hoshin

Hoshin Kaizen Workshop esettanulmny a standardok igazi erejePczely GyrgyA.A. Stdium Kft.

TartalomElzmnyekFelmrsA workshop magaBemelegtsA munkaZrsA feladatok nyomonkvetseTanulsgok

ElzmnyekGarzsvllalkozsbl 500 fs cgFrancia anyavllalat egy ve vette t a vezetstFejetlensgTallkoz az eurpai vezetvel: konkrt ignyek

Felmrs140 elem lista alapjn(kicsit ksn)Feladatok, felelskkel, hogy a kezds rendben legyenA terlet megismerseA termk megismerseA f clokMunkaer megtakartsBelsrsz gyrts beintegrlsa a sorba

A dolgozk mondtk

A workshop maga - bemelegtsA megjelentek (meg nem jelentek) beosztsokBemutatkozsKaizen szemllet

Felejtsd el az eltleteket, dogmkat! Ne abbl indulj ki, hogy a dolgokjelenleg hogyan mkdnek! Ahelyett, hogy azon gondolkozol, hogy valamit mirt "nem lehet megcsinlni", inkbb talld ki, hogy hogyan lehetne megvalstani! A j fejlesztsi tleteket azonnal valstsd meg. Keresd a tkletessget, de ne vrakozz emiatt, valstsd meg a 60 %-ot. Azonnal orvosold a problmkat a keletkezsk helyn. Alapelvek

A nehzsgekbl nyerj j tleteket. Keresd a kivlt/gykr okot, hasznlj elemzsi technikkat, s talld meg a megoldst. Inkbb hasznld fel 10 ember tleteit, minthogy egytl vrd a zsenilis megoldst. Prbld ki a megoldsokat, majd ellenrizd az eredmnyeidet. A fejlds sohasem r vget. Alapelvek

Bemelegts 5SHogy jn az 5S a Hoshinhoz?

Piros cmkk 80 feladat

Szemllet = nem j gy, ahogy van!

Workshop a munkaJelen llapot feltrkpezseTermkek (referencik) mennyisgek Vevi igny, temidSzksges alapanyagokCiklusid mrsek (tllsok)

Diagram1

96119142139165

63135140139165

6597130139165

78137196139165

139165

139165

139165

139165

139165

139165

min

tlag

max

TCT

TT

His

Production

Measurement of Cycle TimeFAU-F-PSG-5009/EN

IssueDateDescription of ChangesCancels or replaces

3Feb. 2010Unique document for all types of Cycle Time measurementFAU-F-PSG-5009issue 2

AuthorJean-Michel Colin, Group Production System

Verified by

OwnerJean-Michel Colin, Group Production System

Approved byAlain Prioul, Group Industrial SVP

&LPlease check that you have the latest version of this documentInternal. Property of Faurecia&RIssue 3 - February 2010&"Arial,Gras"&12&"Arial,Normal"&10FAU-F-PSG-5015/EN

Related Documents

- Hoshin Methods Guide FAU-S-PSG-5001- SW Methods Guide FAU-S-PSG-5025

Purpose This standard Form is the template to measure Cycle Time

Scope All Faurecia plants

Ill


HERE THE INFORMATION ABOUT THE ORGANIZATION OBSERVED: WHICH OPERATOR ON THE LINE (E.G. 2 ON 3) AND THE MODEL (E.G. LINE SETUP INDICATES THE TOTAL NUMBER OF OPERATORS WORKING IN THE LINE).

IMPORTANT INFORMATION TO BE KNOWN ESPECIALLY FOR STANDARDIZED WORK EXERCICE: NAME OF THE OPERATOR OBSERVED.

THIS DETAIL OF WORK SEQUENCE AND MEASURING POINTS WILL BE USED AFTER TO BUILD WORK INSTRUCTION AND STANDARDIZED WORK COMBINATION TABLE AND CHART EXCEPT FOR THE WALKING WHICH CAN BE MEASURED SEPARETELY (WALKING IS NOT AN MANUAL OPERATION). WHEN WALKING IS INCLUDING IN AN OPERATION TIME, USUALLY WE SPLIT WITH THE RULE 1M=1S.

