Remote I/O
Application
Server
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77
Poka Yoke Mapping Exercise:
Description ตวอยาง
Defect
ผาไหม
Error Condition
( Cause of defect )
ลมถอดปลก
Type of solution
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79
Continuous Flow
ไหลอยางตอเนอง
ไหลอยางตอเนอง
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ประโยชนจากการผลตทละชน
1: Improves safety.
2: Builds in Quality.
3: Improves Flexibility.
4: Improves scalability.
5: Reduces inventory. cash is king.
6: Improves productivity.
7: Simplifies material replenishment.
8: Frees up floor space.
9: Makes kaizen take root.
10: Improves morale.
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ตวอยางการผลตทละชนได
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ตวอยางการผลตทละชนได
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ตวอยางการผลตทละชนได
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ตวอยางการผลตทละชนได
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ตวอยางการผลตทละชนได
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แบบฝกหด : ท าไมจงไมสามารถผลตทละชนได
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87
Plan For Every Part
Poka Yoke Mapping
PFEP & Poka Yoke Mapping
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ขนตอนท 1 : Takt Time
ขนตอนท 2 : Operation sequence & Actual Cycle Time & Layout
ขนตอนท 3 : Poka Yoke Mapping
ขนตอนท 4 : PFEP
ขนตอนท 5 : Supermarket ( Shopping Area )
ขนตอนท 6 : Routing : ( Water Spider )
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
![Page 87: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/87.jpg)
ขนตอนท 1 : : Takt Time
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
![Page 88: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/88.jpg)
Elements of Flow
Takt
Time
Takt Time X Units in Process
=Manufacturing Cycle Time
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Elements of Flow
1 sec
/unit
1 sec/unit X 10 units=
10 sec
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Elements of Flow
Takt
Time
Takt Time is the same but the
number of units in process is
less so Lead-Time is less
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Takt Time calculation
Personal Fatigue and Delay
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94
Workcell Design
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ขนตอนท 2 : Operation Sequence &
Cycle time & Layout
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
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96
1 2
Receive Part from supplier
Incoming Inspection
3 Insert Battery to Body
Assy Lighting + Body 4
6 Reflector Sub-Assy
7 Len Sub-Assy
5 Plastic Cover + Pack
8
Reflector + Lean Sub-Assy
9 Ship
Process Flow
Takt Time = 3.00 Seconds
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97
Exercise
1 2
Receive Part from supplier
Incoming Inspection
3 Insert Battery to Body 50 TMU
Assy Lighting + Body 80 TMU
4
6 Reflector Sub-Assy 108 TMU
7 Len Sub-Assy 38 TMU
5 Plastic Cover + Pack
8
Reflector + Lean Sub-Assy 40 TMU
9 Ship 50
80
38
108
40
0
20
40
60
80
100
120
Battery + Body Body Kit +
Refector + Len
Kit
Len + Frame Bulb + Reflector
+ Cap
Refector Kit +
Len Kit
1 2 3 4 5
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98
Front Seat Process Flow
1 2
Receive Part from supplier
Incoming Inspection
3 Picking all parts
Load frame structure to
build pallet/Install silencer 4
5
6
Install back's foam to frame structure
Close out trim to Front Back
8 Install front cushion +
pan to frame structure 7
Load Cushion Foam to Pan
Close out trim to Cushion
10
9
11
12
Install plastic part
Install buckle Head Rest Sub-assembly
Install Head Rest
14 Steam
14 Final Inspection
15 Functional Checking
Plastic bag covering
16 Loading to Shipping Rack
17
18
Dock Audit
Ship to Customer
13 Install SAB
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Cy
cle
Tim
e in
Se
co
nd
s
1 2 3 4 5 6 7 8 9 10 11 12 13
Takt
Time X 60 Sec.
