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To Kaizen is to "add value only."

Updated: May 29, 2022

The car that everyone liked and got.

Have you ever imagined making a car?


Each manufacturer is making various efforts to make it at a low cost.


Kaizen activity.


In the Toyota Production System,

In making a car, I make full use of various ideas.


As you may know, this is called "waste removal".


But think about it for a moment.


Cars are made using a series of equipment called a production line.

It takes about one day for a mass-produced car to start with the moulding of an iron plate and become a self-propelled finished car.

This time is called lead time.


In the iron plate moulding (pressing process), the coiled iron plate is cut with a large press machine.

We will mould it on the outer panel of the door.

Usually, by pressing 3 to 4 times, one flat panel becomes the shape of a door.


Every time it is pushed, it gradually becomes the shape of a door,

If you take a closer look at the scene being pressed,

Set the upper and lower moulds on the press machine (called setup)

Worker sets (supplies) a flat panel on the press

The operator presses the switch of the press with both hands

(For safety, it will not start unless you press it with both hands)

The press machine operates, and the upper mould descends to the lower mould

The shape of the flat panel changes (for a moment)

Upper mould moves up and down to its original position

Do this repeatedly.






I would like you to think about why I gave this explanation here.


Strictly consider the value of paying for the finished vehicle in each of steps 1-6.


Isn't it worth it because we can't be completed it without going through all the processes?

It is likely to be returned, but


5. The shape of the flat panel changes (for a moment)

At Kaizen, we regard only this moment as a value,

I think we will eliminate other things from where we can.


I will narrow down the idea at this time,

1. The process of setting the upper and lower moulds on the press machine (called setup)

You can't just think about it usually.


What to do

Let's take a closer look at step 1.

Even if you think about it for a moment, about three will be more acceptable.

Remove the mould used for the previous panel moulding from the press machine (10 minutes).

Bring the mould to be used from the mould storage area (15 minutes)

Set the mould to be used in the press machine

Ideas here

" Take out the mould used for the previous panel moulding from the press machine.


If you think that the mould will disappear from the press, you push it to the opposite side instead of the front,


(If you raise the level of abstraction a little, you can come up with such an idea)


While the press machine is moving, the mould to be used from now on

Bring it in front and prepare it (called external setup)


I used it to shape the last panel, but at the same time, I moved to the other side.

You will be able to set a new mould.


With this idea, you can reduce the waste by 25 minutes.


In this way, you can come up with ideas and reduce waste.

To put it the other way around, it means adding value only.






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