WHEN YOU HAVE SYSTEMATIC WAITING TIME IN THE CYCLE, YOU HAVE TO MEASURE IT AS PART OF THE WORK SEQUENCE.

QUALITY CHECK CAN BE EASILY HIGH-LIGHTED BY USING QUALITY SYMBOL.

MINIMUM REPEATABLE CYCLE TIME IDENTIFIED ON 20 CONTINUOUS MEASUREMENTS.

sszellt

MEASUREMENT OF CYCLE TIME

PRODUCT:OPERATOR N:LINE SETUP:S-Klasse

PROCESS:ANALYZED BY:

DATE:.TIME:OPERATOR'S NAME:

NELEMENTARY OPERATIONS1234567891011121314151617181920Aver.MinMaxV %

1Schale megfog82858179767774876978.9698721%

Elszerel astalra rak

2Gomboccsvet berak0.0000%

Vrakozs252421214320391811

3meFggny nylik26141919172015171818.3142646%

Kivesz, kalibrl lerak ST asztalra , betesz

4Megnyom Brdel gombot15151714151210171414.3101741%

Elkszt ST re

5Bilincset rak6667646776.14743%

Sta vissz

6a

7MP:

8MP:

9MP:

10MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)154144144140157133144146119142.3333333333157

CT WITHOUT WAITING129120123119114113128108108

OBSERVATIONSd

ae

bf

cg

MP: Measuring PointVariance (%): V = ((M-m)/m) x 100

Stichlock AWI


PRODUCT: 8608101OPERATOR N: 2LINE SETUP:S-Klasse 3 opertor

PROCESS: Stichlock, AWIANALYZED BY: Pczely Gyrgy

DATE: 2011.05.12.TIME: 18:50OPERATOR'S NAME:


1Stichlock ajt felnylik7878972212149810.172268%

Sticklockbl kivesz, AWI-ra tesz

2Belp a Stichlock terletre7111110111227119129.421283%

Haltert pozcionl

3Dob megfog122023191919361919181820.2123667%

Dobot stichlockba berak, indt

4AWI-ra vr termk megfog645579616574765258364260.2367954%

AWI-zs

AWI-zott termket lerak40.2226767%

Robotra vr3645243938282240436760

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)12613914413714214015813014513980140158


OBSERVATIONSd

ae

bf

cg


Lgvesz vgellen




DATE:TIME:OPERATOR'S NAME:


1Lgvesztesg ellenrzbl kivesz19181518171413161816.4131932%

Pecst, r, vgellenrzbe tesz

2AWInl lev termk megfog1114131413141291112.391436%

Lgteszterbe rakja a termket

3Lgteszt indt18222323242321122621.3122654%

Kszlkes ellenrzs

4Vizulis ellenrz megfog20212325272722313125.2203135%

Vizulis ellenrzs kezds

Termk megfog12121210111112111011.2101217%

Csomagols

Lgveszts ellenrzhz rkezik52.6347454%

Vrakozs34373474537462

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)8012112312416614215414196127.4444444444166


OBSERVATIONSd

ae

bf

cg


TT ; CTC

xtc

Industrial data

Available operation time (work time) = "Operating time - (breaks + meetings) "

Operating timeBreaksAvailable operation time (work time)

Morning shift50060440

Afternoon shift50060440

Night shift44055385

Daily operating work time1265.0

Weekly operating work time6325.0

No. Of workdays5

Weekly customer demand2300

TT_Takt Time [sec] =165.0

2. TCT_Cl Ciklusid = Tnyleges heti operatv(munka) id/ Tnyleges heti igny

2323

Selejtarny (%)1%

5408

Changeover time %10%

Non-planned stoppage time %5%

TCT_Target Cycle Time [sec] =139.7

PPH =25.8

CTD

Cycle Time DiagramLine:Colorado 1

FAU-F-PSG-5010/EN

Previous statePlanned stateMeasured state

Date:Date:Date:

