STEP1MAN

TPS Practical Manual
Book 1
Developed by TPS Promotion Section,
Purchasing Engineering Department
TMAP-EM
Toyota Production System TPS (SMEs)
Contents
Contents of
of Step
Step 11
Worksite Control
Making Standardized Work
Worksite
Worksite control
control
1.) 2s
2.) Safety
3.) Built-in Quality
4.) Equipment Operational Condition Control
5.) Production Control
6.) Shipping Control Staging & Shipping Visualization
7.) Manpower Control
Worksite
Worksite control
control
Necessary condition for innovating TPS is,
work site must be under control
Have standard
Work following standard
Check result
Handle when problems occur
1)
1) 22 SS
Fundamental for keeping safety, quality and work efficiency
(1) Seiri
separate what is needed and what is unneeded
eliminate what is unneeded
(2)
Specify the location for what is needed
Seiton
Place where it is easy to use
Indicate what is placed there
Set the rules for placing and follow the rules
Example
Exampleof
of 2s
2sActivities
Activities
Example
Example of
of 2s
2s Activities
Activities
Before
After
2)
2) Safety
Safety
Safety comes first
(1) Confirm the rules of safety that have set
(2) Make the rules of safety well-known to everyone
(3) Follows the rules strictly
(4) Remove all unsafe place, and activate the
measure
Example
Example of
of uniform
uniform and
and
personal
personal preventive
preventive equipment
equipment
Before
standard
standard
After
10
Example
Exampleof
ofequipment
equipmentimprovement
improvementfor
forsafety
safety
Before
After
Using two hands push the button in

Press process
11
3)
3) Built-in
Built-in Quality
Quality
Never let defects outflows
(1) Define the items for quality check clearly ex. Quality
Check Sheet
(2) Define work and quality checking
(3) Prepare equipments for quality check ( for example, sample of
OK/NG part to limit standard level
(4) Implement work and quality check correctly
(5) Set up the management rules, in case abnormal quality, and
follow the rules strictly (stop operation, call respond person, wait
for instruction, etc.)
12
4.)
4.) Equipment
Equipment Operational
Operational Condition
Condition Control
Control
(1) Clarify Equipment operational condition
(2) See and understand operational condition instantly

(3) Operate by following the operational condition
(4) Whenever change any operational condition,

always do check the quality
13
5.)
5.) Production
Production Control
Control
(1) Make operator understand the hourly production plan
(2) Do record to make known the hourly actual result of
production
(3) Understand the cause of unachievable production plan
hourly
(4) Inspect the cause of unachievable plan, and take
measures
14
6.)
6.) Shipping
Shipping Control
Control Staging
Staging && Shipping
Shipping Visualization
Visualization
Set time for Staging/Shipping (diagram) make
shipping diagram
Set the area for staging by route, convenience for
working
prepare the staging are to be ready to work
continuously and promptly
Make the staging and shipping easy to understand
proceeding/delay
whenever anyone sees
Make Waiting Post
15
7.)
7.) Manpower
Manpower Control
Control
(1) Set layout of standard operators in each
process (necessary operator)
(2) Grasp the status of daily attendance, and
understand the absence of manpower.
(3) Set the method to manage whenever theres any
absence.
16
17
18
19
Making
Making Standardized
Standardized Work
Work
Kaizen Step
1.) Clarify the 3 element of Standardized Work
2.) Time Measurement
3.) Make 3 sheet of Standardized Work.
4.) Cycle Time, Cycle Time Fluctuation.
5.) Periodical Job, Change Over Setup
6.) MakeYamazumi Chart.
20
1.) Clarify the 3 element of Standardized Work.
Elements of Standardized Work
1.1 Takt Time
Actual Takt Time

Target Cycle Time
1.2 Work Sequence
1.3 Standard Work-In-Process Stock
21
3 main factor of standardized work

Takt Time
Work Sequence
Std. Stock In Process
Takt Time
Std.Stock in
Process
Finished
part
Work Sequence
Material
22
1.1 Takt Time
T.T.(Takt Time)
Regular working hours

Required production volume
Example
Total required production volume of product A is 5000pcs./month
Working day in 1 month of product A maker is 20 days (1 working
day is 460 min.)
Then Takt Time will be
20 x 460
5000
= 1.84 Min/piece
23
1.1 Takt Time
Actual Takt Time
Regular working hours + Over Time

