TOYOTA KIRLOSKAR AUTO PARTS
PRODUCTIVITY IMPROVEMENT IN TRANSMISSION (T/M) ASSEMBLY LINE THROUGH “JISHUKEN” & “LOW COST AUTOMATION (KARAKURI)”
Need for Project
TKAP Business need: T/M Volume Trend
TKAP Labour Cost Trend
Impact on Product Cost
TKAP Product Cost Target
Conventional Methodology for Productivity Improvement (Labour Cost): Automation
Our Philosophy (Concept)
Effective utilization of Man hour: Increase Value Added work by Reducing Muda (Waste) &
Supplementary work for Productivity Improvement
Our Thinking Way: Collaboration of of Jishuken & LCA for increasing the Value Added Work (reduce CT)
Case Study: T/M Main Assembly & Tester line Productivity Improvement activity
Project Target: 15% Productivity Improvement through CT Reduction (Man loop reduction)
* Project implemented from July’14 to Jan’15 (6 Months)
It's a Japanese word which means "Self Learning to improve Self (HRD) & Workplace by Eliminating 3M's."
Objectives of Jishuken:
i) Enhance problem solving skill by teamwork
ii) Productivity improvement by Tackling and Eliminating 3Ms
iii) Promote TPS skill up (HRD of Members)
What is Low Cost Automation (LCA) – TKAP Definition..?
A System where Man & Machine Collaborate & Work together (No Separation), which meets Expectations of Toyota Way.
TKAP tool for LCA : "KARAKURI"
What is KARAKURI?
It's a Japanese word which means "Achieving motion with No Power or Low power (use counter weight,
rope & pulley mechanism).
Low Cost Automation (LCA) Implementation
Challenge: Conventional Automation V/S TKAP Low Cost Automation (Karakuri)
LCA Innovation & Breakthrough Ideas: After Implementation (in continuation with Jishuken)
Types of Karakuri at TKAP
Competitiveness Sustainability through Innovation & Continuous Kaizen