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1
Kaizen Workbook
continuous improvement
Vers
ion
1.0
| Ju
ne 2
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“ At Mechatronic we adopt the Kaizen philosophy to achieve early day optimisation and a Right First Time process”
“ Straight from order, we commit to the elimination of waste, not only for the good of the project, but for the benefit of the customer’s needs and requirements. We aim to work with the customer throughout the evolution of the project, particularly at the early stages, allowing them to give as much input into the design as desired, using a synergy of minds to ensure the customer’s expectations have been exceeded time and time again”
“A unique approach to design”
Concept Kaizen Mission Statement
321
Synergy of minds
Right first time
realisation of machine
specification and process
Quicker order-
to-delivery times
All stakeholders buy into new
methods
3
Introduction to Concept KaizenMechatronic Solutions offers a unique opportunity for customers to drill down to the vital elements of production equip-ment with their Concept Kaizen Workshop.
This innovative approach gives a practical review of the process before machines are designed and built rather than attempting fine tuning and modifications after machines have been installed, which can be costly and awkward to implement.Kaizen-trained engineers can develop full-scale mock up models of proposed machines, offering customers:
� Right first time realisation of machine specification and process � Operator/technician/maintenance buy-in to new methods � Determining and eliminating jugular elements in the process so there are no surprises later on � Quicker order-to-delivery times � Accurate assessment of tact times and cycle times � Line balancing of the process
The partnership of Mechatronic and its customers not only reduces waste but also, and more importantly, gives a very clear overview of layout and function.
A Right First Time Solution
The practical simulation offered by Mechatronic ensures a ‘right first time solution’ through deep empathetic thinking at the outset of a project.
This method of working provides a fast and economical route to design, which ensures robust solutions and a buy-in from all users of the finished equipment.
Right First Time
Poka yoke
Prevention of Re-
engineeringCustomer Ownership
Self Financing for Both Parties
By implementing the Kaizen approach we
identify the major issues before the design stage.
We identify areas of the machine/process that require poka yoke
implementation.
KAIZENAims &
customer benefits
Elimination of Costly Mistakes
Line
Balance
Mistakes can be identified before any tooling/ fixtures are manufactured.
Using the Kaizen model we are able to balance the workload of the line in
a practical manner.
Develop“Most
appropriate” Solution
Customer Confidence
Proven design
The most appropriate solution to a manufacturing problem can be agreed and proven.
SafetyRisks and hazards of the machine are identified much
earlier in the project.
The early customer “buy in” allows the customer to contribute to the machine design enabling confidence all round.
The design of the machine is proven before CAD modelling commences.
Wealth of Mechatronic Knowledge
Using a wealth of Mechatronic knowledge from over 100+ years of combined engineering experience, a problem will always be resolved.
Work Flow
We are able to trial/visualise the work flow of the process operations at the kaizen stage.
ErgonomicsPracticality
Cost Reduction
We believe a hands on approach to design allows us to visualise the final product.
We are able to physically trial the ergonomics of the machine before design finalisation.
By mocking up before the CAD design, it allows the
cost reduction process to be accelerated.
4
2
1
“At Mechatronic we adopt the Kaizen philosophy to achieve early day optimisation and a Right First Time process”
Mission
Process Model
D
esign/Developm
ent M
anufacture
Lean Design
Work Flow
Safety
Practicality
Ergonomics
Poke-Yoke
Sensing
Customer
Involvement
Proven Design
Customer Ownership
Customer Confidence
Prevention of Re-
engineering
Eliminates Mistakes
Right First Time
Cost Reduction
3
5
Adding value to your manufacturing process
� Existing process Budgets � Customer’s standards
� Integrated, co-ordinated approach � Good communication
� Alternative concepts � Teamwork
� Visible � Take photographs � Make notes � Innovate � Informal teamwork � Encourage comments
� Ergonomics � Material handling � Functionality � Practicality � Lean � Ease of manufacture
� Input from customer � Synergy � Share the ownership � Anticipate and eliminate costly mistakes
Receive Enquiry/Order.
Discuss requirement with Customer. Agree broad
parameters.
Generate/Brainstorm Ide-as. Evaluate, choose the
most promising.
Make/develop wooden prototype.
Evaluate, criticise, develop, refine, generate more
ideas
Review with Customer evaluate, criticise, develop,
refine, generate more ideas
Record and document. Agree with customer. Sign
off
Move into the design and/or manufacturing stage.