Required production volume
Example Total required production volume of product A is 5000pcs./month.
Working day in 1 month of product A maker is 20 days (1 working
day is 460 min.) Over Time is 2 hr/day
Then Takt Time will be
20 x (460+120)
5000
= 2.32
Min/piece
24
1.1 Takt Time
Target Cycle Time

Target Cycle Time is supposed to be cycle time or the minimum
time for 1 cycle of working from measurement of around 10- 20
times by stopwatch.
25

1.1 Takt Time
Takt Time
Acting Takt Time
Target Cycle Time
1.2 Work Sequence
26
1.2 Work Sequence

Work sequence is a set of process
sequence so that an operator can work the
same way every time
27
1.2 Work Sequence

Before Improvement
After Improvement
Setting Standard
No Standard
3rd Time
1st time
E
2nd time
28
Example ; good / no good work

sequence
FG
11
FG
10
13
10
14
12
9
1
1 RAW
MAT.
RAW
MAT
29

1.1 Takt Time
Takt Time
Acting Takt Time
Target Cycle Time
1.2 Work Sequence
30

The standard inprocess stock is the
minimum stock that
allows each operator to
repeat his or her job
following the work
sequence in the same
procedure and motions.
Standard Work-In-Process
the number of piece-work between

each process that need to be kept
so that the next start to operators
could start working promptly
31
II.
II. Making
Making Standardized
Standardized Work
Work
Kaizen Step
2.) Time Measurement.
3.) Make 3 sheet of Standardized Work
4.) Cycle Time, Cycle Time Fluctuation
32
Time Measurement Table
1. Record date
1
2
3
7
5
10
11
2. Process name
3. Recorders name
4. Model name / Part No.
5. Work sequence no.
6. Work elements
7. Time (from stop watch)
8. Minimum time
9. Maximum time
10 Fluctuation (max. - min.)
11. Average time
12. Summary of 1 cycle time
12
33
Time is the motion shadow

Time is controlled by method
of production
34
Time measurement key

point
2 main items
1. Job element
2. Measurement point
35
Time Measurement
Sheet
Objective:
1. To identify what work element has big
process time fluctuation.
2. Tools to kaizen process time
fluctuation.
3. To standardized work element & cycle
time using minimum value
36
Time Measurement Sheet
Step 1-2
STEP 1 Observe work element and separate each element for time measurement
STEP 2 Decide the start and stop points of work element follow step 1and
measure by stop watch
37
1. Exercise analysis job

elements
TOYOTA
38
Exercise of time
measurement
Stand
up
Pick
up
pen
Ope
n
cove
r
writin Clos
e
g
cove
r
Pu
t
on
pe
n
Sit
dow
n
Sit
ting
39
Standardized work
chart
title
from
stand up
Of job
to
chair
sit on the
MGR..
Asst. MGR.
T.L
DATE : 07/01/06
Quality check
table
White board
Safelly point
Std. stock in
process
No. of std stock

in process
Pcs.
Takt time
-
chair
min
25
second
Cycle time
minute
22
second
1/1
40
41
Example of information from step1-2

Working process and time measuring point
1.) Check work-piece and clean
(time measuring point: take the work-piece - put down the
cleaning equipment)
2.) put the work-piece into machine No. P001, and push the switch
(time measuring point: put down cleaning equipments - hand off
the switch P001)
(time measuring point: hand off the switch P001 - hand off the
switch P002)
4.) bring the work-piece to store side line
(time measuring point: hand off the switch P002 - back to the
start measuring point)
Details of working process is divided into
1.) Handling Time/Manual Time
2.) Walk Time
42
1.)
2.)
P001
3.)
P002
4.)
Store Side Line
3
2
2.1
3.1
5.2
2.1
2.1
3
5
2
2
3
4
2
2
4
6
2
1.9
2.9
4.8
1.9
1.9
3
5
2
2
3
Step 3
5
3
3
3
4
1
1
2
6
2
2
3
STEP 3 Measure by stop watch for 10 laps and record.

