3. Getting Started What is a Manufacturing Company ? Make good quality products Selling to Customer Earn Profit Guarantee employee’s better life Bring prosperity to people
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5. Cost,Profit & Price Profit Cost Selling Price Selling Price = Cost + Profit Cost & Profit Profit = Selling Price - Cost Selling Price (Rs) How to earn more profit? Increase the selling price Reduce the cost
6. Cost,Profit & Price Material cost Purchased Parts cost Other cost Facility cost The expenses depend upon the method of manufacturing Every company is same (No big difference in a cost components) There is a difference depending on industry Cost Cost (Expense) Based on TPS Product Manufacturing and the cost KAIZEN Minimum Investment & Maximum Profit
7. TPS What is MUDA (Waste)? Identified by Tenchi Ohno-Japan Waste is the use of any material or resource beyond what the customer requires and is willing to pay for.
8. TPS MURI (overburden) MURA (unevenness) MUDA (waste) Value- Added Work Motions of Worker MUDA= Non Value-Added Work Non Value-Added Work Customer pays money only for Value-Added Work
9. TPS waste of overproduction Waste of waiting Waste of transportation Waste of processing itself Waste of inventory Waste of movement Waste of making defective products 7 Types of Muda
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17. TPS Over Burden Adding work without eliminating Muda Understanding of Adding Work Eliminating Muda through Kaizen Adding Work in Saved Time = work MUDA work work MUDA MUDA Adding Work No Over Burden work work MUDA KAIZEN MUDA work MUDA = Adding Work
18. TPS Minimize Lead Time Minimize Non Processing Time Many types of MUDA will be highlighted when we minimize the Non Processing Time Lead Time = Processing Time + Non Processing Time = + = LEAD TIME Lead Time : time required to process from start to end (i.e. from raw material processing till packing goods)
19. Eliminate all MUDA from work site(NO.1) Injection Shop= Ground Floor Assembly Shop= 1 st Floor Ground Floor Ground Floor+ Use of Trolley [Before] [After]
20. Eliminate all MUDA from work site(NO.2) ライゼン ビデオ Make Process Flow Video-3 Video-4 punching Jig Assy Jig