End of Concept Kaizen phase
The Concept Kaizen Method
6
What is Poka-yoke? Poka-yoke is a Japanese term meaning “fail-safe” or “mistake-proofing”.
A poka-yoke is any mechanism in a lean manufacturing process that helps an operator avoid mistakes within the process. Its purpose is to eliminate product defects by preventing, correcting, or drawing attention to human errors as they occur.
“All equipment and fixturing must be designed to consider all possible operator and component part errors, and eliminate the chance of wrongly assembled or poorly made parts being processed any further”
Mechatronic Poka-yoke
Here at Mechatronic we aim to integrate poka-yoke features into machines in the form of mechanical methods. This reduces the amount of electrical sensing required, therefore reducing the overall cost of the machine for the customer. Working closely with the customer’s demands, we aim to fulfil the poka-yoke requirements with as little physical equipment as possible, using intelligent methods to identify multiple parts and process steps effectively. The Concept Kaizen activity allows us to identify how best to integrate poka-yoke into the design and can be trialled at an early stage of the project to fully optimise
“Concept-Improve-Manufacture”
1
7
The Client’s ChallengeA world leader in domestic door locks and locking systems commissioned Mechatronic Solutions to design and build a bespoke automatic machining centre to process mortise lock levers. The old production method was very labour intensive, involving a great deal of handling. With increasing demand from customers, the client required a much faster and more flexible solution.
The Concept Kaizen SolutionWorking closely with the client, Mechatronic used the Concept Kaizen method to identify the different operations that could be performed whilst the raw blank was held in one position, to prevent multiple handling. A soft model was built in the Kaizen workshop to demonstrate the layout of a semi-automatic machine and examine any possible issues of access, ergonomics, or processes.
The ResultsThe machine regularly exceeds its specification by producing a completed lever in less than four seconds with only occasional manual input required. This is a vast improvement on the previous labour intensive method of manual manufacture. The machine also offers improved quality whilst reducing labour requirement to serve four lock assembly lines.
A unique feature is the automatic removal of any reject part due to faulty components. Additional benefits are a vastly reduced floor area in comparison to the previous machines and quick change tooling by operators, which gives increased production flexibility within a shift rather than increasing stock levels.
Case StudiesMechatronic Provides the Key to High Speed Lock Lever Production
1
8
The Client’s ChallengeA world leading printer manufacturer commissioned Mechatronic to design and build a high speed, high output, semi-automatic toner bottle filling machine. The machine was to be capable of identifying and processing many different variants of product type/colour using poka-yoke techniques and bespoke design. Mechatronic’s job was to work with the customer to produce a machine capable of the tight cycle times and demanding variation required within the process.
The Concept Kaizen SolutionUsing the Concept Kaizen methodology, Mechatronic began creating mock ups of the machine design. The customer had input and reviewed the prototype, the ergonomics of the machine and process handling before CAD design even began. Production staff from the printing company were invited to trial the flow, enabling time study indications from very early on. A soft model was finalised with the customer, enabling a strong design baseline to work from and accelerating the CAD design phase.
The ResultsThe machine solution was within the space constraints of the customer, ergonomically practical and accessible for maintenance work during downtime periods. Using clever poka-yoke techniques the machine can identify all variations of product and flag reject parts to the operator efficiently, and the customer can tweak each product variant via the on-screen HMI. The design also integrates the ability for super quick changeovers to different product colours/types allowing greater flexibility for Supply Chain Management purposes. Delivered on time and to spec, the customer is in the process of discussing potential new orders.
The Client’s ChallengeA world leading manufacturer of fresh water aerators and flow regulators approached Mechatronic to improve their in-house production method of assembling 1400 subtle variations of regulator, all requiring different insertion forces and speeds to assemble. The customer wanted 10 machines that were identical in appearance and functionality, with the ability to cater for all variations of part.
The Concept Kaizen SolutionUsing a synergy of minds, Mechatronic staff generated and evaluated suitable designs. The most relevant ideas were mocked up in a wooden prototype and the customer was invited to evaluate the initial design and physically test the ergonomics of the assembly process. As 10 machines were required, it was critical that the Kaizen activity took place to allow any problems to be resolved at an early stage. Small amendments were made to optimise the layout of the machines for maximum comfort and to further reduce the risk of RSI.
