respect for poduct - guidelines manual

8/6/2019 Respect for Poduct - Guidelines Manual

1/26

June 07, Ver 0

1

Toyota Rules

A BIG PART of ELIMINATING WASTE consists ofpreventing defects.

Defective products entail a grievous waste of humanresources, equipment, and material. And measures

for eliminating waste by preventing defects are adefinitive feature of the Toyota Production System.

By identifying waste and eradicating it, companiescan reduce their costs.

Excerpts from THE TOYOTA PRODUCTION SYSTEM

-Sakichi Toyoda; Kiichiro Toyoda ,Taiichi Ohno


2/26

June 07, Ver 0

2

Contents

Respect of Product What 3

Why RoP ? 4

RoP for all functions 5

How To ? 6

RoP deployment Step1 24



Receiving Damaged Pallet 7

Good Example 8

Proper Protection 9 Clean Containers 10

Line Supply Component Stick Out 11

In process protection 12

Piled Material 13 Part Drop 14

Clean trolley and container 15

Process Secure clean holder 16

Identified Place 17 Incomplete Set 18

Unnecessary Stock 19

Reject Part Handling 20

Tool Misuse 21

Warehousing 22 Storage and Shipping 23

Contents List of Pictures and Templates


3/26

June 07, Ver 0

3

Respect for Product What ?

To continuously improve Quality & Productivity, theworkplace has to be clean and components in the rightcondition so that operation can be done with zero defect

mind set. Respect for Product is a set of preventive rules to

maintain integrity of product/component during alloperations starting from suppliers to customers

Rules for Respect for Product are simple to implementand a matter of common sense

Application of Respect for Product rules iscomplementary to 5S

It is the foundation stone for APS implementation

Respect for product at each stage of the process isMandatory and essentially a matter of vigilance

RoP : Respect for Product


4/26

June 07, Ver 0

4

Why Respect for Product ?

It gives good visibility of product/component for qualityevaluation

Easy to count

Easy to store & handle Easy to maintain cleanliness

Easy to identify damaged product/component

It is reproducible and therefore sets standards for producthandling & movement

It is a necessary condition for getting Zero Defects

At each stage of the process it is essential to implement RoP to thesmallest detail

End of line rejects

Parts in damaged packets sent to Customer is a logistic incident

Parts not packaged correctly will lead to noise, leakage due toimpact and dents, visual defects


5/26

June 07, Ver 0

5

RoP for all Functions

Precaution during manufacturingProcess

Handling & re-integration in product cycle

Delivery for prototype and initial samples

Logistics contract packagingPurchasing

Non-acceptance of abnormal situations whatever they may beManagement

Withdrawal of products for analysisLaboratory

Assembly recommendation for customerProject

Arranging for prototype, tooling & packaging designR&D

RoP Applicable inFunction

Examples of Areas where RoP is applicable for different functions


6/26

June 07, Ver 0

6

How to ?

RoP Is applicable across operations

Receiving & Warehousing Line Supply

Process

Storage

Shipping


7/26

June 07, Ver 0

7

Receiving*

Damaged pallets and boxes shall not enter in the plant

Properly protected against dents, shocks, dust, water, chemicals.

Damaged Pallet

Should be discarded


8/26

June 07, Ver 0

8

Receiving

Door protects from dust,

humidity and tampering

Individual parts

arranged in an array,

well separated

Incoming

Material Bins

with Cover

Good Example


9/26

June 07, Ver 0

9

Receiving*

Properly protected against dents, shocks, dust, water, rust, chemicals

Rusted Parts not acceptable


10/26

June 07, Ver 0

10

Receiving

Dirty or damaged returnable containers must either be cleaned or discarded

Dirty and damaged

container to berejected Clean Containers


11/26

June 07, Ver 0

11

Line Supply

No parts or components should stick out of the container

Good Packing StandardNot Acceptable - Parts Sticking out


12/26

June 07, Ver 0

12

Line Supply*

Materials supplied to the production line are properly protected

Protected against scratch, dents, greaseExposed part liable to damage


13/26

June 07, Ver 0

13

Line Supply

The supply of components to the line piled together is not acceptable

Material Piled Together


14/26

June 07, Ver 0

14

Line Supply

A part drop on the floor is immediately scrapped

Part to be Scrapped


15/26

June 07, Ver 0

15

Line Supply

Clean containers

Trolley & Bins are changed now dust

and oil will not stayDust & Oil stays at bins and trolley


16/26

June 07, Ver 0

16

Process*

Each part should be placed in a secure clean holder - during productand process development supports are clearly defined and validated

Part not in proper place All parts on proper holder


17/26

June 07, Ver 0

17

Process

Each Standard parts should be placed in an identified clean place

Product Identification

for assigned storage

area


18/26

June 07, Ver 0

18

Process

Appearance parts should be handled with clean gloves No incomplete sets of components Unless finished do not use

components from other sets

For similar parts (below), use

from container 2 only when

container 1 gets empty

2

1


19/26

June 07, Ver 0

19

Process

Zero illegal stock (unnecessary stock) between workstations

Specific holders /supports /packaging should be used for sub-

assemblies stocked between two workstations

Specific holder for in process tubes

Illegal Stock


20/26


21/26

June 07, Ver 0

21

Process

No use of tools not specified by the standard (work instruction,maintenance, )

Parts cannot be used as tools to put nuts, bolts, grease, washer othercomponent

Improper use of tools piston

rod being used as a hammerProper Tool

being used


22/26

June 07, Ver 0

22

Warehousing

Good Example

Products inside the bin with

separators preventing

physical contact and

associated damages


23/26

June 07, Ver 0

23

Storage and Shipping

Zero illegal storage of containers in other parts of the plant Containers should protect products from damage

Damaged containers shall not leave the plant

Damaged Cartons.Stacking Rules violated

Not to be shipped

Stack Height Limit

Zone for Stacking

ID Labels

Handling precautions


24/26

June 07, Ver 0

24

RoP Deployment Step1

Each department/line/cells evaluate the status in regard of the best practice

Extension to suppliers and

customers

No example of non respect

for the product

Green

Application of the Best

Practice is auditedBlue

Best Practice customized

with pictures of the plant

situation

Communication and trainingdone to the all employees

Formal deployment is

defined

Yellow

No formal deploymentRed

ConditionsStatus


25/26

June 07, Ver 0

25

RoP Deployment Step2

Official launch by Management communicatingthe objective to the site

Micro training sessions with practical application

in the field Each cell defines 10 rules according the Best

Practice.

Operator and Supervisor should identify on their owncells the root cause which can generate defect duringprocess operation

Action plan to implement the corrective actions

needed is set up and followed up These rules become a part of standards

These rules are incorporated in the workstation

and line and audited during process audit


26/26

June 07, Ver 0

RoP Deployment Step 3

Applicable to Suppliers Everything arriving in our plants from suppliers should be

faultless

All defective products and containers should be sent back to

the supplier Product Respect rules must be integrated into the

purchasing standards of products

Qualification of product/process must include compliancewith Product Respect rules

Applicable to Customers :

Project Manager should communicate to the customerrecommendations for Customer product storage and handling conditions

Movement of products between the warehouse and the customers

production lines Proper use of the product on the customers production lines.

respect for poduct - guidelines manual

Documents