For time measurement we need stopwatch that can measure lap by lap, to
be able to record easier and faster, especially when theres any mistake
43
Example of information from step1-2

Working process and measured time (sec.)
1.) Check work-piece and clean
(3, 5.2 , 5 , 4, 6, 4.8, 5, 5 , 4, 6)
(2, 2.1, 2, 2, 2, 1.9, 2, 3, 1, 2,)
(time measuring point: hand off the switch P001 - hand off the
switch P002)
(2.1, 2.1, 2, 2, 1.9, 1.9, 2, 3, 1, 2,)
4.) bring the work-piece to store side line
(3.1, 3, 3, 4, 2.9, 3, 3, 3, 2, 3)
44

1.)
2.)
P001
3.)
P002
4.) Store
Side Line
3
2
2.1
3.1
5.2
2.1
2.1
3
5
2
2
3
4
2
2
4
10.2 12.4 12
12
6
2
1.9
2.9
4.8
1.9
1.9
3
5
2
2
3
5
3
3
3
4
1
1
2
6
2
2
3
Step 4
14
13
12.8 11.6 12
STEP 4 Summarize the data of each row (Cycle time) and select
minimum data (cycle time) to make the Standardize Work
Combination Table.
45
Practical training kaizen at shop

floor
46
II.
II. Making
Making Standardized
Standardized Work
Work
Kaizen Step
2.) Time Measurement
47

3.1 Machine Capacity Sheet
3.2 Standardized Work Combination Table

3.3 Standardized Work Chart
48
Objectives:
1. To compare the machine capacity
with customer demand.
2. To standardized the change over time
and its frequency.
49

1. Recorders name
2. Record date
3. Production Section
4. Line Name
5. Part No.
6. Part Name
7. Require Volume
8. Takt Time
9. Before/After
10. Working Time
11. Sequence Number
12. Process Name
13. Code Machine
14.Manual Time
15. Auto time
50

16.Time complete
17.Tool Changes Time
18. Changes (pcs/time)
19. Capacity
20. Remark
21.Total Time
22. Document No.
23. Work sequence No.
24. Section who makes Doc.
25. Brach where makes Doc.
26. Company where makes Doc.
27. Recorder
28. Checked person
29. Approved person
51
Example Line Name : 243R/C Reinforce SUB ASSY

Product Code :
1600
Product: Reinforce
Process
Material
Layout
(pipe)
B-101
13800
B-102
P-101
(bending) (bending)
(press)
B-101
Material
SP-101
(arc-welding)
(spot-welding)
B-102
P-101
Required volume 890 pcs/shift
Completed work
Working Time 1shift (460 min.)
AC-101
243R/C
LINE
PROCESS
13800-1600
PART No.
PART NAME
DEPARTMENT PRODUCTION
..
NO.
PROCESS
BENDING
1
BENDING
2
PRESS
3
SPOT-WELDING
4
ARC-WELDING
5
Step 1
Step 2
TIME MACHINE TIME

CODE HANDING
MIN. SEC. MIN. SEC.
B-101
2
8
B-102
3
11
P-101
2
9
SP-101
5
5
AC-101
8
21
Step 3
TOTAL
20
Step 4
SP-101
KOTEI BETSU NORYOKU HYO

BASIC TIME
Completed
work
AC-101
22 / 6 / 2001
APPROVED
MR.DEN
REPORTED
MRDANGI
TOOLING
FINISH TIME PCS./ CHANG CHANGING

SEC.
1 TIME
TIME
MIN.
CHECKED
MRDUM
10
14
11
10 1,000
29
Step 5
50
CAPACITY
(951)
2,760
1,971
2,509
2,746
951
Step 6
HANDING
MACHINE
2
3
2
11
9
5 5
8
21
Step 7
52
Making Method
STEP 1 Input number by order all processes
STEP 2 Input the name of processes
STEP 3 Input machine No. in each process
STEP 4 Record the time
(1) Man working Time; the working time without walking
(2) Machine working time
STEP 5 TOOL CHANGE can divide into
(1) The number for changing : total number for production before changeover
(2) Time for changeover : time for setup when change model
STEP 6 Production Capacity (for 1 shift)
1. The number that can produce in limited time for 1 shift
Production Capacity
Working time / shift

Time to complete (sec/pc) + Tool change (sec/pc.)
STEP 7 Remark
Show the time, which the solid line means working time
Human working time
Machine working Time
53
Example ofMachine Capacity Sheet