Required
Manning Operators
Optimal
Manning Operators
Operators
Available Production Minutes
Takt Time
Customer Requirements
Sum of Manual & Walk Times
Takt Time
Sum of Manual Cycle Times
Cycle Times vs. Takt Time Percent Loading Bar Chart
450 240
1.875 112.5
150
140
130
120
110
100
90
80
70
60
50
40
30
20 32
97.0
27
55 73
61 57 53 67
105 120
75
12
X 60
450 240
1.875 112.5
150
140
130
120
110
100
90
80
70
60
50
40
30
20
67
112.5
Example
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Process Layout Product Layout
Customer Focused/ModuleTeams/Business Units
Reduce WIP
Simpler Material Flow
Condensed Bills and Routings
Fewer Data Collection Points
Process vs.Product Layout
Traditionally the efficiency of individual operations was
considered more important than moving the product through
the total production process.
Workcell Design
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กระบวนการผลตทไหลซบซอน
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
ขนตอนการผลตไหลสลบไปสลบมาท าใหเกด Stagnation Time
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A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
ขนตอนการผลตไหลไดในทศทางทเปนเสนตรง Stagnation Time มนอย
กระบวนการผลตทไหลไมซบซอน
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U- cell / Linear Integration
U- cell / Linear Integration
U- cell / Ideal
Linear Ideal
High
Low
High Low
Varia
nces
Volume
Typical
Lean
Linear – U-cell Integration
![Page 102: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/102.jpg)
LOAD
ENTRY
Lin
ear L
ine
1
4
2
3
5
6
7
Integrated U-shape cell with Linear
Back Frame sub-assembly
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105
Right – Sized Equipment / Machine
Large Machine Small
Machine
Small
Machine
Small
Machine
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106
Capital Management
Product A
Time
Capacity, Cost
Large Machine
Small Machine
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Operation : Work Cell & Ownership concept
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108
Operation : Work Cell & Ownership concept
Proposed Design
IN OUT
IN OUT
IN OUT
IN OUT
IN OUT
IN OUT
IN OUT
IN OUT
IN OUT IN OUT
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Operation : Work Cell & Ownership concept Rev.2.0
Proposed Design @ 4200
R/M Supermarket
F/G Supermarket
Min-Max K/B
Air Cure 1 Hr
Drill Disassy Clean
Water Spider Internal Logistic
In- Line Process
Sep 11’2011 Rev 2.0
Sand Blast
End Plate Cutting
Sort Hopper
Hopper Seal
Drill Hopper
Refill Toner
Hopper+
Mag Roller + End Plate
Attach Clip Poka Yoke Picking Box
Remove Stricker
Silicone
Wiper Blade
PCR Cleaning
PCR+ Housing
Final Assy
Post Test Packing
Min-Max K/B
Remove Stricker
Production Control Board
Before After
No. of Operator 18 13
No. of Station 25 21
Distance ( meter )
( ไมรวมความถ )
448 0
Rework @ Post Test 30% 0%
Hight Light : 1. Poka Yoke Picking Box ( InprocessTray )
2. Closed loop @ Disassy + Clean
3. New design “ Sand Blast “
4. Send the current filling machine to additional modify
5. Small Wiper Blade 6. Process Excellence “ Change type of Silicone “
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Lot Production - Monthly
C
Month
Req. One Month
A
B
300
100
200
Model
100
200
300
One Month
A
B
C
100
300
200
50
100
150
50
100
150
Model Month
Req.
Lot Production - Semi-Monthly
Types of Production
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One Day
A
B
C
5
10
15
5 10
15
Month
Req. Model Day
Req.
300
100
200
Daily Production
FLOW
Day
Req. One Day
A
B
C
5
10
15
Model Month
Req.
300
100
200
Synchronized Production - Mixed Stream
Leveling Production (cont.)
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112
Leveling
Leveling
Executive Line Mixed Flow Line
Multi Flow Line
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ขนตอนท 3 : Poka Yoke Mapping
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
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123
Poka Yoke Mapping :
Operation
Description #1 #2 #3 #4 #5 #6 #7 # 8 #9 #10 #11 Rwk C/S H/R
Monitor
Touch Screen Monitor
Bar Code Scanner
Bar Code Printer
LPS Software
Poka Yoke Lighting
PLC Program + Wiring
ToolNet
Prevent for wrong part
Prevent for no torque
Prevent for wrong bolt
As of Aug 13’2009
Off-Line
![Page 122: Poka Yoke Mapping - Panyapiwat](https://reader031.vdocuments.net/reader031/viewer/2022032610/623a7a196d7475611545b4d5/html5/thumbnails/122.jpg)
System Architecture
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125
Poka Yoke Example : Pick to light
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126
Poka Yoke Example : Light to Pick
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ANDON SYSTEM
Because an image is worth a thousand words
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What does it mean?
