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2014/11/036th TPS Kaizen Experience Dojo" in Vietnam

TPS Kaizen experience dojo is a course starting from Kaizen (improvement) activities of field observation and standardization, helps acquiring Kaizen skills throughout fostering the eyes to find waste, Kaizen method and "awareness" part. 

Also, through the team organization and therefore the experience of thinking with the others, it helps growing up the teamwork and communication skills.

 Hirayama Vietnam held 6th "TPS Kaizen Experience Dojo", with 18 companies and 20 participants.

 

The training program of TPS Kaizen Experience Dojo is as below;

 First Day) seminar

Cultivation of eyes to find waste: explain 7 wastes, especially the ones of walking, keeping and searching, with specific examples.

 Principle of motion economy: Reducing human's motion as much as possible leads to an improvement in productivity. Exercise of "block assembly"; experience the effect of minimizing the movement.

 Line balance: Commentary on tips to achieve over 95% of line balance efficiency, exercise of "dice composition line"; experience taking hands-on work line balance.

 Lot production VS1 piece flow production: Explain the fact that multi-process handling and one-by-one production lead to productivity increase. Experience the superiority of one-by-one production through exercise of "CD case assembly" line

 Flexible production: Explain the way of "flexible Kaizen" thinking and its method. Flexible line practice through "rolling ball" lines.

 Second Day:  Dojo " bicycle assembly work" Kaizen experience

 Training Flow:

Bicycle assembly process description → assembly practice (before Kaizen), work time analysis →Kaizen ideas extraction

Kaizen planning → summarize Kaizen plan → assembly practice (after Kaizen), work time analysis → effect confirmation, reviews

 Results attained:

 Bicycle assembly work time: before Kaizen= 412 seconds ➡ after Kaizen = 181 seconds, Productivity is improved to 2.27 times

 ・Greatly updated the best record over past 5 times of dojo, 201 sec, to 181 sec as a new record

 ・Principle application of motion economy, both hands work, parts convey/elimination of walking walk, practical use of jig/ratchet tool, etc.  

 Applying the lecture of previous day, participants continuously came up with great Kaizen ideas and achieved to reap a great effect.

 Seminar Atmosphere

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