1. Manual operation and then
machine running.
ex.: set part and push switch.
Draw a straight line to

represent manual time and a
dot line for auto time.
2. Machine running and then

manual operation
ex.: press part and take out
part.
Draw a dot line represent auto

time and a straight line for
manual time
3. During auto time have

operation ex.: hang part to the
painting conveyor.
Draw a straight line on dot

line.
4. Automatic machine
(no operator).
Draw a dot line.
54

55
56

1. Line name
2. Model
3. Part No.
4. Part Name
5. Operator No./total operators No.
Objectives:
1. To visualize the activity of operator
and identify waiting time.
2. To compare cycle time and takt time
3. To use as kaizen tool to reduce the
gap between C.T. and T.T
6. Takt Time
7. Require Volume
8. Record date
9. Require Volume
10. Before/After Kaizen
11. Symbol for working
12. Process order No.
13. Safety Symbol
14. Work description
57

15. Machine No.
16. Human working time
17. Machine working time
18. Walking Time
19. Graph showing working time
20. Total time
22. Brach where makes Doc.
23. Company where makes Doc
24. Revised Time
25. Document No.
26. Recorder
27. Checked person
28. Approved person
58
Step 2
LINE
Step 1
J 97
Step 3
890 PCS.
PART NO.NMF 001-27200-FHYOJUN SAGYO KUMIAWASE HYO
1/1
TAKT TIME 31 SEC.
PART NAME
NO.
PROCESS
(SEC.)
1
2
3
B-102 Set Part/Sw.ON 3
4 P-101 Set Part/Sw.ON
2
5
SP-101 Set Part/Sw.ON 5
6
AC-101 Set Part/Sw.ON 8
7 , F/G Pallet
1
1 Part
2 B-101 Set Part/Sw.ON
Step 6
8
11
9
5
21
-
1
1
1
1
1
1
1
10
20
CT.= 29 TT.= 31
30
40
SYMBOL.
Step 4
Step 5
Step 8
Step 7
22 7
2
Step 9
STEP 1 input line name, part No., Part name

STEP 2 Working sequence, by No. of operator from all operator ex., 2/6
means operator No. 2 from 6 operators
STEP 3 Required volume for each period (shift or day)
59
STEP 4 TAKT TIME

STEP 5 Draw T.T. line in the table with red color
STEP 6 Input sequence No. and machine No
STEP 7 Input time for each process, divided into 3 parts (manual time,
machine time, walking time)
STEP 8 Draw the time lines in the table by each, divided into 3 types;
Solid line
Dot line
Wavy line
Man working time/manual time

Machine working time
Walking time
STEP 9 Draw C.T. line in the table
60

1.)
2.)
P001
3.)
P002
4.) Store
Side Line
3
2
2.1
3.1
5.2
2.1
2.1
3
5
2
2
3
4
2
2
4
10.2 12.4 12
12
6
2
1.9
2.9
4.8
1.9
1.9
3
5
2
2
3
5
3
3
3
4
1
1
2
6
2
2
3
12.8 11.6 12
14
13
STEP 1
Select the minimum value (Total C.T.) from Time

Measurement Sheet
61
1.
2.
P001
3.
P002
4.
P001
P002
STEP 2
Write down the details of working process in the
table, if the process is about Quality use
,and if it is
about safety use
62
1.
2.
P001
3.
P002
4.
3.8
P001 1.9 3
P002 1.9 5
STEP 3
Fill in the time by separate into Manual or human
hand-work time, Auto M/C time, and wolking time.
63
10 12 14 16 18 20 22 24 26 28
3.8
P001 1.9 3
P002 1.9 5
STEP 4 Write down the working time line into the table
Solid line
Dot line
Wavy line
Human working time

Machine working Time
Walking Time
64
10 12 14 16 18 20 22 24 26 28
C.T. = 10.6 sec
3.8
P001 1.9 3
P002 1.9 5
STEP 5
Draw the walking line back to the first process and
draw the Cycle Time.
65
10 12 14 16 18 20 22 24 26 28
C.T. = 10.6 sec
3.8
P001 1.9 3
P002 1.9 5
STEP 6
Draw Automatic Machine Time line, in case its over Cycle
Time back to the beginning from zero and draw all the rest
66
10 12 14 16 18 20 22 24 26 28
C.T. = 10.6 sec
3.8
P001 1.9 3
P002 1.9 5
T.T. = 10 sec
STEP 7
Draw Takt Time Line with red color, with Takt Time number
67
Example of Standardized Work Combination Table Record

1. Reverse-line of M/C time in
case of C.T. < T.T.
Draw M/C line to T.T. line and

back to start at 0 until finish M/C
time
2. Reverse-line of M/C time in

case of C.T. > T.T.
Draw M/C line to C.T. line and

back to start at 0 until finish M/C
time
3. Waiting time in case of C.T. <

T.T. C.T. < T.T.
Put the arrow

in waiting
period with waiting time
4. Waiting time in process

Put the arrow
in waiting
period with waiting time
5. Same-time operation (ex. 2
M/C is operated when push
switch)
6. Work while walking (working

time is not over 1 sec) (ex.
Push switch while walking)
Write the parallel line at the

process which operate in same
time
Write the circle at the point of
operation over walking line
68
Example of Standardized Work Combination Table Record
7. Work while walking (ex.

