The individual improvement activity

In the obstruction loss of the facility overall efficiency, "the breakdown loss" makes trouble zero by the activity of the autonomy maintenance and the schedule maintenance.
However, it sets an item respectively and "the plan loss" "the tool exchange loss" "the speed decline loss" "the minor key stop loss" "the bad modification loss" "the handwork loss" and so on must be improved.
Concretely, it measures the model line facility overall efficiency which was set by the activity of the autonomy maintenance and it grasps loss structure.
It decides "the individual improvement item", "the grappling member" "the improvement plan" and "the improvement par" on it and it develops an activity.

The way of the advance by individual improvement's activity is as follows.

Step 　　The active name 　　　　The active contents
1step The grasping of the loss which
obstructs facility overall efficiency		 ･ It measures the facility overall efficiency of the model line facilities.
･ It makes the obstruction loss of the overall efficiency of each of the facilities clear.
･ It puts the item of the individual improvement in order and it placards it at the active board of the model line.
･ It shows both of "the facility overall efficiency" and "the yield control for every the time" in the graph.
･ It makes a loss item table
2step The making of an individual improvement plan
The study and training of the individual improvement means		 ･ It organizes an improvement team according to the individual improvement item and it makes an improvement plan.
･ It prepares the study and training of the improvement means and a use record according to the loss item.
･ The loss repartition is "the housekeeping exchange" "the minor key stop" "the tool exchange" "the cycle abridgment" "the bad modification" "the work time abridgment" "the work organization", "the others".
･ It makes an individual improvement plan progress table.
･ It makes a graph with individual improvement number.
･ It makes a graph with effect amount of money.
3step The implementation of the individual improvement ･ It implements improvement every team.
･ It implements the report meeting of the improvement elapse regularly.
･ It placards the elapse of the improvement at the individual improvement activity board.
4step The announcement of the improvement result ･ It gathers and it announces an improvement result to the improvement case announcement meeting.
･ It puts improvement contents in the MP information in order and it issues them.
･ It makes an individual improvement report.
5step It makes the manual of the individual improvement.
 ･ It makes the ﾞ individual improvement manual ﾞ which is different from the loss, inserting an improvement case.
･ It holds an improvement training seminar in the company with ﾞ improvement manual ﾞ.
・It expands an active object line.


[Make it be possible to see the loss which can not be seen].

It develops individual improvement in parallel with the autonomy maintenance activity.Then, the loss of the facilities of the object to improve individually must be tight grasped in the present situation.
It develops the mechanism to measure facility overall efficiency and then it makes the obstruction loss of the facility overall efficiency every each line clear.Moreover, it grasps the loss of the direct material and the indirect material (the specific productivity loss) and so on.
That is, it is "to make it be possible to see the loss which can not be seen".The loss which can be seen becomes the theme of the individual improvement.However, the loss which can not be seen is because it doesn't become an improvement theme.To grasp loss tight in the present situation is to lower this surface of the water which can be seen.The leaving of the loss which can not be seen is the problem of the management.

[Make relation between the loss structure and the factory finance value clear].

The relation between the financial value and the loss item of the factory must be made clear.
For example, the improvement of the minor key stop loss of the obstruction loss of the facility overall efficiency is productivity improvement of course．Ｗｈｅn seeing this at the financial value, it is a direct labor and moreover it concerns energy expenses, too.Also, the bad improvement of the process is not only a direct material cost.This becomes expenses such as "the direct labor", "the energy expenses" and then "the expenses about the defective product disposal".
The middle plan at the factory does composition with this factory finance value how by the improvement activity of 3 years or decides it.Then, it sets a goal about making a factory gross profit how many %.It piles a loss improvement item according to this goal finance value.Then, it implements an individual improvement activity.

