otrs@naver.

com KAIZEN ROADMAP

TAKT/Customer Capacity/TOC Load /Line Value Stream

Demand Analysis Balance Analysis Mapping

(As-is) (As-is) (As-is & To be) Understand

Understand VOC Understand current Understand current current Process
situation/Baseline situation/Baseline

Spaghetti Map

(As-is & To be)

On-going Cell
Continuous Develop Design/Develop
Improvement Continuous Flow New Layout

Waste elimination (To be)

Cost down
1. VOC- Takt time KAIZEN ROADMAP

•Takt Time = Demand Rate

Available time
Takt Time =
Requested Qty

Ｂ
① Ａ
 2. Capacity analysis KAIZEN ROADMAP

VOC vs Capacity vs Output Customer demand

18000 capacity
16000 Real output
14000

12000

10000

8000

6000

4000

2000

0
Jan Feb Mar Apr Maj Jun Jul Aug Sep Okt Nov Dec
3. Load/Line Balance KAIZEN ROADMAP
Load/Capacity cumulative
600 540(Capacity)

500

400 360(Capacity)
360(Load)
300 242(Capacity)

200 180(Load) 135(Load)

100

0 Machine B
Machine A Machine C
(3pc) (3pc) (2pc)

A、For machine B load exceed its capacity(242-180=62H);

B、To keep OTD it should arrange overwork time 62H for machine B(Load/capacity adjustment)
 3. Load/Line balance KAIZEN ROADMAP

35.0 Utilization
T.T=33 loss
30.0
TOC 25.0 29.0 29.2
=29.2 26.2 27.0 26.5 28.0
24.2 23.0
20.0 22.0 Balance
loss
15.0

10.0

5.0

0.0
01 02 03 04 05 06 07 08 09

Line balance(%)=(∑C.T/∑29.2*n ) × 100%=89.5%

Line balance loss (%)=1-Line balance(%)=10.5%
 3. Load/Line balance KAIZEN ROADMAP
9.7 9.7 Over-WIP and waste will generated if line 9.7
not balanced
7.0
Bottleneck
5.4
EOLR

Bottleneck
5.4

Knitting Dipping 2nd Washing/drying Heat transfer marking Packing

Line balance(%)=(Capability 5.4*n/∑capability ) × 100%=52.7%

Line balance loss (%)=1-Line balance(%)=47.3%
Production loss=Average capability-current capability= 8.3- 5.4=2.9
 KAIZEN ROADMAP
Capacity calculation---EOLR

Process Process 1 Process 2 Process 3 Process4 Process5

Capacity 100 pc/H 75pc/H 110pc/H 80pc/H 125pc/H

DTD=26 day?
MCT=308sec(25 person?)
Pcs C/T=? sec
4. Value Steam Mapping KAIZEN ROADMAP

Supplier VSM-Current Customer

Monthly demand:11000pr?
Daily demand: 500 pr?
Forecast
Production Control
(2 months)
Daily Order
Weekly MRP
FAX

Daily Ship Schedule

Weekly Schedule

Distance? Distance? Distance?

EOLR? EOLR? EOLR?

?
Cutting sewing Forming EOLR? Packing
RAW FINISHED
MATERIAL C/T=?(TCT1) C/T=?(TCT2) C/T=?(TCT3) C/T=?(TCT4) GOODS
People: ? People:? People: ? People: ?
Uptime=? Uptime=? Uptime=? Uptime=?
C/O=?min C/O=?min C/O=? C/O=?
Batch size=? Batch size=? Batch size=? Batch size=?
FTY=? FTY=? FTY=? FTY=?
Shift:1 (8H)? Shift:1(8H)? Shift:1(8H)? Shift:1(8H)?
WIP? WIP? WIP? WIP?
10days? 3days? 1day? 2days? 10days?
80sec? 140sec? 30sec? DTD=26days?
58sec?
VA=308 sec?
VAR%=VA/DTD*100%=?
5. Spaghetti Map KAIZEN ROADMAP
Different factory comparison
Non-Flow VS. Flow
Non-Flow Flow

Part Parts
A A&C

Part
B
Parts
Part B&D
C

Part
D Part
E
Part
E
5. Spaghetti Map KAIZEN ROADMAP
Material Flow in a Process-Orientated Layout
Traditional Layout

Machines grouped together according to their function

5. Cell Design EXAMPLE KAIZEN ROADMAP

17 Workshop Layout
Cast Clean Bench Area Tumble
16
5
7 12
1 Inspection 8
6

Drill Area Mill Area

10 2

13 4

FPI
9
Broach

3
Heat Treat
14 11

Shot/Glass Peen

15
Cell Design KAIZEN ROADMAP
 Layout Improvement KAIZEN ROADMAP

To WIP room From RM pile Lathe 1

Lathe Mill
3 2
Lathe 2
RM house
Grinder Grinder Mill Grinder Lathe Roll
6 5 2 4 1 8
Grinder 4

Grinder 5

Grinder Semi-FP/FP house

7

Lathe Lathe Grinder Grinder Grinder

3 1 6 6 6

Before After