Dolgoz123456789TotalStation12345678910TotalStation12345678910Total

min96636578302min1289678302min1087279

tlag11913597137488mean0mean142140127

max142140130196608max0max157158166

Sys.WartenSys.WartenSys.Warten

Observations:Observations:

Number of good products [pcs]/person/hrVals id (Real time)Number of good products [pcs]/person/hrVals id (Real time)Number of good products [pcs]/person/hrVals id (Real time)

TCT139139139139139139139139139139TCT139139139139TCT139139139

TT165165165165165165165165165165TT165165165165TT165165165

CTD

min

tlag

max

TCT

TT

RL

_______ Takt id --------------- Target Cycle Time

min

mean

max

TCT

TT

_________ Takt time --------------- Temps de cycle

_________ Takt time--------------- Cycle time

robot 2

calibration

halter welding

preassy

welding

pre assy welding

engraving

5

Op1 Point weldingOp2 Inner part weldingOp3 Inner part welding (outgoing tube)Op4 Riveting Op5 Robot & ReworkOp6 Halter-weldingOp7 Halter-weldingOp8 AWI repairingOp9 Leakage testing, Final inspection, Packaging

_______ Takt id--------------- Target Cycle Time

Op1 Pre-assembly, Change Brdel product, calibrating, preparing to stichlockOp2 Serving stichlock robot, AWI weldingOp3 Leakege testing, final inspection, packaging

min

mean

max

TCT

TT


j Layout

MBD0003E9F1.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

MBD0003D203.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

Workshop a munkaA jv llapot megtervezseA munkk jraelosztsaLean vesztesgek kikszblse cljbl

j Layout

Diagram2

128139165

96139165

78139165

139165

min

mean

max

TCT

TT

His

Production





Verified by




Related Documents




Ill








sszellt






1Schale megfog82858179767774876978.9698721%



Vrakozs252421214320391811

3meFggny nylik26141919172015171818.3142646%



Elkszt ST re

5Bilincset rak6667646776.14743%

Sta vissz

6a

7MP:

8MP:

9MP:

10MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)154144144140157133144146119142.3333333333157


OBSERVATIONSd

ae

bf

cg


Stichlock AWI









Haltert pozcionl

3Dob megfog122023191919361919181820.2123667%



AWI-zs


Robotra vr3645243938282240436760

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)12613914413714214015813014513980140158


OBSERVATIONSd

ae

bf

cg


Lgvesz vgellen










3Lgteszt indt18222323242321122621.3122654%

Kszlkes ellenrzs



Termk megfog12121210111112111011.2101217%

Csomagols


Vrakozs34373474537462

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)8012112312416614215414196127.4444444444166


OBSERVATIONSd

ae

bf

cg


TT ; CTC

xtc

Industrial data





Night shift44055385



No. Of workdays5




2323

Selejtarny (%)1%

5408




PPH =25.8

CTD


FAU-F-PSG-5010/EN


Date:Date:Date:


min96636578302min1289678302min1087279

tlag11913597137488mean0mean142140127

max142140130196608max0max157158166




TCT139139139139139139139139139139TCT139139139139TCT139139139

TT165165165165165165165165165165TT165165165165TT165165165

CTD

min

tlag

max

TCT

TT

RL


min

mean

max

TCT

TT



robot 2

calibration

halter welding

preassy

welding

pre assy welding

engraving

5




min

mean

max

TCT

TT


j Layout

MBD0003E9F1.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

MBD0003D203.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

Diagram1

108142157139165

72140158139165

79127166139165

139165

min

mean

max

TCT

TT

His

Production





Verified by




Related Documents




Ill








sszellt






1Schale megfog82858179767774876978.9698721%



Vrakozs252421214320391811

3meFggny nylik26141919172015171818.3142646%



Elkszt ST re

5Bilincset rak6667646776.14743%

Sta vissz

6a

7MP:

8MP:

9MP:

10MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)154144144140157133144146119142.3333333333157


OBSERVATIONSd

ae

bf

cg


Stichlock AWI









Haltert pozcionl

3Dob megfog122023191919361919181820.2123667%



AWI-zs


Robotra vr3645243938282240436760

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)12613914413714214015813014513980140158