Assembly while walking)
8. Forward and back

working
9. Working with the same

process repeatedly (ex.
3 times Nut welding )
10. Human works while

machine is processing
(ex. Setting work into
painting booth)
11. Human continually

working (non-stop)
Write working line over walking

line by using time you have
measured compare with the time
scale
Draw working line back to the
process that operator go back
to do
Write down number to know how

many times they do the job
Write down the human working

line over machine working line
Write down the continuous

working step with continuous
69


70
Objectives:
1. To identify which process has quality
and safety concern.
2. To set standard work in-process
quantity.
3. To visualized standard operators
movement and kaizen criss-crossing
movement.
71

1. Record date
2. Line Name
3. Part No.
4. Part Name
5. Recorders name
6. Before/After
7. Work description
8. Picture of standardized
work
9. Quality Check symbol
10. Safety Check symbol
11. STD. work in process
12. Work In Process No.
72

13. Require Volume
14. Actual production
Time/piece
15. Operator No./total
operators No.
17. Brach where makes
Doc.
18. Company where makes
Doc.
19. Revised Time No.
20. Document No.
21. Recorder
22. Checked person
23. Approved person
73
HYOJUN SAGYO HYO
Example
243 R/C
LINE
PART No. 13800-1600
PART NAME
Step 10
Standardized Work Chart
MATL
To
P-101
7
F/G
AC-101
SP-101
Quality
Check
Step 6
Step 7
STD. stock
REPORTED
Step 3
Step 4
Safety
CHECKED
Step 1
Step 2
Step 12
B-102
Step 5
APPROVED
Putting F/G on Pallet
B-101
Record date 25 /04 / 2004
from Taking MATL
Job description
Step 11
Step 8
Step 9
Work
TAKT TIME CYCLE TIME
Stock in
process No.
SEC.
SEC.
Sequence
31
29
1/1
74
Step 1
Line:
Intake Manifold
Model:
ABC
P/No.:
17111-24060
HYO JUN SAGYO HYO

(Standardized Work Chart)
P/Name.: Intake Manifold

Date:
28/05/2008
Work
Approved
From: Pick up material
Step 2
Description To: Place finished product
Step 4
Checked
Writen
Production Section
Step 3
MI - 1764
Step 7
Material
2
1
3
Finished
DR - 2424
6
5
Products
Step 9
TP - 1101
Step 6
Step 5
Qualily Safety Std. Stock

Check Caution Stock In Pro.
3
Step 1: Input the line, model, part no., part name and date.
Step 2: Input the process name from start until finish the job cycle.
Step 3: Draw the line layout and input the work elements.
Step 4: Connect the work elements by following the work sequence.
Step 8
Time
Takt Cycle
31"
30"
Step 10
75
Step 1
Line:
Intake Manifold
Model:
ABC
P/No.:
17111-24060
HYO JUN SAGYO HYO


Date:
28/05/2008
Work
Approved
Step 2
Step 4
Checked
Writen
Production Section
Step 3
MI - 1764
Step 7
Material
2
1
3
Finished
DR - 2424
6
5
Products
Step 9
TP - 1101
Step 6
Step 5

3
Step 8
Step 5: Input the standard In Process Stock of each process (if any).
Step 6: Input the Quality Check symbol for the processes with quality check.
Step 7: Input the Safety symbol for those processes concern about safety.
Step 8: Input the total quantity of In Process Stock.
Time
Takt Cycle
31"
30"
Step 10
76
Step 1
Line:
Intake Manifold
Model:
ABC
P/No.:
17111-24060
HYO JUN SAGYO HYO


Date:
28/05/2008
Work
Approved
Step 2
Step 4
Checked
Writen
Production Section
Step 3
MI - 1764
Step 7
Material
2
1
3
Finished
DR - 2424
6
5
Products
Step 9
TP - 1101
Step 6
Step 5

