Kaizen examples

Case Study 1 Optical Instruments Manufacturer Company A

Case Study 1 Optical Instruments Manufacturer Company A

Company A, optical instrument manufacturer, were doing contract manufacturing. Since the main lines of its client have been shifted to overseas, production for domestic market declined more than half. Aiming to recover its contract manufacturing business, Company A used Hirayama Consulting Services.

Before > After

issues

  • Frequent production stops has affected the production volume and equipment operational availability
  • “achieve the planned production is not needed” mood spreading
  • Low Productivity awareness among technical personnel
issues
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Analysis

  • Assembly process workload reduction is not possible with current line lay-out
  • Assembly workers motion Workbenches and material placement are cause of waste on Assembly workers Motion.
  • Parts Supply Equipment is not efficiently designed
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implementation

  • Planning and setting of semi-annual improvement targets
  • Monthly analysis on current situation: issues, kaizen proposals, results.
  • Daily Improvement tasks by Supervision Personnel
  • Lay-out design review
  • Workbench, parts, jig and tool placement review. Reduction of worker motion, process review.
arrow

Results

  • Semi-annual targets achievement
  • Practice of PDCA Cycle properly implemented and
  • Formation of personnel with Waste finding and elimination
  • High Capacity to adapt to new models orders
Why did you choose Hirayama Consulting?

The availability of implement the Toyota Production System while nurturing internal personnel capable of keep continuous improvement was the main reason..

  1. Toyota Production System Basis
  2. Practical improvement rather than lectures
  3. Nurturing personnel able to give continuity to Improvement Policies as a primary objective
Other major decisive factor was the consistency with our Company orientation.

Case Study 2 Automobile Parts Manufacturer Company B

Reducing Cost through Operation availability Improvement Project

Company A, optical instrument manufacturer, were doing contract manufacturing. Since the main lines of its client have been shifted to overseas, production for domestic market declined more than half. Aiming to recover its contract manufacturing business, Company A used Hirayama Consulting Services.

Before > After

issues

  • Frequent production stops has affected the production volume and equipment operational availability
  • “achieve the planned production is not needed” mood spreading
  • Low Productivity awareness among technical personnel
issues
arrow

Analysis

  • Line stop causes investigation for different equipment parts conducted
  • Spare parts management system is not efficient
  • Improvement measures, process visualization not existent
  • Lead-time for performance test not appropriate (long)
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implementation

  • Improvement Emphasis in eradicate Line stop causes (i.e. coating method review)
  • Elimination of missing parts through Spare parts Control implementation
  • Visualization of improvement and process progress and sharing of issues
  • In-house Performance Tests and Inspection performed simultaneously
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Effects

  • No. 1 Plant Production Goal achieved by improvement on line usability
  • Elimination of missing parts through Spare parts Control implementation
  • Improvement of awareness of employment productivity and its relation with line stop and production
  • Performance of planned production, enabling measures from Client’s point of view
Why did you choose Hirayama Consulting?

Have gained a thorough understanding of our worksite and a perfect match of Hirayama with our Improvement activities were the main reason.

  1. Customer Perspective
  2. Production based on Standardization
  3. Pursuit of Plant total optimization
  4. All process visualization management system structure
  5. Personnel training through Improvement activities
Besides consistence on above items, having received a 3 days worksite research in our plant prior to start the consulting, made us sure about Hirayama commitment.

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