Less Engineering Example - 29oct15 PDF

EXAMPLE LESS ENGINEERING
1
This material prepared by HLMG Management Co Sdn. Bhd, QPP Department, for Graduate Development Programme (GDP) (Sep15)
LESS ENGINEERING IN RELATION WITH FACTORY CONTROL
Factory control Office Control
Man Machine Material parts Method Quality Safety Control office
Look-less Air-less Bolt-less Neck-less reject-less Roller- paper-less

Walk-less Conveyor- Bar-less Stock-less Failure-less accident- Stamp-less
Search-less less Weight-less Non- less Make-
Rough- Air-cut-less Spot less standard- Sandwich- business-
motion Air-press Welding- less less less
less less less Body-cut- Telephone-
Parts- less less less
Crash-less Meeting-
etc etc less
etc etc etc Mistake-
stop-less
etc
etc
2
3MU MEMO Tools
EXAMPLES OF KEY Man

WORDS IN LESS Machine
ENGINEERING
Air-less,
Look-less, conveyor- Stop-less,
walk-less, less, air cut- Adjust-less,
search-less, less, air ear pick-less,
building press-less, dust-less,
block-less, sump-less tool box-less
rough motion- etc
less Qualit
etc yDefective goods-
Material less, bungle-less,
& parts nonstandard-less,
clicking-less,
etc
3
EXAMPLES OF KEY
WORDS IN LESS Box-less, bar-less,
Safety
weight-less, spot-
ENGINEERING less, welding-less,
parts-less Roller accident-less, drop-
etc less, sandwich-less, body
cut-less, crash-less
etc
Method
Administration
Neck-less, over stock- Paper-less, post
less, hungry-less, setup- code-less, stamp-
less less, make- business-
less, telephone-less,
etc meeting-less
etc
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Less Engineering ----Focused on Human
Less Engineering Explanation of Contents Expected Results

LOOK-LESS *Though installing automatic *Workers can handle many
machines, but when workers must machines at once, so as to
still observe the machine, it is reduce cost.
useless . *work can be solved with
*Is the division works badly that one less workers.
should wait?
*Did m-m chart used?
WALK-LESS *Moving and walking should not be *Reduced work hours

associated with work *create state where workers
* only 2 ~ 3 steps in 1 day could be can handle many machine
able to make the distance far. at a go.
*Relay out as much as possible to *Reduce place
reduce the possibility of workers to
walk?
5
Less Engineering ----Focused on Human

SEARCH-LESS *Is it because of poor Seiri -Seiton *Very useful for 5S
hard to find stuff?
*Are items placed in a way such that
workers do not need to look again?
BUILDING BLOCK-LESS *Building blocks is a kids game . *Eliminate muda movement
*what to break enjoy stacking and taking and putting the
dropping stuff over and over? goods, as well as reducing
material in the process.
ROUGHMOTION-LESS *Eliminating vigorous and big *painful work reduced.

movement. *Muda movement
*change work according to the eliminated.
principle of economy action . *Efficiency increased.
*Observe return material storage and *Quality improved.
utensils, work tables, and so forth. *Safety improves
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Less Engineering 3 MU
Less Observed
Look- Less MURI MURA MUDA
Description of existing condition:
(Existing Condition) Date:
Time for the process to-1 = 22.3 seconds, while the
time for the 2nd = 57.8 seconds. Due to unbalanced
processing time, waiting time incurred every 5 units.
There is a waiting time of 2.8 seconds for the
process to-2. Would this be removed?
(After KAIZEN) Date:
Description of details of improvement made:
Sections that had been processed in the 2nd, was

transferred to the 1st. Time for the process to-1 =
29.3 seconds, while the time for the 2nd = 40.8
seconds. Thus, so there is no waiting time.
Point of Improvement KAIZEN Result Money Saved

By analyzing the process of cutting Total daily production = 28
time, we can maintain a balance pieces. So start to do the
between processes. By moving the processing in large quantities.
process of cutting, productivity can be
increased. 7
Less Observed
walk- Less MURI MURA MUDA
(Existing Condition) Date: Description of existing condition:
Requires many walking steps to carry welding outer
bracket that is in the robot side up to a distance:
10m. 1 day 200 pieces want to reduce the walking
distance in some way.

By changing the layout will change walking distance
of 10m into 2m.reduce 11 steps. Relay out is done by
moving the robot to the work table.
I was surprised after calculating the Yen 0.96 x 11 steps x 200

monetary value of the results of the pieces x 20 days
layout changes made after realizing
the presence of the muda in the 42.240 Yen/month
running. 8
Less Observed
search- Less MURI MURA MUDA
Heater machine are in some places, and at the time of replacing the
V belt, requires considerable time to ensure or searching belt
numbers. The frequency of replacement belt is 2times/month. There
are 60 types of V belt, so that the time required to ensure the V belt
is 30min / 1 time replacement. Is there an easier method of control?

In addition to include no. belt and the replacement date on
each lid V belt heater, also attach labels to clarify the
direction of rotation of the V belt. 60 types V belt is made
easier by categorizing known by its stages.
I was surprised after calculating the 30 Yen / month x 30 minutes x
monetary value of the results of the 2 times / month = 1,800 yen/
layout changes made after realizing month
the presence of the muda in the
running. 9
Less Observed
Rough motion- Less MURI MURA MUDA
Work is taken from the storage area is to the left, and then do
retrieval burr, and who have completed transferred to the storage area
is on the right. Because the work is done by sitting, and there is a
large movement in moving heavy work with One hand, at the time
workers must bend his waist. Is there a way to remove the worker
from a difficult job like this? (After KAIZEN) Date:

To change from the work done by sitting into the work being done by
standing, has determined specific height workbench, storage areas and
work that has not been processed, and also the height and location in
order to be as short as possible hand gestures. The work can be done with
a comfortable posture
1.Has made a special workbench that follow the
principles of economic action, and adapted to the work Productivity increased by 30%,
itself. the same as eliminating the
2. By transforming into the work being done by standing, cost for 6 people part-time
productivity increases. workers (6 hours / day) (for 20
3. Equipment as much as possible placed near the hand. days)
10
Less Observed
Because the mold height under 230mm, when installing or
removing the cord, workers should lengthen his hand
horizontally, and arched her back. So that sore shoulders, and
back ache. 339pieces/jam x 8 hours x 22 days = 59 664 pieces /
month. Labor costs for each piece = 5.8 yen

Height of the mold under the shortened 50mm, so 180mm, so the work
can be done easily.
After the action is taken, the amount of production increased to
438pieces/jam x 8 hours x 22 days = 77 088 pieces (up 99 pieces /
hour).
Labor costs for each piece = 4.5 yen (Total production increased by 29%)
When you can do the job in large quantities like The cost down as much as
this, it is kaizen which proves how important 22.4% per 1 piece.
posture of workers. 100.214 Yen/month
11
Less Observed

(Existing Condition) Date: At the time of assembling parts with screws, made a squeezing
liquid into the locking screw, but the squeezing is done one by one
using a liquid container lock, so it is tedious, and time consuming.
Is such a troublesome job can be stopped?
1 machine requires 12 screws. There are 40 machine / day

before locking fluid put in a plastic container, and a magnetic
locking screw on the screwdriver, and then dipped into liquid
locking screw which is inserted into the container.
The time is shortened to 0.2 minutes for every 1 screw.
After taking action to flatten or even the results of 0.2 minute x 12 pieces x 40 x
squeezing the liquid, squeezing difficulty in doing, 20 machine days
so lost productivity increases.
69.120 Yen/month
12
Less Observed
Arm height adjustment holes for the shelf parts that is in line a bit
so it can not be raised again from the current altitude. Therefore the
muda arise where workers had to craning his hand, besides the
waist pain of having to bend down, this is not a condition of a ease.
Is there a way for workers to work with the posture a little more
comfortable? (After KAIZEN) Date:
Has taken actions that lengthen stay 150mm compared to the

previous one, so it can be lifted as high as possible for each process.
Has been able to raise the average height of 100mm from the
process.
0.3 DM x number of parts 63
We need to consider how to bring parts to hand, Bending
and how to make that workers are not in forced Reduced
posture. Stretching out
a hand
39.000 Yen/month 13
CASE EXAMPLE KAIZEN WHICH FOCUSED FACILITIES AND MACHINE (PART)
AIR-LESS ENGINEERING SUMP-LESS ENGINEERING
DUST-LESS ENGINEERING AIR CUT-LESS ENGINEERING
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EAR PICK-LESS ENGINEERING -1 EAR PICK-LESS ENGINEERING -2
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CASE EXAMPLE KAIZEN WHICH FOCUSED
FACILITIES AND MACHINE (Explanation of Contents)
AIR-LESS *Do not transport in an empty state. *Rationalization of
*Do not let any area empty. distribution of parts
*Eliminate space that is not value *create excess space, and
added (Lori, shelf parts, containers, workplaces that enhance
conveyors, and the like as well as the value-added.
the layout and other unused 3
dimensions.
CONVEYOR-LESS *Is the conveyor to be false work *Creating extra space

flow? *Easy in taking and putting
*Did the movement took, and put back less
too much? *Reduced quantity flow in the
*Is the top of the conveyor is used process
only as a storage parts?
*Does it 1 piece flow of parts without
conveyor?
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AIR CUT-LESS *Is it even though the switch is *Reduced Cycle time
turned on, is done cutting the *Energy usage saving
blanks? *Saving in the number of
*Value added created, only when machines / facilities
cutting audible sound.
*Is it possible to eliminate muda
time not for cutting ?
*Minimize the blank cutting time
AIR PRESS-LESS *Is the work of the press, too many *Reduced Cycle time
empty(air) press? *Energy usage saving
*Did cylinder or ram movement can *Saving in the number of
be reduced further? machines / facilities
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SUMP-LESS *If there are no oil leaks, no sump is *5S in the workplace is effective
needed *A clean and efficient work
*Take action to stop the oil leak place created
cause *Prevention of degradation
machinery and improve
maintenance
MACHINE STOP-LESS *Take action to stop the cause of *The number of units owned
(SHORT TIME MACHINE the Short time machine down. increased.
DOWN)
*To create awareness that Short *Total unit machine/ facility
machine down time is a big loss. reduced
*Productivity increases, the
downtime decreases, and the
percentage of work increase
*Prevention onset of NG product
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TOOL BOX-LESS *Whether in the workplace need a *Eliminating excess or
tool box of unknown contents? Set shortage of tools and others
by laying an easy way. *Eliminating muda in
Make an easy way of laying out searching tool
EAR PICK-LESS *Looking for a way to stop cleaning *Rationalization of cleanup
narrow places such as poker clean work. The workplace
the ear with ear (ear pick). Take becomes clean
action for a tough spot cleaned
DUST-LESS *Clean and prevent foreign objects *Kaizen environment,

like dirt, dust, etc. from the source. preventing the machine
*Taking action with closing part. work too hard, and
degradation machinery,
improve quality and
productivity
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Less Observed
Air - Less MURI MURA MUDA
Depending on the type of fuel tank, (XT, TDM) can not get into the
lorry 4 floors, but with lori 3 floors, a large distance between
shelves, so that the storage of the many empty spaces, in addition
to the amount that can be loaded into lorries only slightly . Here
are the current conditions
(1) Frequency of replenishment parts (lorries) many
(2) The number of lorries less (After KAIZEN) Date:
(3) Lori takes place
Doing kaizen on the 4th floor of a lorry to be 1.630mm by

inserting a pipe joint.
Could save 200,000 yen compared when making a new lorry
again. Moreover, generating a space of 6.3 m2

Keep using the existing lorry, but with dial by Generate space 2,000 Yen x
extension pipe, so it can use the lorry 4 floors. 6.3 m2
12.600 Yen/month 20
Less Observed
Air Less, Rough -motion less MURI MURA MUDA
1. When viewed from an height of work, the distance between the

shelf lori large (16cm), therefore the storage of a lot of empty space.
2. At the time of going to take or put work into the bottom shelf,
workers must bend down, so do the job with a forced posture.

Close up of the bulkhead shelf lori has 7 levels had become
shelf lori 11 level with the distance between the shelves are
reduced to 5cm2 starting from the waist to the upper limit.
Limit the waist down left blank. So that:
1. Capacity increased 57%
2. No longer forced posture
By running the Air-less, in addition to adding Save space: for 3 units lori x
capacity lorries, can also liberate workers from 2.7 m2
forced posture. 2.000 Yen x 2,7m2
5.400 Yen/month 21
Less Observed
Air cut- Less MURI MURA MUDA
(Existing Condition) Date: After checking the Air- cut (cutting blank) at the time of delivery of cutting
M / C, altitude determination of the location of the surface fast delivery
3mm from the surface.
Center drill, end mill and all also be 3mm or more from the surface. When
determining the location, after moving the XY axis, so move the 2 axis.
I want to try to reduce the Air- cut though slightly.
To reduce the water cut, height determination of the location of

delivery quickly to a flat surface was changed to 1mm from the
surface. It also has tried to replace that when deciding on the
location of other fast delivery, so removal is as close as possible.
1. Narrow the range of Air cut 6 minutes Shorten the time of 1 min 85
Center <F100> (13 point 2mm x 28 16,8secs
min unit23 1,955 days
Drill <F350> (10 point x 3mm x 30 5,1 secs
30 Yen/mnt x 1.955
Endmill <F22> (5 point 3mm x 15 40 secs
2. This is an example of that Air cut-less can be 58,6000 Yen/month
done up like this. 22
Kaizen other examples
1. less engineering that focus on material and parts(explanation of contents)

BOLT-LESS *The number of hours worked proportional to *Big cost down.
the number of bolt assembly *Working hours reduced
*Use minimum number of required bolt as *Quantity of parts
possible reduced
*When we reduce the number of parts points, *Reduced working hours
then the number bolt would be reduced for the settings
BURR-LESS *Eliminate the concept of burr as a manual *Productivity increases
(BURRING-LESS) work *Quality improves
*Planning parts and mold design that will not *Quantity flow in the
produce burr process reduces
*Do simultaneously at the end of the last *Cost down
process?
WEIGHT-LESS *What is the weight can be alleviated? *Useful for cost down
*Was terms of material quality can be achieved *Productivity increases
with a light? *Feeling of tired at work
*Are able to handle heavy objects be light? reduced
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1. less engineering that focus on material and parts(explanation of contents)

SPOT-LESS *Whether to do an effort to reduce the *Productivity increase
number of spot welding points? *Cost down
*Are structure is the best?
WELDING-LESS *When you place a lot of welding, the *Cost down

number of work hours is more *Quality improves
*Due to many parts, welding length *Productivity increases
becomes much more
PARTS-LESS *Is the number of parts can be reduced? *Cost down

*Are 1 parts as much as possible to have
a dual function?
24
2. less engineering that focuses on methods(explanation of contents)
NECK-LESS *Before process the material, should be *When the neck process
looking neck process (inhibitors) that cause (inhibitors) can be corrected
delay in a row, then all the
*Di among the amenities (jobs), facilities processes run smoothly
(jobs) which are the most time consuming? *The will be a reduction in
*In terms of quality, cost, and delivery time, is the cycle time
there a barrier? *The number of streams in
*If you find your neck process (inhibitors), find the process will be reduced
ways to eliminate them.
OVER STOCK-LESS *Understand lead times and stock levels using *Number of stock reduced
parts flow curve *Prevent excess stock
*Do a system that does not produce excess resulting from management
stuff in capturing the relationship between estimates
estimated and achievement *Maximize vitality
*When we create a system, that can make management
things desirable *Reduce lead time
*Are the stock be made just-in-time system? *Reduce raw material costs
*Stock is the source of all evils
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2. less engineering that focuses on methods(explanation of contents)
SETUP-LESS *Production with many kinds of products of *Ensure the need for
small-scale production will result in small lot size preparation by using a
*Find and Know the situation by general set-up break-even graph
*Do walk-less, search-less, and bolt-less *Even though lot to be
effectively small, can run
*Changing the on-line setup to be off line setup production cost down.
*Seiri Seiton and roles are important *Cost down
ADJUST-LESS *Work adjustment takes time * It contributes to the
*Think of a method that does not require setup-less
adjustment
HUNGRY-LESS *Is the material had to wait until let machine *Percentage of machine
idle? working time increased
*Perform manual work after inserting the *Cycle time reduced
material into machine
*Is there muda contained in incorporating the
time between jobs to machines and the work
manually?
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3. less engineering that focuses on the quality (explanation of contents)