In 'ancient' Japanese, Andon was a paper lantern (a handy vertically collapsible paper lampshade with an open top and a candle placed at the central section of the closed bottom). It functioned as a flashlight, a signaling device in distance, or even a commercial sign.
ANDON
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Definition: Plant floor process control and communication system used to signal abnormal or out of standard conditions.
ANDON
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So, why does it get used? In order to provide the ability for operators to call for assistance and obtain support to
contain build problems in station. Nowadays, Andon at many manufacturing facilities is an electronic device: audio
and/or color-coded visual display. For example, suppose an Andon unit has three color zones (red, green, and orange) and when the orange zone flashes with a distinctive sound, it calls the attention
and is signaling an operator to replenish certain material.
A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
Andon
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Andon display boards
ANDON examples
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Position of the lights above the line for Easy Visual Management
Signification of the lights (Scan Workstation) :
• Flashing Green >>>>>> Scan OK
• Flashing Orange>>>>>> Above Time
Andon flashing lights
ANDON examples
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In order to ensure a rapid response, each Team Leader
should have a small number of operators to manage
and that small team should be a group working
together to improve the quality in their cell! When one
workstation of the cell stops and the Andon alarms go
on, there’s no point in having the rest of the
workstations working – in fact, the other members of
the team should participate in finding the root cause of
the problem that caused the stoppage and put in place
mechanisms to avoid the same situation in the future
(eg: Poka Yokes).
ANDON
Be aware!
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1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
456200 997846 4981654
A107 A108
Audio signals (music/tones) provide audible
signals when Andon system is activated.
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Andon Visual Display Board Positioning (Overhead View)
FPS FPS FPS FPS FPS FPS FPS FPS FPS
FPS FPS FPS FPS FPS FPS FPS FPS FPS
“A” Line
Aisle
Aisle
Andon Display Board
Suspended Middle of Line
Marks
on
Floor
Work
Station
Lights
Viewable in
two directions
Fixed
Position
Stop
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LED Messages
Andon Call Line Stopped
Andon Call Line Running
Line Running Normal Operation
1 2 3 4 5 6
7 8 9 10 11 12
Emg.
Stop
Buffer
Full
Error
Proof Maint. Plan Actual
Front Seat Line
Unique tone or music
by team or area.
Error Proofing Device Fault
Emergency Stop
End of Line Buffer Full Maintenance Breakdown
Scheduled Production
Actual Production
A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
Workstation Stack Lights
Line Address Sign
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A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
Line Running
Normal Operation
No Andon Calls
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
Andon Call
Line Running
at 12th Operation
Andon Call
Line Stopped
at 12th Operation
Andon Workstation Light & Unique Audio Tone
A112
A112
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Line Running
Error Proofing Fault
at 1st Operation
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
1 2 3 4 5 6
7 8 9 10 11 12 Emg.
Stop
Buffer
Full
Error
Proof Maint.
Plan Actual
Front Seat Line
Line Stopped
End of Line
Buffer Full
Line Stopped
Error Proofing Fault
at 1st Operation
A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
A-107A-107
Andon
Stop
Andon
Call
Normal(No Call)
Over
Cycle
Andon Workstation Light & Unique Audio Tone
A101
A - 107
Andon Stop
Andon Call
Normal (No Call)
Over Cycle
A - 107
Andon Stop
Andon Call
Normal (No Call)
Over Cycle
A101
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ขนตอนท 4 : PFEP
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
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140
ขนตอนการประยกต PFES & PFEP
ขนตอนท 1 : Plan For Each Station ( PFES ) : ค านวณหาความตองการในแตละสถานงาน ( Lineside presentation requirement )
ขนตอนท 2 : Standard Packaging : ก าหนดมาตรฐานบรรจภณฑ ขนตอนท 3 : Plan For Every Part ( PFEP ) ค านวณปรมาณและความถในการสงของแตละชนงาน 1. Center supermarket
2. Signal
3. จ านวน Water Spider
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141
Foundation
• On-Hand Inventory considerations
• Bulk Storage requirement
• Central Supermarket requirement
• Line Side presentation requirement
• Material Flow planning
• Material Handling planning
• Pull System / Kanban
• Plan For Each Station (PFES)
What is it?
