Improve productivity and aggressiveness through the introduction of TPS that is easy to understand and can be implemented by anyone, and through theoretical improvement activities.

Results
  • Raising the level of shop floor capabilities by building a corporate culture of improvement through company-wide participation.

We introduce a TPS introduction project for a surface treatment maker in Kunshan, China.

Introduction background
Our company’s “TPS Intensive Improvement” significantly reduced their labor cost three years ago, so the management began to think about further improvement activities. As the next step, we started a project aimed at raising the level of shop floor capabilities by building a corporate culture of improvement through company-wide participation.

Industry details
Surface treatment (Plating)
Country
China
Company size
About 160 employees
Issues
Strengthening of improvement activities
Purpose
Human resource development
Industry
Metal
Schedule
  1. TPS Improvement Basic Seminar
  2. Survey of current situation and identify issues
  3. Summary of issues,Consider improvement ideas
  4. Implement improvement ideas
  5. Verification of effects
Project schedule of 4 months
1st month
  1. Kick off
  2. TPS Improvement Basic Seminar
    ・Introduce the steps for TPS introduction
    ・What is “Overburden, Waste, and Fluctuation”?
    ・What is “12 wastes of motion and 8 major wastes of factory”?
    ・Concept of operation improvement
    ・Method of Time Study
    ・How to use the improvement document
  3. Survey of current situation and identify issues
2nd month
  1. How to use the improvement document
    ・Improvement Potential Sheet
    ・Classification of wastes and Totalization sheet
  2. Opinion of process operator, etc. (other 11 kinds points)
    ・Summary of issues
    ・Consider improvement ideas
3rd month
  1. Consider and implement improvement ideas
  2. Study session for the improvement tool, “Creform”
    ・Introduction of use examples
    ・Notes on production
    ・How to use the Joint system
    ・Precautions when putting in the shop floor
4th month
  1. Implement the improvement
  2. Verification of effects
    From the 4th month, they entered the phase of “Reviewing and implementation of the improvement ideas”, and they created work trolleys and carts by themselves because they can realize the improvement ideas by themselves. The improvement members became more aggressive and worked on improving workability, eliminating wastes in delivery and storage, and reducing labor. The significant improvement effect has surprised managers and improvement members.
Photos of activity
Gemba Kaizen specialist
Shigeyuki Obara

RICOH Production Engineering Department

At Ricoh, he implemented improvement education for managers and general employees. He proactively stayed at shop floor and implemented improvement activities. After that, he was transferred to a consulting section for external companies, and conducted shop floor diagnosis and consulting for various industries.
As areas of specialty, regardless of the industry or business, he establishes shop floor improvements and realizes development of key personnel, improvement of quality and productivity, and reduction of lead time through the improvement activities.

Consultants from major companies
with experience in over 40 countries will respond.
Please feel free to contact us.

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 – 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays

3 reasons why we are chosen REASON

REASON 1

Improvement experience of
more than 1,000 companies in 40 countries

There must be the shop floor issues that cannot be solved by your own company alone. Improvements and reforms for manufacturing industry to survive, regardless of country or industry, need development of your human resources through practical experiences of improvement, and strengthening of your production system base.

REASON 2

Consulting that shop floor workers
acknowledge our superiority and be pleased

In conventional consulting styles, there was a distance between consultant and the shop floor because it was promoted mainly consultant and management executives. Our consultant can provide a guidance without a distance between consultant and the shop floor through the guidance based on the “seeds of improvement” in a concrete way, instead of “finding fault” like a critic.

REASON 3

Continuous improvement will continue
even after the end of guidance

While strengthening “human resource development”, we focus on the “overall flow” from design to purchasing, manufacturing, logistics, and production control, and provide guidance that matches the actual situation of your company. Continuous improvement will continue even after the end of guidance through the guidance that is acceptable to the shop floor workers.

Consultants from major companies
with experience in over 40 countries will respond.
Please feel free to contact us.

If you are in a hurry, please call us.

03-5783-3571
Open 08:30 – 17:30
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays