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

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Impact on Product Cost

TKAP Product Cost Target

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Approach

Conventional Methodology for Productivity Improvement (Labour Cost): Automation

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DEMERITS

  • SAFETY
    - High Power Equp. (LWD or Fatal Accident)
  • COST
    - High Investment & Running cost (Sensors etc)
  • SPACE:
    - Huge Space coverage (Special Barrication)
  • MAINT:
    - Difficult to Trouble shoot (High Maint Cost)
  • ENVIRONMENT:
    - More Actuators & More Energy Consumptioncs19

Our Philosophy (Concept)

Effective utilization of Man hour: Increase Value Added work by Reducing Muda (Waste) &
Supplementary work for Productivity Improvement

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Our Thinking Way: Collaboration of of Jishuken & LCA for increasing the Value Added Work (reduce CT)

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Project Planning

Case Study: T/M Main Assembly & Tester line Productivity Improvement activity

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Project Target: 15% Productivity Improvement through CT Reduction (Man loop reduction)

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Project Implementation*

* 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)

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Jishuken Implementation

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Project Implementation

What is Low Cost Automation (LCA) – TKAP Definition..?

A System where Man & Machine Collaborate & Work together (No Separation), which meets Expectations of Toyota Way.

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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).

Why KARAKURI?

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Low Cost Automation (LCA) Implementation

Challenge: Conventional Automation V/S TKAP Low Cost Automation (Karakuri)
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LCA Innovation & Breakthrough Ideas: After Implementation (in continuation with Jishuken)

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Types of Karakuri at TKAP

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Competitiveness Sustainability through Innovation & Continuous Kaizen

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