[Use yield control for every the time]

The writer is recommending to do yield control for every the time in parallel with the facility overall efficiency.
The facility overall efficiency control is the average of the efficiency in the measurement period persistently.However, as for the production line, the yield changes every moment with the various loss every hour.The production line is life just like.
In the seeing of the looseness of the yield every this time, the actual state of the line can be grasped apart from the facility overall efficiency.Also, when using the average of the yield for every the time, the relation to the facility overall efficiency, too, can be grasped.Moreover, it becomes a yield in one piece of time if dividing by the linear investing number of persons.That is, it becomes an index with direct labor productivity.
In the individual improvement, it improves the factor of the looseness of the yield for every the time.Then, it is to make the stable production line which doesn't have looseness.It does the improvement which raises the average of the yield for every the time in the next.

［In the right hand "The autonomy maintenance"、In then the left hand "The individual improvement"］

The writer is saying that one "In the right hand "The autonomy maintenance"、In then the left hand "The individual improvement" fault is worthless.
Because, when restoring the defect of the facilities by the activity of the autonomy maintenance, as for the defect of the minor key stop and doing manufacture bad and so on, only the activity of the autonomy maintenance is come to a deadlock.
Therefore, it notices the necessity to improve by analyzing tight after grasping these in the present situation.Moreover, also, by to wrestle with the individual improvement, it learns the structure of the facilities and the principle of the manufacture.
Then, the defective point of view becomes deeper.It is reflected in the activity of the autonomy maintenance.
For the result to appear in the division of the man-day of the activity takes time fairly for the autonomy maintenance.

However, the result appears at once by implementing individual improvement in parallel.It becomes the catchword that the whole activity of this thing is expedited, too.


[In the big result is born the big improvement., it however becomes a big result if implementing a lot of small improvement, too.]


It judges the contents of the individual improvement from "the technical difficult degree" and "the improvement investment sum" and so on and the period and the taking charge of the improvement are decided.
The long-range big improvement (Equal to or more than 6 months)
This is the improvement theme of the whole line.Or, the technical difficult degree is high and is improvement contents with high improvement investment sum.
The manager organizes a project team in the center and improves this.
The improvement during the middle (1 month-4 months)
This is the improvement of the specific process and the facilities.This is improvement with the improvement cost of the number of which the technical difficult degree is rather high and then it is necessary.
The supervisor and the circle improve this in the center.
The small improvement of to be short-term (The 1st-1 week)
This is specifying work and the improvement of the specific loss item.This is the improvement that the technical difficult degree is low.
The reader and the operator improve this.

The big improvement invents a big result.Therefore, it is better to narrow down a theme, too, and to improve.
Also, as for the small improvement, only the small result is born.Therefore, it is necessary to solve a lot of themes to the short time.It says "that it becomes a mountain if piled with dust" by the proverb in Japan.


[The basis of the present situation grasping is "4W1H1F1T"].

The first step of individual improvement's beginning is the present situation grasping.The basis of the present situation grasping is "4W1H1F1T"
What --------- "By what" "What kind"
Where --------"Where" "By the place"
Who --------- "By whom" "Which facilities"
When -------- "The when" "What time"
How ----------"How many""How much"
Frequency -----"By what frequency"
Trend ---------"What trend"
In the step of this present situation grasping, it doesn't use "why".
Especially, "When" is important about the chronic minor key stop and the bad modification and so on.Generally, classification in "what time" is classified as follows.
"During continuation operation" "Of plan exchange" "Of start-up in the morning" "Behind the noon recess" "Of working change" "Of tool exchange" "When the minor key stops" "The others"
"What time" about "during continuation operation" is a problem."How is it being changed from the operation beginning in the morning in the continuation operation on the 1st?" is because it doesn't know that it doesn't take a continuation dater.It calls this search procedure "the way of the 1 shift continuation measurement".
Moreover, it investigates what change there is within 1 week of the weekend from Monday.It calls this search procedure "being a way of the continuation measurement in 1 week".
Moreover, the defective occurrence investigation by the season, too, is sometimes necessary.That these measurement takes the measurement data of "the temperature of the facilities" and "the temperature of operation oil and manufacture liquid", "the temperature, the humidity and the atmospheric pressure in the factory" in addition to the measurement of the defective item is important.
It did detailed present situation grasping only and cause is sometimes proved.In this case, it does at once of the measure of the cause.The necessity and there is not an analysis having to do with an appendix.It advances towards the factor analysis only when not finding cause.


Return English TPM HOME