3
Step 9: Input the Takt Time (T.T.) of this line.

Step 10: Input the Cycle Time (C.T.) of 1 job cycle.
Step 8
Time
Takt Cycle
31"
30"
Step 10
77
Making
Making Standardized
Standardized Work
Work
Kaizen Step
78

Cycle Time
(C.T.) is the total amount of time required for a
worker to complete one cycle of his entire job process,
including manual working time and walking time. In ideal
conditions, Cycle Time should be same with Takt Time
(T.T.) to prevent either over-production (if C.T. < T.T.) or
lack of production capacity (if C.T. > T.T.).
Cycle Time Fluctuation

is caused by the operation conditions such as
motion, equipment, quality that is unable to follow
standard of operation & etc. Kaizen need to be taken to
improve the fluctuation in order to maintain the stability
of Cycle Time.
79
Making
Making Standardized
Standardized Work
Work
Kaizen Step
80
Periodical Job
is the non-value added job that is necessary to perform under
present work conditions such as return an empty box, record the
production output every 1 hour, clean the machine every 15 min.,
etc.
Kaizen of periodical job is necessary to change the non-value
added job into value added job in order to level up the productivity of
line.Ex.: Supply component parts piece by piece, without the box.
Change Over Setup
Setup time is the time it takes to change over from the
production of one product to another, from the instant that the
processing of the first good sample of the next type of component. It
includes all the time needed for change over of the dies, cutting
tools, etc.
81
Example of Calculating Periodical Job

It is time that use for changing box, and box is
over than normal C.T. (might cause Lot)
Periodic Work
Periodical Job of 1 job cycle
Total time required for a Periodical Job

Total unit produced in 1 Periodical Job
Calculating Method
changing box and taking box time
Periodic Work
20 sec./time
1 Box
10 pcs.
20
10
2 sec/pc.
82
Making
Making Standardized
Standardized Work
Work
Kaizen Step
83
6) MakeYamazumi Chart.
This chart shows the relationship of T.T. & C.T. It shows the cycle time of
each operator by the current job elements. It is used to decide manpower or
O.T. requirement by analyzing the information from this chart.
Objectives:
1. To show the gap between C.T. of
each process and the required T.T.
2. To as kaizen tool to level the process
C.T. of each operator.
3. To decide if Average
there is Time
an OT needed to
produce the customer demand
Setup
time
Maximum Cycle Time

T.T.
Periodical
job
C.T. Fluctuation
CT.
Minimum Cycle Time
84
Step 1: Plot the Yamazumi chart by using the minimum Total

C.T. value from Time Measurement Sheet.
Step 1
Yamazumi Chart
Seq.
JOB Element
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
Press
25
24
24
26
25
25
24
23
26
27
Spray
18
19
19
17
18
17
16
19
19
17
Heater
Press ornament
24
25
23
24
25
24
24
24
26
24
29
Assy
31
31
29
32
33
29
31
33
25
27
24
TOTAL
104
105
102
105
106
101
102
106
102
102
101
6
17
Minimum
C.T.
25
Min C.T
Max C.T.
Average C.T.
Fluctuation
101
106
103.5
85
Step 2: Plot the C.T. Fluctuation on the right side of the bar by using the
maximum Total C.T. value from Time Measurement Sheet.
Step 2
Yamazumi Chart
Seq.
JOB Element
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
Press
25
24
24
26
25
25
24
23
26
27
Spray
18
19
19
17
18
17
16
19
19
17
Heater
Press ornament
24
25
23
24
25
24
24
24
26
24
29
Assy
31
31
29
32
33
29
31
33
25
27
24
TOTAL
104
105
102
105
106
101
102
106
102
102
Max
6
17
Min.
C.T.
C.T.
25
Min C.T
Max C.T.
Average C.T.
Fluctuation
101
106
103.5
86
Step 3: Input the average Total C.T. value from Time