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142
• Requirements:
• Accurate Bill of Material (BOM)
• Accurate customer forecast
• Accurate “Weekly Component Schedule”
• Packaging dimensions
• Packaging Standard Pack quantities
What do I need to create it?
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143
ขนตอนท 1 : Begin to populate the PFEP spreadsheet
Part # Part Description Supplier Std Pck Cntnr Retrn
or Exp Container Size
Width
(cm) Length (cm)
Height (cm)
A001 Bracket Supplier 1 20 Return 12 24 10
• Row, Part Name, Part # & Color, Supplier, Std Pack
• Container info – dimensions, returnable or expendable etc.
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144
ขนตอนท 2 : Add usage data
Part # Part
Description Usage Part Delivery
Avg Wkly
Usage Avg Daily
Usage Cntrs per
day Station # Super
Market
(Y/N)
Sequence
(Y/N)
A001 Bracket 1,000 1,000/5 = 400 400/20 = 20 1 Y N
• Avg weekly use from actual customer schedule
• Station # and whether it’s a bulk or supermarket part
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145
ขนตอนท 3 : Line Side Calculations
Station # Part # Part
Description Min. Station side inventory Max. Station side inventory
Min. Inv.
Hours on
hold Min Inv Min
Contnr
Max. Inv.
Hours on
hold Max Inv Max
Contnr
1 A001 Bracket 2 (400/8) x 2 =100
100/20 = 5
4 (400/8) x 4 =200
200/20 = 10
• Assumes Min of 2 hours / Max of 4 hours
• Calculates requirements and rounds up to Standard Pack
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ขนตอนท 4 : Storage Calculations
Part # Part
Description
Part
Location at
supermarket
Inventory control - Supermarket
Max Inventory
Hours OH
~
Include Safety Stock
Max Inv.
Max Cntnr
Cntnr per
pallet
A001 Bracket A15 24 24 x 20 = 480 480 / 20 = 24 24 / 6 =4
• How many hours on hand (based on receiving schedule)
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• Layout Bulk Storage to actual utilization
• Layout Supermarket correctly
• Institute Kanban
• Max Line Side Column = # of Kanbans
• Develop flow lanes / delivery routes
• Consolidate material handling roles
• Control material / packaging handling
• Apply Visual Management techniques
ขนตอนท 5 : Apply the tools
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148
4527864 9973421
5673021 9856482
Small Lot Delivery to Workstation.
Returnable container with
lift handles or slots weighing
less than 20 kg. each.
Maximize Trailer Liquid Cube Utilization
ตวอยางการจายวตถดบ
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Lift Out Returnable Containers
Small Lot Delivery to Workstations
4527864 9973421
5673021 9856482
ตวอยางการจายวตถดบ
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150
Smart Manifest
Sequencing
Smart Manifest
Sequencing
Smart Manifest
Sequencing
In-Build Sequence Delivery from Supplier
Dolly Delivery to Workstation
In-Plant Build Order Sequencing
ตวอยางการจายวตถดบ
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151
4527864 9973421
5673021 9856482
Downsize (Repack)
to Smaller Containers
Downsize (Repack)
Bulk Sequencing
25
20
30
ตวอยางการจายวตถดบ
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Small Container Conveyance & Central Material Storage
Rack 1 Rack 2
B
A
B
A
B
A
Central Material Storage
Empty
Containers
X
Standardized routes delivering
small containers on a frequent
schedule (once per hour or less).
More frequent deliveries lower
material inventory at operations.
12 1 2
3
Overflow Only
B
A
Shelf Level
Designation
• Labels affixed to rack using Velcro
backed clear plastic pockets.
• Labels located directly below
containers on the front & back of rack.
• Label content includes: Part name,
Part number, Standard pack size,
Minimum and Maximum Quantity.
• Label size as defined
• Racks identified by section and
shelf levels.
Part: Side Shield
Part No: 9873214
Std. Pack: 60
Min. 2 Max. 5
CHI DET NY BOS PHI MIN
Returnable Container Sorting Area
Rack 3
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153
Work shop : Apply PFEP & PFES
Working Plan
Develop Master Data Base for Plan for Every Part (PFEP)
Std Pack Qty
Packaging Sizes
Packaging Type (Expired vs Returnable)
Receiving Frequency plus Safety Stock (Hours on Hand)
Develop Plan for Each Station (PFES)
Lineside Presentation
2 to 4 Hours where possible (Kanban Cards)
Plan for Bulk Replacement Signals
Develop Routing for Every Part - Bulk / Sequence / Mkt Place
Origin to Point of Use Routes
Material Handling Equipment Requirements
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154
Workshop PFEP & PFES
Working Plan ( Cont. )
Develop Material Storage Plan
Market Place Location
Bulk Storage Locations
Address System
Flow Racks, Straight Racks
Develop Inbound / Outbound Procedures
Receiving Schedule
Returnable Container Procedures (Freq / Ratio to Delivery)
Determine ManPower Requirements to Support Production
Lift Truck (Tow Motor) Personnel
Tugger
Marketplace Support
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Standard Packaging
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156
Standard Packaging
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157
Central Material Storage
Rack 1 Rack 2
B
A
B
A
B
A
B
A
Rack 3
Len
B
A
Rack 4
B
A
Rack 5
Frame Reflector Pole Battery
Rack 6
B
A
B
A
Body
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158
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ขนตอนท 5 : Supermarket :
Shopping Area
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
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A-107 Line “A” Designation
Product Designator:
- Front Row “100 Series
- Second Row “200 Series
- Third Row “300” Series
Sequential Line Space
Locator “07”
8.5 (inches)
3.5
” (
inch
es)
Page 6 of 13 Revision Date: 06/11/03
A-107
Andon
Stop
Andon
Call
Normal (No Call)
Over
Cycle
Linear Conveyor Sequential Address System Configuration
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A
B
C
D
A-1
01
A-1
02
A-1
03
A-1
04
A-1
08
A-1
05
A-1
06
A-1
07
A-1
08
A-1
06
A-1
07
B-1
01
B-1
02
B-1
03
B-1
04
B-1
08
B-1
05
B-1
06
B-1
07
B-1
08
B-1
06
B-1
07
C-1
01
C-1
02
C-1
03
C-1
04
C-1
08
C-1
05
C-1
06
C-1
07
C-1
08
C-1
06
C-1
07
D-1
01
D-1
02
D-1
03
D-1
04
D-1
08
D-1
05
D-1
06
D-1
07
D-1
08
D-1
06
D-1
07
A-108A-108A-108
8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft. 8 ft.
One Pitch (Footprint = 8 ft. spacing)
Sequential Line
Address Affixed
to Stack Lights
Front
Seat
Line
Second
Seat
Line
Third
Seat
Line
Other
Seat
Line
Linear Conveyor Sequential Address System Configuration
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A132 8.5 (inches)
3.5
” (
inch
es)
A132
Andon
Stop
Andon
Call
Normal (No Call)
Over
Cycle
Grid Layout Address System Configuration
A
B
1
2
3
1 2 3 1 2
A132
10
20
30
40
Feet
Column A1
Sub-section 3
Sub-section 2
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A-111
A-1
23
A-131
C-213
C-211
C-233
C-212
C-231
Grid Layout Address System Configuration
1 2 3 4 5
1 2 3 1 2 3 1 2 3 1 2 3 A
B
D
E
C
1
2
3
1
2
3
1
2
3
1
2
3
10
20
30
40
Feet
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Part: Adjuster
Part No: 9981427
Std. Pack: 90
Min: 1 Max: 3
Stack: 3 High
• Sign suspended directly above containers using wire, chain or conduit.
• Clear plastic sleeves used to protect sign.
• Type font size must be clearly visible.
