26th International Conference of the

TOC Practitioners Alliance - TOCPA

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19-20 May 2016, Fukuoka, Japan

CCPM

Using CCPM to build management process

in mold manufacturing

Yasuaki Yamamoto

TAKAGI CO.,LTD
Plastic Mold Manufacturing Dept. Manufacturing Division

19 th May, 2016


Yasuaki Yamamoto

1990 ()

2012 ()

TOC20157
CCPM

Yasuaki Yamamoto is the production manager of Takagi Co., Ltd.

He joined in 1990, and was engaged in mold manufacturing and mold
design since then.

yamamoto16@takagi.co.jp

He started CCPM implementation with the help of Juntos Consulting.

Mold Manufacturing Dept. has moved to the full execution since July 2015,
and achieved significant results of reducing production lead time and
increasing throughput.
He is currently working on solving problems for POOGI through the use
of CCPM.
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26th International Conference of the TOC Practitioners Alliance - TOCPA

1.
2.
3.
4.
5.
6.
7.

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26th International Conference of the TOC Practitioners Alliance - TOCPA

2-4-1

365

463153 615

19,776m5,993

10,608m 8,318m
2,486m 2,531m

ISO9001ISO14001

775m

20163

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26th International Conference of the TOC Practitioners Alliance - TOCPA

1961

7,800

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26th International Conference of the TOC Practitioners Alliance - TOCPA

1%
2%

3%

16%

35%

10%

33%

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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26th International Conference of the TOC Practitioners Alliance - TOCPA

CCPM

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CCPM

26th International Conference of the TOC Practitioners Alliance - TOCPA

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26th International Conference of the TOC Practitioners Alliance - TOCPA


2015
1
Jan

2
Feb

3
Mar

4
Apr

5
May

6
Jun

Concerto
Go-live

&

WIP
WIP
Reduction

CRS & Solution

Design

TOC

7
Jul

8
Aug

9
Sep

10
Oct

Concerto
Go-live

PJ

Task
Mgmt
Impl

PJ
Ctrl
Impl

&

CRS &
Solution
Design

CCPM
:

10w

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11
Nov

26th International Conference of the TOC Practitioners Alliance - TOCPA

WIP

WIP
Redu Task
ction Mgmt
Impl

CCPM
:

4w

10

12
Dec

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26th International Conference of the TOC Practitioners Alliance - TOCPA

11

*WIP Work in Process

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()

High WIP

26th International Conference of the TOC Practitioners Alliance - TOCPA

12

High WIP

Rule 1:

Rule 2:

Rule 3:

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WIP

FK

26th International Conference of the TOC Practitioners Alliance - TOCPA

13


WIP
Low WIP3
()

WIPOne-out & One-in

One-in

One-out

WIP
1
2
3

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14

Rule 1:
WIP

WIP3

WIP2

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Rule 1:
Low WIP

NCE
High WIP

Low WIP

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Rule 1:

One-in

One-in

OK

One-out

One-out

FK
2

FK
1

WIQ1

NG

WIQ2

One-in

100

<100

One-out

FK

WIQ3

WIP = 5

WIP Work in Process

WIQ Work in Queue

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Rule 1:

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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Rule 2:

FK
1

FK1

FK
2

FK2

()

(T1)

(
)

(
)

(S)
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Rule 2:
Concerto

D
E

D
C

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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Rule 3:

50%&50%

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26th International Conference of the TOC Practitioners Alliance - TOCPA

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Rule 3:

16:30, <15

9:00, <10

Concerto

24:00

@
16:45, 30

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Rule 3:

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Resource Mgr

Executive

Project Mgr

30
/

Short Work TL

15
/

30
/

Task Mgr

10
/

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No.2 /
: WIP/5
WIQ:
WIP:

:
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LT
LT

()LT

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TP

: 5/

TP

TP

: 5.3/

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60

45

48

20%

22.4

11

15

33%

4/

5.3/

5.3/

33%

30%

20%

33%

60

48

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33%

22

15

5.3

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CCPM

2015/12

up

PJ/SW1

LT

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CCPM
TP
TPWIP
CCPM31

(2016/3-4)

21

10

57%

57%

21
9

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