DEFECTIVE GOODS-LESS *Find items emergence of NG *Increased productivity
(TIDAK ADA BARANG DEFECTIVE) *Quantify the NG items due to eliminating goods
*Stop root of the problem with the NG
nominal value be based on statistical *Challenged to remove
*Is 7 QC tools have been used properly? goods NG
*Making pokayoke
*Checking sequential ,checking own
inspection , sequence upstream control
BUNGLE-LESS *With just be warned, carelessness will *Useful as an effective

(Pokayoke) not be removed way in removing items NG
*Remove by considering pokayoke
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3. less engineering that focuses on the quality (explanation of contents)
NON-STANDARD-LESS *Is the standard of work and quality *Improve quality,

standards have been made? eliminate NG goods, and
*Are these standards easily observed increase productivity
and understandable?
*Was QC process chart there?
*How about checking the condition of
the implementation?
CLICKING NOISE-LESS *If during the removal of the product *Improve quality by
you hear a Klek-Klek means the former preventing the emergence
impact of a former impact on the
*Make efforts not to hear it again product surface
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4. less engineering that focuses on the safety (content explanation )
Accident-Less Explanation of Contents

Engineering
ROLLER ACCIDENT- *Are objects rotating at high speed such as shafts, couplings, gears, chain,
LESS pulley, belt, etc. in the open?
*Would have taken action by installing a safety cover that hands, fingers,
work clothes, gloves, hats, or hair not touching the rotating parts?
SANDWICH-LESS *Is there a possibility sandwiched between moving parts and parts that
do not move in tooling, mold, work, machinery and so forth?
BODY CUT-LESS *Is there any possibility of scratches with wood processing machine, press
machine, grinding machine, and others?
CRASH-LESS *Is there any possibility forklift collided with heavy equipment, machinery
transporter, cars, etc.
*Is there a way, or a ladder is damaged, or the lighting is poor, or where
the floor was slippery because of oil?
*Job well done by hanging using the correct ring, and with prudence
operators and providers of cue
29

Engineering
MISS STEP-LESS *Whether at work or walking on the slate, folded-plate roof, or scaffold
board, there is the possibility of stepping on a nail or a bolt protruding, or
broken glass scattered about?
DROP-LESS *Is there a fear of falling from scaffold boards, stairs, bridges, and so
forth or fall into the pit, manhole etc.?
SPARK-LESS *Are there concerns that there are objects flying, falling, or rolled?
Does the way the accumulation and arrangement of bad stuff, whether
to leave tools or items to work on high?
HANDLING *Whether at the time of loading and unloading, or transporting material