• Sign content includes: Part name, Part number, Standard pack size, Minimum
quantity, Maximum quantity and Maximum stack height.
• Signs are 24 x 18 inches and font size must be adequate to make signs
clearly visible.
Central Material Storage Bulk Container Visual Aids
18’
Part:
Part No:
Std Pack:
Min. Max.
Stack:
18”
24”
Draft
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Small (Hand Delivery) Parts Central Material Storage
Part: Side Shield
Part No: 9873214
Std. Pack: 60
Min. 2 Max. 5
• Labels affixed to rack using Velcro backed
clear plastic pockets.
• Labels located directly below containers on the
front & back of rack.
• Label content includes: Part name, Part number,
Standard pack size, Minimum Quantity and
Maximum Quantity.
• Labels are 6 x 4 inches for standard flow
racks and 3 ½ x 2 ½ inches for pipe style flow racks.
• Racks identified by section and shelves.
Rack 1 Rack 2 Rack 3
C
B
A
C
B
A
Part: Side Shield
Part No: 9873214
Std. Pack: 60
Min. 2 Max. 5
6”
4”
Rack Label
Velcro Backed
Clear Plastic Laminate
Draft
3 ½”
2 ½”
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Small Container Presentation Visual Aids
Line Rack Labels
• Labels affixed to rack using Velcro backed clear plastic
pockets.
• Labels located directly below containers on the
front & back of rack.
• Label content includes: Part name, Part number, Standard
pack size, Minimum Quantity and Maximum Quantity.
• Labels are 4 x 6 inches for standard flow racks and
21/2 x 31/2 inches for pipe style flow racks.
Part: Bolt
Part No: 9958763
Std. Pack: 60
Min. 1 Max. 3
6
4”
Rack Label
Line Address Signs
• Attached to Stack Lights
• Alpha numeric numbering convention four (4) characters
- Spot 1: alpha line designator (e.g. “A” Line)
- Spot 2: numeric product designator (e.g. “1” = Front Row)
- Spot 3 & 4: numeric designator (e.g. “08” = 8th Space)
Line Flow Rack
(conventional style) Line Flow Rack
(pipe style)
Part: Side Shield
Part No: 9873214
Std. Pack: 60
Min. 2 Max. 5
Draft
A-108A-108A-108
Velcro Backed
Clear Plastic Laminate
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181
Central Material Storage
Rack 1 Rack 2
B
A
B
A
B
A
B
A
Rack 3
Len
B
A
Rack 4
B
A
Rack 5
Frame Reflector Pole Battery
Rack 6
B
A
B
A
Body
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ตวอยาง Supermarket
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ตวอยาง Supermarket
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ตวอยาง Supermarket
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Supermarket Design
Storage Address above pick point
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Adjustable gravity racks
Supermarket Design
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Safe. Well Guarded
Supermarket Design
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Supermarket Design
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189
Types of Expendable Packaging
• Interior Dunnage Types
– Layer pads
– Bags – LLDPE / HDPE
– Foam
– Partitions
• Bags
– Material Types
• Low Density Polyethylene
• Linear Low Density Polyethylene
• High Density Polyethylene
• Low and High Polyethylene
• Blend
• Silk Film
– Additives
• UVI
• Antistatic
• Slip
• Antiblock
– Colors
• Tints to Opaque
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190
Types of Returnable Packaging
Baskets
Dunnage
Pallets
Pallet Boxes
Racks
Totes
Trays
Sleeve Packs
Foam
Plastic
Steel
Wood
Returnable Product Types
Material Types
Options
Hot stamps, labels, & silk screen printing
Label placards/ Card Holders
Lids: Attached or detached
Colors
Collapsible
Stackable
Drain Holes
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191
32”L x 15”W x 7.5”H
24”L x 15”W x 7.5”H
*24”L x 15”W x 9.5”H
24”L x 15”W x 11.5”H
24”L x 15”W x 14.5”H
48”L x 15”W x 7.5”H
*12”L x 15”W x 7.5”H
12”L x 15”W x 9.5”H
24”L x 22.5”W x 7.5”H
*24”L x 22.5”W x 11”H
24”L x 22.5”W x 14.5”H
Selection Menu Standard Returnable Small Fixed-Wall Containers
