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Kaizen Workbook

continuous improvement

Vers

ion

1.0

| Ju

ne 2

013

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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