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Production Preparation Process
Things to Consider
Production Preparation Process
Things to Consider
Add Value to the Product Continuously Through the Process
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Raw Material
Finished Goods
Production Preparation Process
Things to Consider
Batch Production VS. One Piece Flow
Production Preparation Process
Things to Consider
Which is smoother?
Pushing Pulling
Production Preparation Process
Things to Consider
Use Ideas NOT Money
Production Preparation Process
Things to Consider
MACHINES
No ONE-WAY Machines

Bring the part back to the operator
No Dinosaur Machines
We know what happened to the dinosaurs
Production Preparation Process
Things to Consider
Sacred Cows make the BEST Burgers
Production Preparation Process
Things to Consider
Use Equipment Necessary to Permit One Unit Flow
Production Preparation Process
Things to Consider
Keep Height of all Items in the Workplace Very Low
Production Preparation Process
Things to Consider
Don’t Build Big Ships with Big Guns…
Think Small and Responsible
Production Preparation Process
Things to Consider
Explanation NOT Necessary
Production Preparation Process
Things to Consider
Keep an OPEN Mind to Change and New Concepts
3
P
Production Preparation Process
Things to Consider
Avoid Machines with Loads of Unneeded Accessories
Think Bare Bones…Add Options When Necessary
Machines
Production Preparation Process

Things to Consider
No Catalog Engineers
Get your hands DIRTY
Production Preparation Process
Things to Consider
Design Machines to be Like Town houses NOT Ranch style Houses
Wide
Frontages
Space far
apart
Narrow & Deep
Closely Spaced
Production Preparation Process
Things to Consider
Don’t Use Brainstorming
Try Use TRYstorming
Production Preparation Process
Things to Consider
Use Shuttles to Allow Throw-in Loading
With Auto-Ejection (Hanedashi)
Hanedashi
Shuttle
Safety
Barrier
Production Preparation Process
Things to Consider
Don’t attach Roots and Vines to Machines
Make them easy to relocate
Machines
Machines

Production Preparation Process
Things to Consider
Don’t think about
CO$T
Shoot for BEST:
Q
uality,
Q
uantity and
T
iming
Q
Q
Q
Q
T
T
CO$T
Production Preparation Process
Thought on Machines
Installation of Andon
Installation of Andon
Production Preparation Process
Thought on Machines
Abnormalities can be found at a glance.
Production Preparation Process
Thought on Machines
Animal like machines
Animal like machines
Feed in the front. Waste out the back.

Localized covers. Collect dust / debris at source.
Production Preparation Process
Thought on Machines
Right
Right
-
-
sized
sized
Not too big, fast, or powerful
Do not use special purpose machine.
Production Preparation Process
Thought on Machines
POKAYOKE
POKAYOKE
Pokayoke is build in to the process.
It prevents making defect, sending defect to next
process, and accepting the defect.
Right processing
position
Wrong processing
position
Right position
Example
Production Preparation Process
Thought on Machines
Hanedashi
Hanedashi
Auto ejection
Hanedashi

Shuttle
Safety
Barrier
Parts