Diversity recommended sizes for standardization
* Most common containers
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Collapsible Pallet Box
Standard Pallet Box Sizes
32”L x 30”W x 25”H
32”L x 30”W x 34”H
48”L x 45”W x 25”H
*48”L x 45”W x 34”H
Extended Length Pallet Box Sizes
64”L x 48”W x 25”H
64”L x 48”W x 34”H
70”L x 48”W x 25”H
70”L x 48”W x 34”H
Selection Menu Standard Large Returnable Containers
Diversity recommended sizes for standardization
* Most common container
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193
Benefits of Returnable Packaging
• Cost Savings
– Material
– Labor
– Disposal ( จ าหนาย )
– Elimination of Dunnage กนกระแทก • Environmental Issues
– Minimize the amount of waste sent
to landfills • Facility Maintenance Issues
– Cleaner and more functional plant
– Improve safety and ergonomics
– Increase floor space
– Easier Handling
– Common Sizes/Standardization
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194
How Packaging Impacts Supply Chain
• Material Flow
– Inbound from Suppliers
– WIP (Work In Process)
– Outbound to Customer
• Inventory
– Levels and turns
– Lean Manufacturing practices
– Pull system
• Logistics
– Trailer density
– Frequency of delivery (JIT)
• Line Presentation requirements
– Space constraints – Height, floor layout,etc.
• Ergonomics
– Weight
– Handling
– OSHA Requirements
• Packaging Guidelines
– OEMs and Tier Suppliers can have their own packaging guidelines for incoming product.
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ขนตอนท 5 : Routing :
Water Spider
5 ขนตอนในการสราง กระบวนการใหไหลอยางตอเนอง
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1. จายตามเวลา : Fixed Peroid Supply การขนสงแบบก าหนดเวลาไมก าหนดปรมาณ เชน รถไฟ
3. จายตามล าดบ : Sequencial Supply
การปอนแบบเตมตามจ านวนใช ปอนชนสวนตามจ านวนทถกใชไป
การปอนตามล าดบ ปอนชนสวนตามล าดบการผลตในจ านวนทแนนอน
2. เบกจายตามจ านวน : Fixed Quantity Supply การขนสงแบบก าหนดปรมาณไมก าหนดเวลา เชนรถตไมเตมไมออก
ประเภทของการขนสง
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Tugger & Dolly
180 Degree turn inside 10 Feet !!
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Tugger & Dolly
Each Line / Area has own dolly
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199
4527864 9973421
5673021 9856482
Small Lot Delivery to Workstation.
Returnable container with
lift handles or slots weighing
less than 20 kg. each.
Maximize Trailer Liquid Cube Utilization
ตวอยางการจายวตถดบ
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200
Lift Out Returnable Containers
Small Lot Delivery to Workstations
4527864 9973421
5673021 9856482
ตวอยางการจายวตถดบ
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Smart Manifest
Sequencing
Smart Manifest
Sequencing
Smart Manifest
Sequencing
In-Build Sequence Delivery from Supplier
Dolly Delivery to Workstation
In-Plant Build Order Sequencing
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4527864 9973421
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Downsize (Repack)
to Smaller Containers
Downsize (Repack)
Bulk Sequencing
25
20
30
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Small Container Conveyance & Central Material Storage
Rack 1 Rack 2
B
A
B
A
B
A
Central Material Storage
Empty
Containers
X
Standardized routes delivering
small containers on a frequent
schedule (once per hour or less).
More frequent deliveries lower
material inventory at operations.
12 1 2
3
Overflow Only
B
A
Shelf Level
Designation
• Labels affixed to rack using Velcro
backed clear plastic pockets.
• Labels located directly below
containers on the front & back of rack.
• Label content includes: Part name,
Part number, Standard pack size,
Minimum and Maximum Quantity.
• Label size as defined
• Racks identified by section and
shelf levels.
Part: Side Shield
Part No: 9873214
Std. Pack: 60
Min. 2 Max. 5
CHI DET NY BOS PHI MIN
Returnable Container Sorting Area
Rack 3