The ResultsThe machines consistently outperform their predecessors, and output easily keeps up with the high demand of the customer. Due to the ergonomics of the machine (nailed down in the Kaizen phase) the operator can comfortably work for a shift with minimal risk of RSI. The turntable design has also proved to be a roaring success, catering for all variants of product. Using clever programming techniques, the customer can select the required recipe settings based on product, and the insertion forces and speeds are automatically tweaked for optimum assembly of the regulators.
The machines exceeded the customer’s expectations and they are currently in talks with Mechatronic for another batch of similar machines to complement their existing process.
2
3
Toner Bottle Filler
Fresh Water Regulator Assembly
9
The Client’s ChallengeA leading supplier of automotive components and parts enquired about the design and build of a machine capable of semi-automation and poka-yoke control of the assembly of a truck key. The process had to be capable of feeding screws to a local position, enabling the operator to fasten a small intricate screw consistently, and controlling the operation of carefully gluing a chip in place.
The Concept Kaizen SolutionAt Mechatronic we brainstormed to find the optimum solution to the problem. These initial ideas were pitched to the customer and upon agreement, a Kaizen model was born. The Kaizen model allowed the customer to physically see and trial the fixture and tooling and the operative motions that follow. It was critical for a Kaizen model to be created due to the customer’s space constraints. The model allowed us to create full size representations of the equipment and enabled the customer to see the practicality of the parts feed system from the rear of the machine and understand how the operator could interact with the surrounding parts.
The ResultsThe machine, ergonomically designed and to customer spec, can consistently assembly the truck key using semi-automated methods. Information on missing parts and incomplete operations within the process is fed back to the operator via an HMI. The screw dispensing unit, along with the pneumatic screwdriver set-up, allows the operator to assemble the outer shell to the base cover, with torque feedback creating the signal for the completion of operation. The glue dispensing unit is capable of applying the glue in the correct location, in the correct quantity, time and time again. The tube and bracket framework makes the machine lightweight and easy to relocate, as requested by the customer.
The Client’s ChallengeMechatronic was approached by a plastic mouldings automotive supplier to create a machine capable of applying numerous clips to V shaped plastic moulding, and poka-yoke sensing of manually-loaded fir tree clips. The key problem was identifying the best possible holding method for applying the clips. As both types of clips were required to be loaded on the inside of the V profile, it would prove difficult for the operator to access this area for assembly in an ergonomic manner.
The Concept Kaizen SolutionMechatronic built a Kaizen model of the proposed machine to identify the holding and loading difficulties. It became clear that the application of both clips could not be done in the same holding position. The Kaizen phase revealed that a rotating hinged base would enable the part to be rotated enough for the clip application cylinders to apply the metal clips to the moulding in an automated manner, while giving the operator sufficient room to manually load the clips comfortably. The Kaizen activity also highlighted that the holding nest would need protection for the moulding due to the risk of heavy loading by the operator and datum holding by the machine. A poly coating was introduced to counter this effect.
The ResultsThe resulting machine can successfully complete the clip application process in a stable manner, with feedback of the results and poka-yoke to the operator via the on-screen HMI indicators. The machine is also capable of a re-work sequence if a child part is missing. Ergonomically, the machine is a success, as all clips can be populated at a natural height for the operator with no restrictions in place, allowing comfortable loading and unloading. Additionally, the self-datum function integrated into the machine simplifies the process by speeding uploading and unloading of tasks.
4
5
Truck Key Assembly
Clip Assembly
10
6Fuel Rail Assembly
The Client’s ChallengeA leading car components manufacturer approached Mechatronic for a solution to the poka-yoke and assembly of a fuel rail consisting of 2 child parts that required pressing into position onto a tube. The solution would have to be robust, ergonomic for the operator and capable of achieving a cycle time of 35 seconds P2P. The Mechatronic team decided that the best solution to the problem should be determined through a Kaizen activity.
The Concept Kaizen SolutionMechatronic started work on the Kaizen mock up, focusing first on part holding and assembly of the child parts. A part nest was created through trial and error, and a means of holding and pressing the child parts into position was derived through brainstorming and discussions within the team. A frame to house the parts nest and pressing fixture was constructed using standard machine base dimensions. This prototype allowed the team to identify practically the best possible locations for Kanban loading trays. The customer reviewed the mock-up design and further improvements were agreed for maximum efficiency within the process operation.