OBSERVATIONSd

ae

bf

cg


Lgvesz vgellen










3Lgteszt indt18222323242321122621.3122654%

Kszlkes ellenrzs



Termk megfog12121210111112111011.2101217%

Csomagols


Vrakozs34373474537462

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

MP:

CYCLE TIME (CT)8012112312416614215414196127.4444444444166


OBSERVATIONSd

ae

bf

cg


TT ; CTC

xtc

Industrial data





Night shift44055385



No. Of workdays5




2323

Selejtarny (%)1%

5408




PPH =25.8

CTD


FAU-F-PSG-5010/EN


Date:Date:Date:


min96636578302min1289678302min1087279

tlag11913597137488mean0mean142140127

max142140130196608max0max157158166




TCT139139139139139139139139139139TCT139139139139TCT139139139

TT165165165165165165165165165165TT165165165165TT165165165

CTD

00000

00000

00000

00000

00000

00000

00000

00000

00000

00000

min

tlag

max

TCT

TT

RL


min

mean

max

TCT

TT



robot 2

calibration

halter welding

preassy

welding

pre assy welding

engraving

5




min

mean

max

TCT

TT


j Layout

MBD0003E9F1.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

MBD0003D203.vsd

MAG

belsrsz

lgteszter

vgellenrz

WIG

csszda

elszerel

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

belsrsz

Shoot

kalibrl

AWI

asztal

asztal

Els OK db

S-klasse 2

Red bin

Re-work

Fixtures 2

storing

storing

storing

Re-work

PPOH

Workshop a munkaA bels rsz gyrts thelyezse

Megoldhat, bebizonytottuk

MAG

belsrsz

204 9625 101

csszda

255

csszda

3

Robot time: 103 sec

table

table

Robot

Fixtures

Fixtures

Shoot

Shoot

Shoot

Fixtures 2

storing

storing

storing

Lgteszter/gravroz

WIG

AWI

kalibrl

elszerel

asztal

asztal

start

Els OK db

Red bin

Re-work

PL-6

PC

Kis bels heg

nagy bel heft

Kis bels heg

csszda

PPOH

Re-work

Re-work

Workshop - zrsFeladatok sszersaHosszabb tv feladatok

A workshopon megkezdett munkk befejezse

74 feladat

Workshop - eredmnyekMegtakartsok:1. Termkcsald: 4 helyett 3 dolgoz 25 %2. Termkcsald: 5 helyett 4 dolgoz 20 %

Sikeres?

A feladatok nyomonkvetseA kvetkez munkanapon a workshop kulcsfigurja tvozik a vllalattlLegtbb tapasztalatSok felvllalt feladatA gyrtsor a rgi ltszmmal indul elAz j projektvezet lelkes, DE

Nem haladnak a feladatok

Workshop feladatkvet megbeszlsMegbeszlst szerveztnk a workshop rsztvevivel1 f jelenik megFogalma sincs a feladatairl

????

Hinyzik a vllalati kultra?

Kvetkez lpsek Az eurpai vezet elgondolkodik

Taln nem Hoshinnal kellett volna kezdeni (az eltvoltott kollgk vlemnye)Dnts:5SVSM workshop (hogy tlssk a teljes folyamatot)

TanulsgokA vllalati kultra fontossga (szalmakunyhra bramack cserp tett?)

Cameron-Quinn

Hangsly a munka sornelksztsels lpsekbevezetsKlnAdhokrciaPiacHierarchiaBizalomCsapatszellemKlssgekRugalmassgRendszerptsWorkshopokEredmnyekBeszmolkGrdlkenysgPontos tervTervnek megfelelsFokozatossg

Tanulsg a projektek hrom dimenzija

TanulsgokNe egy kalapccsal akarjunk minden szget

Higgynk a beosztottainknak, krjk ki a frontvonalon levk vlemnyt (fejlesszk ki ezt a kpessget)

(Krjk ki a tancsad vlemnyt, bzzunk a tapasztalatban)

Ksznm a megtisztel figyelmet