OVERSEA CAREER TRAINING
IN SUMITOMO RUBBERTHAILANDTRAINING PROGRAMWORK OBSERVEACTIVITY(WOA)
DEPARTMENT: IE(KAIZEN)DATE: 4-15 AUG’2014*9-13.AUG IS HOLIDAY

BY:LI MENGLUBANTITA CH. (Yaikaew)

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OUTLINE• TIRE KNOWLEDGE• OUR KAIZEN PROJECT• IMPRESSION OF THIS TRAINING

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Sumitomo Rubber (Thailand) Co., Ltd Overview• PRESIDENT : MR. TORUNAGAHATA• PRODUCTS : RADIAL TIRESFOR PASSENGER CAR• FOUNDATION : MAY 2005

• LAND AREA : 608,880 ㎡• HEADCOUNT : 6,311
EMPLOYEES INCLUDING 33
JAPANESE
3SCHEDULE OF OVERSEA CAREER
TRAINING
4 Aug'14> Present Company Profile> Factory Tour

5 Aug'14
5-7 Aug'14> Explain Basic WOA(3STD Chart)> On The Job Training in Line ; Material Process

8 Aug'14> TPS Study: Find "MUDA" in Process

14 Aug'14> Factory Tour

15 Aug'14> Factory Tour(SRT)> Final presentation and free discussion
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WORK OBSERVE ACTIVITYPROCESS

Meeting5

WORK OBSERVE ACTIVITYPROCESSStudying

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WORK OBSERVE ACTIVITYPROCESS

Observation
7Mixing
Topping(Textile&Steel)

ExtrudingMaterial(Tread&Side wall)-Inner-Ply-Bead Apex
-Breaker-JLB-Chaffer

Building
CuringInspection
8Warehouse

TreadJLB

PLY

BreakerSW (Side wall)

Chaffer

Inner liner

BEADBead

Duties: As part of a wire coil in a circle. Which serves tomaintain tire to the rim. By mounting the canvas on bothsides.
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The components that are important in increasing
strength.

1. Get C/B put in M/C10

2. Run M/C11

3. Join rubber
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4. Run M/C
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5.Get B/A put in arm
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BEAD APEX M/C#7

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ANALYZE DATA PROCESS (BEAD APEX
M/C#7)
Baratsuki

0%
1%

1%
1%

5%

2%

Necessary loss

4%

6%

16%

Rotate Arm
lot change
Size Change + Die Plate

5%long join
3%talkingset mc

5%adjust apex
long input C/B
push rubber
pull rubber
apex NG
51%

adjust C/B
record datatarget4500 pcs/day

operation time

75600 sec/day

target takt time

16.8 sec/pcs

Actual takt time

17.18 sec/pcs

max baratsuki

394.62 sec/pcs

average baratsukiCT

4.10 sec/pcs
8 sec/time

Unnecessary loss

KAIZEN Point is “Size Change”
because it costs most timein the process.

16STANDARD WORK TABLE - - - > BEAD APEX M/C#7

Before17

STANDARD WORK COMBINATIONCHART- - - > BEAD APEX M/C#7Before

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STANDARD WORK TABLE - - - > BEAD APEX M/C#7

KAIZENBefore

After

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STANDARD WORK COMBINATIONCHART- - - > BEAD APEX M/C#7

KAIZENAfter

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STANDARD WORK TABLE - - - > BEAD APEX M/C#7

After

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CAPACITY UP
SIZE CHANGE USE TIME
BEFORE 635.34 SEC/TIMEAFTER

591.81 SEC/TIME

REDUCE 43.58

SEC/TIMESIZE CHANGE DIE PLATE 15 TIMES/DAY
REDUCE USE TIME

43.58 X 15= 652.95 SEC/DAYACTUAL TAKT TIME

= 17.02 SEC/PCSCAPACITY UP=652.95/17.02=38 PCS/DAYTARGET 4500 PCS/DAY
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BEAD APEX M/C#10

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ANALYZE DATA PROCESS (BEAD APEX
M/C#10)Baratsuki

1%

size change

3%

lot change

6%

30%

7%

push arm
pull C/B

batratsuki
return rubber

18%

button4%
8%23%

Target5000

pcs/day

Operation time75600

sec/day

Target takt time

15.12

sec/pcs

Actual takt time

16.46

sec/pcs

Max baratsuki

120.71

sec/pcs

Ave. baratsuki

1.32

Sec/pcs

Cycle Time

8sec/pcs0%

operator change
check screen
talk

KAIZEN Point is “Size Change”
because it costs most timein the process.
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STANDARD WORK TABLEM/C#10
BeforeAfter

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STANDARD WORK COMBINATION
CHART- - - > BEAD APEX M/C#10
Before

CT=400.31

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STANDARD WORK COMBINATION
CHART- - - > BEAD APEX M/C#10
After

CT=390.74

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CAPACITY UP
Size Change use time
Before 400.31 sec/time
After 390.74 sec/time

Reduce 9.57 sec/time
Size Change Die Plate
13 times/day
Reduce use time

9.57 x 13=124.41 sec/day

Actual Takt time= 16.43 sec/pcs

Capacity up=124.41/16.43=8 pcs/day(TARGET 5000
PCS/DAY)28

IMPRESSION• KAIZEN• SAFETY FIRST• COMMUNICATION
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