The ResultsThe resulting machine can successfully complete the fuel rail assembly in around 30 seconds on average, well within the specified cycle time. The Kaizen activity and customer input has resulted in a process where the operator can grasp each part ergonomically and place it into its fixture in a natural manner. The design of the machine also allows for easy reloading of parts from a second operator, without disrupting work in progress.
Concept Kaizen Method Flow
01
02
03
04
05
06
07
�Gain Initial Specification �Complete Design Inception Document
� Assign person to lead construction of concept �Briefing of activity and aims to fitter
� Internal Review � Apply proposed changes; document and photograph
�Customer review and input � Apply proposed changes; document and photograph
� Record all aspects of the mock-up; dimensions, layout, equipment, sensors etc
� CAD model creation of Kaizen activity then dis-assembly of mock-up
� Initial mock-up �Document and photograph
Pro
cess
Fai
lure
Mo
des
Eff
ects
Ana
lysi
sP
roce
ss o
r M
/C N
ame:
Com
plet
ed b
y:P
age:
of
Cus
tom
er:
FME
A D
ate:
Rev
.
Key
Pro
cess
Ste
p o
r In
put
Po
tent
ial F
ailu
re
Mo
de
Po
tent
ial F
ailu
re
Eff
ects
SE
VP
ote
ntia
l Cau
ses
OC
CC
urre
nt C
ont
rols
DE
TR
PN
Act
ions
Rec
om
men
ded
Res
p.
Act
ions
Tak
enS
EV
OC
CD
ET
RP
N
Wha
t is
the
Pro
cess
S
tep
or In
put?
In w
hat w
ays
can
the
Pro
cess
Ste
p or
In
put f
ail?
Wha
t is
the
impa
ct
on th
e K
ey O
utpu
t Va
riabl
es o
nce
it fa
ils
(cus
tom
er o
r in
tern
al
requ
irem
ents
)?
How Severe is the effect to the customer?
Wha
t cau
ses
the
Key
In
put t
o go
wro
ng?
How often does cause or FM occur?
Wha
t are
the
exis
ting
cont
rols
an
d pr
oced
ures
th
at p
reve
nt e
ither
th
e C
ause
or
the
Failu
re M
ode?
How well can you detect the Cause or the Failure Mode?
Wha
t are
the
actio
ns fo
r re
duci
ng th
e oc
curr
ence
of
the
caus
e, o
r im
prov
ing
dete
ctio
n?
Who
is
resp
onsi
ble
for
the
reco
mm
ende
d ac
tion?
Not
e th
e ac
tions
take
n.
Incl
ude
date
s of
co
mpl
etio
n.
Giv
e (S
EV,
OC
C a
nd D
ET)
a r
atin
g be
twee
n 1
to 1
0 w
here
1 is
non
e an
d 10
is lo
ts
To c
alcu
late
RP
N m
ultip
ly S
EV
by
OC
C b
y D
ET
Rep
eat t
his
afte
r su
gges
ted
cont
rols
/act
ions
in p
lace
13Kai
zen
Saf
ety
Ch
eckl
ist
Saf
ety
Co
nsid
erat
ion
Req
uire
d?
Y/N
Mea
sure
Saf
ety
Co
nsid
erat
ion
Req
uire
d?
Y/N
Mea
sure
Doe
s th
e op
erat
ion
requ
ire a
ddi-
tiona
l lig
htin
g?Is
ther
e a
risk
of fa
lling
or
ejec
ted
part
s du
ring
oper
atio
n?
Are
ther
e an
y sp
ecifi
c P
PE
re-
quire
men
ts?
Are
ther
e an
y sh
arp
edge
s to
be
tak-
en in
to c
onsi
dera
tion?
Will
the
oper
ator
be
expo
sed
to
any
haza
rdou
s su
bsta
nces
?A
re th
ere
pote
ntia
l pin
ch p
oint
s pr
esen
t?
Mov
ing
part
s re
quire
gua
rdin
g?Is
ther
e a
risk
of im
pact
to th
e op
er-
ator
?
Will
lase
rs b
e us
ed w
ithin
the
proc
ess?
Is th
ere
a ris
k of
cru
shin
g to
the
oper
ator
?
Will
the
mac
hine
be
carr
ied/
mov
ed?
Ris
k fro
m s
peed
of m
ovin
g pa
rts?
Will
PP
E r
estr
ict t
he p
roce
ss?
Mov
able
gua
rds
requ
ired?
