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SUMITOMO RUBBER THAILAND
TORU KIRA (TUMSAT)
SAKDA JAMPASA (CU)
Presented by
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Our Safety Motto
When I cross road, I point both side by fingers
I will always keep the rules during the operation
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Introduction of company
Finding Issues
KAIZEN
Conclusion
OUTLINE
President Mr. Toru Nagahata
Foundation May 2005
Products
Capacity 78,150 pcs/day
Co-workers 6354 including 35 Japanese
Introduction of company
Tires
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Tire production process
Primary Production
Material
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Inspec.
Steel & Textile
Mixing
Extruding
Topping
Building Curing
Material process
Tire components
Tread JLB
Breaker PLY
SW
Bead
Inner Chaffer
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
WOA=WORK OBSERVE ACTIVITY
Study of
KAIZEN
Observe
Check
time
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
How to do WOA
Analyze
Data
Discussion
Find KAIZEN
Points
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
How to find KAIZEN
3M
Muda
Mura Muri
Actual
Takt time,
620.2
Target
Takt time,
600 595
605
615
625
635
645
Sec
/rea
l
Yamazumi chart of Inner Chaffer #1 S
ec/r
eal
How to reduce
Baratsuki
Baratsuki is variance of data.
Lot change, 352
STD Time Baratsuki % Loss
Cycle time 203 17.2 74%
CF Change 22 0.8 3%
Lot Change 352 5.2 23%
Total (sec) 577 23.2 100%
Baratsuki cycle (sec)
Length/reel 9.2
Operation 8.0
Total 17.2 sec
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Data analysis
17.2
17.2 sec KAIZEN
Finding KAIZEN
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
What is KAIZEN point?
Manual doesn’t instract the timing of checking
the width of Inner Chaffer
Timing is different depending on operators
Baratsuki
Layout pathways of operator
CHULALONGKORN
UNIVERSITY
Tokyo University of Marine
Science and Technology
Quality Safety Stock Starting : setting Liner
Finish : Stock Mat.
A B
step Pathway A Hand Auto
4 Setting CF 5 Auto 21 6 Check WID#1 12 7 Auto 59 8 Check WID#2 12 9 Auto 92
10 Check WID #3 13 Total 37 172
step Pathway B Hand Auto
4 Setting CF 5 Check WID#1 6 6 Auto 99 7 Check WID#2 12 8 Auto 73 9 Check WID #3 13
Total 31 172
PC
11
7
5
9
4 6 8 10
PC
10
6
8
4 5 7 9
A
B
Comparison of layout pathways
Before After
Max.Barastuki 80 80
Lot Change 352 352
CF Change 22 22
Cycle time 203 203
Actual Takt time 620.2 613.6
Target Takt time 600 600
Avg.Baratsuki 25.2 18.6
Cycle time, 203 Cycle time, 203
CF Change, 22 CF Change, 22
Lot Change, 352 Lot Change, 352
Actual Takt time, 620.2 Actual Takt time, 613.6
Target Takt time, 600 Target Takt time, 600
0.0
100.0
200.0
300.0
400.0
500.0
600.0
700.0
Sec
/rea
l
Yamazumi chart comparison
Before After
614.2
614.2
19.2
Actual Takt time,
620.2 [系列名],
614.2
Target Takt time,
600
Target Takt time,
600 595
605
615
625
635
645
Sec
/ree
l
STD Time Baratsuki
Before
Max Baratsuki 80 Lot Change 352 5.2 CF Change 22 0.8 Cycle time 203 17.2
Actual Takt Time 620.2 Target Takt Time 600
STD Time Baratsuki
After
Max Baratsuki 80
Lot Change 352 5.2 CF Change 22 0.8 Cycle time 203 11.2
Actual Takt Time 614.2 Target Takt Time 600
Yamazumi chart comparison
Before After
Actual Takt Time = Necessary loss + Ave. Barasatki + Cycle Time
Plan B put in manual
Standard Quality
Kindness
Team work
SAKDA’s impression
Communication
Safety
Keep rules
TORU’s impression
Product Development of Food
improve Feedback Find
problem
TORU’s impression
Thank you
for your attention