Operational Excellence in Large Motor Assembly: Japan Visit

Japan Visit Learnings & Best Practices

Operational Excellence in Large Motor Assembly

Daily Work Start-Up Activities

The day begins with structured discipline. The Tool Box Meeting (TBM) sets the daily agenda, covering safety alerts, quality checkpoints, and 5S briefings. The 'KY Sheet' (Kiken Yochi) system ensures every potential hazard is identified and predicted before work commences.

Operational Targets & Goals

Clear numerical targets drive the group building system. The facility aims for high volume motor production while maintaining absolute zero in safety incidents and quality defects. This creates a high-performance culture.

Group Building Structure

Team Leader: Coordinates production head and oversees multiple groups.

Group Leader: Conducts daily safety briefings, allocates work, and segregates materials.

Sub-Group Leader: Monitors quality and takes charge in the leader's absence.

Operators: Execute tasks per drawings and maintain 5S discipline.

5S Implementation: Discipline Driven Culture

1S (Sort): Remove all unwanted packing materials immediately. 2S (Set in Order): Arrange tools process-wise using shadow boards and visual labels. 3S (Shine): Daily cleaning of workstations and gangways, with immediate reporting of abnormalities.

Material Management & Kanban

Materials are segregated process-wise before work starts, often using color-coded bins and the Kanban system (KSD, KSA, SA grades). Empty pallets are removed immediately to prevent clutter. This ensures high efficiency and prevents 'search time' waste.

Best Practice Tools & Fixtures

Pneumatic Tapping Gun: Reversible rotation for fast, controlled thread cleaning.

Hydraulic Torque Wrench: Precise bolt elongation and tightening.

Aluminum Support Blocks: Lightweight, easy-to-handle alternatives to steel.

Specialized Wire Ropes: Insulated wire ropes for safe shell insertion.

Visual & Administration Controls

Efficiency is maintained through rigorous visual management. Name display tags and timesheets monitor workforce availability. Helmet stands and designated PPE storage bins ensure equipment is respected and easily accessible. Every item has a home.

Incentivizing Performance

Group members are rewarded for achieving holistic success metrics:

Completion of weekly production targets (on time).

Zero quality observations and Zero PTI observations.

Zero safety incidents and effective 5S maintenance.

Discipline builds safety. Ownership improves productivity. Visual management is critical.

Key Takeaways - Japan Visit