Doe
s th
e pr
oces
s op
erat
ion
feel
co
mfo
rtab
le (
ergo
nom
ical
ly)?
Fixe
d gu
ards
req
uire
d?
Is th
e op
erat
or r
equi
red
to r
each
ex
cess
ivel
y?D
oes
vibr
atio
n po
se a
ris
k to
the
oper
ator
?
Is th
ere
a ris
k of
bre
ak u
p du
ring
oper
atio
n?Is
ther
e du
st o
r ga
s em
itted
from
the
proc
ess?
Are
ther
e ris
ks if
the
oper
ator
in-
terv
iens
in th
e pr
oces
s op
erat
ion?
Is th
ere
a ris
k of
the
oper
ator
bei
ng
trap
ped
with
in th
e m
achi
ne?
Pro
cess
Fai
lure
Mo
des
Eff
ects
Ana
lysi
sP
roce
ss o
r M
/C N
ame:
Com
plet
ed b
y:P
age:
of
Cus
tom
er:
FME
A D
ate:
Rev
.
Key
Pro
cess
Ste
p o
r In
put
Po
tent
ial F
ailu
re
Mo
de
Po
tent
ial F
ailu
re
Eff
ects
SE
VP
ote
ntia
l Cau
ses
OC
CC
urre
nt C
ont
rols
DE
TR
PN
Act
ions
Rec
om
men
ded
Res
p.
Act
ions
Tak
enS
EV
OC
CD
ET
RP
N
Wha
t is
the
Pro
cess
S
tep
or In
put?
In w
hat w
ays
can
the
Pro
cess
Ste
p or
In
put f
ail?
Wha
t is
the
impa
ct
on th
e K
ey O
utpu
t Va
riabl
es o
nce
it fa
ils
(cus
tom
er o
r in
tern
al
requ
irem
ents
)?
How Severe is the effect to the customer?
Wha
t cau
ses
the
Key
In
put t
o go
wro
ng?
How often does cause or FM occur?
Wha
t are
the
exis
ting
cont
rols
an
d pr
oced
ures
th
at p
reve
nt e
ither
th
e C
ause
or
the
Failu
re M
ode?
How well can you detect the Cause or the Failure Mode?
Wha
t are
the
actio
ns fo
r re
duci
ng th
e oc
curr
ence
of
the
caus
e, o
r im
prov
ing
dete
ctio
n?
Who
is
resp
onsi
ble
for
the
reco
mm
ende
d ac
tion?
Not
e th
e ac
tions
take
n.
Incl
ude
date
s of
co
mpl
etio
n.
Giv
e (S
EV,
OC
C a
nd D
ET)
a r
atin
g be
twee
n 1
to 1
0 w
here
1 is
non
e an
d 10
is lo
ts
To c
alcu
late
RP
N m
ultip
ly S
EV
by
OC
C b
y D
ET
Rep
eat t
his
afte
r su
gges
ted
cont
rols
/act
ions
in p
lace
14
Manual Handling Guide
Women
Shoulder height
Elbow height
Knucleheight
Mid lower leg height
Shoulder height
Elbow height
Knucleheight
Mid lower leg height
Lifting and Lowering
Men
5 kg
7 kg
10 kg13 kg
15 kg16 kg
10 kg13 kg
5 kg7 kg
10 kg
3 kg
20 kg7 kg
25 kg10 kg
20 kg7 kg
10 kg3 kg
15
Design Tools Kaizen Reference Tools
Exp
erim
enta
l Le
arni
ng C
ycle
16
Kaizen Conclusion Checklist
Question Y/N Comment
Has the customer agreed to the final Kaizen concept?
Have the Kaizen progressions been documented?
Have photos been taken of the final Kaizen concept?
Has the customer requested additional equipment not shown in the Kaizen concept?
Have the poka-yoke requirements been agreed with the cus-tomer, post Kaizen?
Have cycle time studies been undertaken? Does the process achieve cycle (in theory)?
Does the concept model require disassembling?
Have all calculations been documented?
Were there any major problems to overcome?
Were there any issues that delayed the Kaizen activity?
Will there be any changes to the moulding/part/product?
Mechatronic Production Systems Ltd57 Melchett RoadKings Norton Business CentreBirminghamB30 3HP
Tel: 0121 459 2347Fax: 0121 459 2424
Email: richard.evans@mechatronic.co.ukWeb: www. mechatronic.co.uk
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