SMOOTHENING LOGISTICS AT TOYOTA
IMPLEMENTING JIT - JUST IN TIME AT GENERAL ASSEMBLY
EXECUTIVE SUMMARY
The project assigned was to carry out various activities in measuring the bandwidth of the panel gaps, figuring the root-cause of the same and implementing the countermeasures in order to reduce the same. Seating of the body was analyzed, root cause was found out and countermeasures were suggested. Certain ‘Kaizens’ were proposed targeting the problem.
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ABOUT
- Heinrich’s Principle.
300 near misses have the potential to cause a minor accident. 29 minor accidents have the potential to cause a major accident;
- Kiken-Yochi Training.
This practice is based on the belief that accidents (major or minor) can be avoided if danger is spotted before it causes any problems. “Kiken-Yochi” directly translates to Danger Spotting;
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Year
2017
Client
TOYOTA
Services
SUPPLY CHAIN
Project
LOGISTICS
RESULTS
Safety
The countermeasures will completely eliminate the manual dolly change over process. This reduces one man power whose job location was of safety concern as he had to work on the gangway where all the tow motors ran causing frequent traffic jams. By reducing traffic jams we are reducing the probability of future accidents.
Efficiency
Average Dolly changeover time for Dolly 1 = 52.75 seconds
Average Dolly changeover time for Dolly 2 = 50.75 seconds
Average Dolly changeover time for Dolly 3 = 51.5 seconds
Average Dolly changeover time for Dolly 4 = 54.25 seconds
Average dolly changeover time = 51.3125 seconds
Thus we have improved the efficiency of the work in Trim-03 by eliminating the dolly change over time of 51.3125 seconds which is 21.31% of the total takt time that the gangway is occupied.
By reducing the traffic congestion, we ensure the supply of parts at right time hence reducing line stops leading to better efficiency.
Cost
Eliminating the dolly changeover process would reduce the number of worker in Trim-03 by one.
Thus the monthly salary of the worker = Rs10000 / month
Salary of worker in a day = Rs 454.54/day
Total number of car produced in 1 shift =195
Cost reduced per vehicle = Rs 1333.33/195
= Rs 2.33/vehicle
Quality
Changing the process which was earlier done by human intervention and converting it to Karakuri system will definitely improve the quality of the part supplying system (eliminating human errors)
Others
The worker which was previously used for dolly changeover can now be used to work on some improvement activities. These Karakuri system has generated space which can be further utilized in other activities.