Measurement Sheet inside the Cycle Time fluctuation bar.
Step 3
Yamazumi Chart
Seq.
JOB Element
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
Press
25
24
24
26
25
25
24
23
26
27
Spray
18
19
19
17
18
17
16
19
19
17
Heater
Press ornament
24
25
23
24
25
24
24
24
26
24
29
Assy
31
31
29
32
33
29
31
33
25
27
24
104
105
102
105
106
101
102
106
102
102
TOTAL
106
101
6
17
25
Min C.T
Max C.T.
Average C.T.
Fluctuation
101
106
103.5
87
Step 4: Calculate the Periodical Job of 1 job cycle & input into
chart. (over the min. C.T. bar on the left side)
Ex.
Component part package size is 5pcs per box.
Operator need to return the empty box of
component part supply and prepare for a new box
of component part. Assume that it takes 30sec for
this periodical process.
Step 4
Yamazumi Chart
106
101
29
24
Periodical Job per

job cycle
30sec
5pcs
6
17
6sec/pc
25
88
Step 5: Calculate the Setup time of 1 job cycle & input into chart.
(over the periodical work bar)
Ex.
Lot size of 50pcs is used in the production line.
Die change over setup time is 8min and
adjustment time is 2 min.
Step 5
Yamazumi Chart
106
101
Setup Time per

job cycle
=
=
(8min + 2min) x 60sec/min
29
50pcs
24
12sec/pc
6
17
25
89
Step 6: Repeat step 1 to 5 for other operators in the same production line.
Step 6
Yamazumi Chart
29
106
103.5
101
100
80
24
24
6
17
6
17
25
25
70
90
Step 7: Input the Takt Time value of the production line.

Step 7
Yamazumi Chart
T.T. = 120 sec

29
106
103.5
101
100
80
24
24
6
17
6
17
25
25
70
91
Remark Points for Standardized Work

Combination Chart (Kaizen + Control)
Separate works when there is walking.
If there isnt walking, group works together.
Write same machine down in the same line.

Arrange by using machines order, not work order.
When operator goes, machine is still
operating so operator cannot do manual
work.
Combine human work with machine work.
92
3-3
Standardized Work
Kaizen
(1) Production work sites use Standardized Work as a base in all

operations
:
Standardized
operate
by following
Work and use it
as a base for doing Kaizen.

Consider about many sides such as Muri, Muda, Mura, working
(2) efficiency, safety, etc. that are related to operation, following
Standardized Work.
Motion
Motions that are muda such as holding things

Motion range
Operating Condition and Layout
Walking that is muda

Walking back to starting point
Position and height
93
3-4
Making of
Efficiency
Produce necessary quantity (number) with the decided

time and the number of people as few as possible.
94
3-4-1 Making of Yamazumi Chart

CYCLE TIME
Know cycle time. (measure 10 times and enter in the

time measure sheet)
(1) CYCLE TIME

Take CT of the best 1 cycles which could measure.
(2)
Periodical Work is the work which occurs one time in

every cycle. (Ex., changing box, blade tool
exchange, quality check)
95
3-4-2
Fluctuation in Work
Kaizen
Fluctuation in work is an evidence for having

problems.
work difficultly
worry about quality
worry about safety
have a large waiting
so it is necessary to do Kaizen.
96
3-4-3 LINE BALANCE CHART

Making of Line Balance
Chart
Draw one operators job into piled graph. With

this graph, you will be able to compare all
operators Cycle Time and Takt-Time.
40
50
40
TT :
60
50
30
97
3-4-4 LINELine
BALANCE
Balance Kaizen
Make each operators Cycle Time close to Takt-Time
as much as possible and progress to Manpower
Savings
40
50
40
50
30
Before Kaizen
60
60
60
TT : 60"
TT : 60"
30
After Kaizen
98
There are 7 types of Muda in a Production System

Muda of Over
Production
Muda of
Waiting
Muda of rework
Increase
Cost
Muda of Inventory
Muda of motion
Muda of Processing
Muda of
Conveyance
Among the 7 Muda which is the worst Muda? Why?
99
Muda of over-production is the worst muda of all
Why products are over-produced

than its selling volume?
Having excess man-power and

machinery
Concern over-production as Muda
Why are we tempted to overproduce?
Emergency stock for down time,

defects, and absentees, etc.
Approval of over-production causes

additional muda
Increase of pallets and boxes
Over-production hide problems and

makes it impossible to be solved
Increase of conveyance tools and

forklifts
Construction of warehouse
Cant reduce cost

100
Muda Identification from

Video
101

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TPS Practical Manual

Toyota Production System TPS (SMEs)

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1.2 Work Sequence

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1.1 Takt Time

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day is 460 min.) Over Time is 2 hr/day

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Target Cycle Time

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1.2 Work Sequence

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Time Measurement Table

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