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Defects on TA (2.2%) PowerPoint PPT Presentation


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Theme:. Name: Company:. Toyota Business Practices (TBP) ■ Problem Solving Flow Chart. The division you belong to: Paint shop in the assembly operations division

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Defects on TA (2.2%)

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Defects on ta 2 2

Theme:

Name:

Company:

Toyota Business Practices (TBP)

■ Problem Solving Flow Chart

The division you belong to: Paint shop in the assembly operations division

The background of the job: ▼ New paint floor will be established in June 2006, which will increase the production. Currently the incidence of outflow of paint defects has increased.

     ▼ Before establishing the paint floor, we have to decrease the defects without major capital expenditure.

Step 1 Clarify the Problem

Step 2 Break Down the Problem

【Ultimate Goal】

Having 0 painting defect.

【Process】

By defects categories

Units without defects

Flow out from

Paint shop

Units bought off

By final paint

inspection

Units painted &

Baked in top

coat

Units prepared

For painting

Units

primed

Contribution

Runs & Sags

(42%)

【Ideal Situation】

(Should be Situation)

2 % or less of vehicles leave assembly hall with paint related defects that require repair.

【Break Down】

By part

Thin paint

(34%)

Step 3 Target Setting

By car

Tail gate

(57%)

【Prioritized Problem at point of occurrence】

Defects on HILAY

(8 %)

【Target】

Paint defects occur

Reduce paint defects

Dirt

(24%)

【Problem】

Door interior left

(17%)

Paint defects leaving assembly hall need to be reduced by 4 %

Defects on

TA

(2.2%)

Door interior right

(22%)

Step 4 Root Cause Analysis

Defects on

CORLA

(2%)

Machine is inappropriate

Staff’s performances are poor

Painting materials are poor

Painting methods are ineffective

【Current Situation】

Currently 6 % of vehicles leave assembly hall requiring paint related repairs

Other area

(4%)

Defects on

RUX

(2.1%)

Difficult tasks to do

Skills are poor

Staffs do not have capacity to learn

There is a no skill development training for staffs

【The points that you cannot fit in the PS steps,

The researched data that were not apply for breakdown (Incl. Division Points)】

【Countermeasures】

【Root Cause】

. Conduct a training that can improve staffs’ skill development

. Make a poster that reminds staffs not to produce paint defects and put it to a wall

Step 5 Develop Countermeasures


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