ACCIDENT-LESS of concerns drop the charge, or pinched?
*At the time of transporting heavy goods by human power together,
whether there muri in doing so stuff does not fall because of sprains,
slips Does the job done without experience and lack of preparation?
30
Engineering
PIOSON-LESS *Are there any chances of getting or remove items that are highly toxic, acid
vapor, or gas dangerous?
*During the work on the narrow enclosed, or come into the pits or
underground tanks containing gas, is already ascertain whether any
dangerous gases before entry
BOMB-LESS *Is there a concern explosion of dangerous goods, steam, compressed air,
water vapor, high-pressure gas, dust, and other?
*Would have taken action to prevent the collapse of the molten metal or slag
into the stagnant water on the floor or pit?
BURN-LESS *Is there any possibility of contact with high-temperature objects (casting,
forging, welding electric, etc.), low-temperature, or chemicals?
*Does the job done with bare feet, and without wearing protective gloves
fire? Are you careful to keep the face or eyes did not hurt as light or heat that
comes out of the high-temperature furnace and metal objects such as iron
plate, and the other .
OVERHEAT-LESS *Do you work at a high temperature for a long time?
*Would have taken action to deal with heat exhaustion?
31
Engineering
FALL-LESS *Is the fear of building materials and the material will fall by the crane is not
stable?
NO LICENSE-LESS *Is the work done without permits, and internal qualification?
NO CAUTION-LESS *Is the work done that is not safe because of the lack of training and
guidance
NO REMARK-LESS *Is the most needed have been installed signs or markers? Signs is a
reminder of the time we forget. The letters should be kept simple and
attractive eyes, for example by color.
*Content markers dangerous goods are as follows: 1. Names of objects, 2.
Hazard level, 3. Ways of handling, 4. Instructions act first and emergency
cuts
FRUSTRATION- *Taking action handling a mental problem arising from a sense of useless
LESS because it is too easy to work, frustration, and a sense lonely.
*Establish a counseling system.
32

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EXAMPLE LESS ENGINEERING

Man Machine Material parts Method Quality Safety Control office

Look-less Air-less Bolt-less Neck-less reject-less Roller- paper-less

EXAMPLES OF KEY Man

Less Engineering Explanation of Contents Expected Results

WALK-LESS *Moving and walking should not be *Reduced work hours

Less Engineering Explanation of Contents Expected Results

ROUGHMOTION-LESS *Eliminating vigorous and big *painful work reduced.

Description of details of improvement made:

Sections that had been processed in the 2nd, was

Point of Improvement KAIZEN Result Money Saved

Description of details of improvement made:

Point of Improvement KAIZEN Result Money Saved

I was surprised after calculating the Yen 0.96 x 11 steps x 200

Description of details of improvement made:

Description of details of improvement made:

Description of details of improvement made:

Description of existing condition:

Description of details of improvement made:

Description of details of improvement made:

Has taken actions that lengthen stay 150mm compared to the

AIR-LESS ENGINEERING SUMP-LESS ENGINEERING

DUST-LESS ENGINEERING AIR CUT-LESS ENGINEERING

CONVEYOR-LESS *Is the conveyor to be false work *Creating extra space

Less Engineering Explanation of Contents Expected Results

Less Engineering Explanation of Contents Expected Results

Less Engineering Explanation of Contents Expected Results

DUST-LESS *Clean and prevent foreign objects *Kaizen environment,

Description of details of improvement made:

Doing kaizen on the 4th floor of a lorry to be 1.630mm by

Point of Improvement KAIZEN Result Money Saved

1. When viewed from an height of work, the distance between the

(After KAIZEN) Date:

Description of details of improvement made:

Description of details of improvement made:

To reduce the water cut, height determination of the location of

1. less engineering that focus on material and parts(explanation of contents)

Less Engineering Explanation of Contents Expected Results

WELDING-LESS *When you place a lot of welding, the *Cost down

PARTS-LESS *Is the number of parts can be reduced? *Cost down

Less Engineering Explanation of Contents Expected Results

BUNGLE-LESS *With just be warned, carelessness will *Useful as an effective

Less Engineering Explanation of Contents Expected Results

NON-STANDARD-LESS *Is the standard of work and quality *Improve quality,

Accident-Less Explanation of Contents

Accident-Less Explanation of Contents

HANDLING *Whether at the time of loading and unloading, or transporting material

Das könnte Ihnen auch gefallen

WALK-LESS Moving and walking should not be Reduced work hours

ROUGHMOTION-LESS Eliminating vigorous and big painful work reduced.

CONVEYOR-LESS Is the conveyor to be false work Creating extra space

DUST-LESS Clean and prevent foreign objects Kaizen environment,

WELDING-LESS When you place a lot of welding, the Cost down

PARTS-LESS Is the number of parts can be reduced? Cost down

BUNGLE-LESS With just be warned, carelessness will Useful as an effective

NON-STANDARD-LESS Is the standard of work and quality Improve quality,