A practical discussion of implementing TPS and TPM activities
|關鍵字:||即時生產;零不良;零故障;零工安;Just-in-time;zero defect;zero failure;zero accident|
The goal of the study is to practicing Toyota Production system (TPS) and to deploying production management activities to organizations by means of total participation of employees. Through production activities that adopt“just-in-time”as a measure,treat material and information flow as critical information to reduce safety quantity of stock,and discussing effect of defective parts that affect practical production lines, by implementing TPS,TPM activities to eliminate or reduce quality defect during process that ensures smoothness of assembly lines and manufacturing of quality equipment, which is able to meet requirements of customers on equipment. As matter of fact, companies that adopt essential factors of TPS can totally eliminate waste during operation production, TPM is supported by two pillars which are JIT (Just-In-Time) and autonomous defects control “autonomation” or “Jidoka” to eliminating wastes and increasing quality of production lines. The deployment of TPM activities which include (1)“Maximizing efficiency of production system”, (2)“Zero defects”,(3)“ Promoting efficiency among departments in a corporate”,(4)“ Full participation of employees to implementing TPM”,(5)“Achieving goal of each step through small team activities” , is essential throughout every department in the company. The study found implementing TPM activities in the organization not only can prevent quality defects from happening again but also can improve understanding to TPM activities of vendors. Although vendors are excluded in TPM activities, TPS principles are followed up by vendors through tutoring of the company to learn 4M in operation management against defect components, to carry out detailed control of quality matrix (QM) to achieve status of zero defects. Although the vendors does not implement TPM activities they still can go to the direction of zero failure through guidelines of TPS principles. The Victor-Taichung Machinery works implements TPS, and TPM activities, one of purposes is to reduce inventory costs. Hence, the company adopts that pre- assembled components to be distributed by warehouse control. The overstocked components often result in high inventory cost, by implementing a concept of “Just-In-Time” which can not only reduce space needed for assembly but also can reduce inventory cost and reduction of waste on transporting of components. The study focuses on saving costs of unnecessary working hour that occurred because of interruption of production lines, those interruption are contributed to defect components. The study focuses on quality defects of the assembly line of injection molding machine. Firstly, introduction to assembly processes, technicians assemble injection machines, when defect components are found, technicians fill out defect report that be signed by the foreman, the report then be forwarded to QC department for record, time of receipt to record and time of start to completion to be deemed as loss of statistic working hour. Monthly discussion over report of defect components and loss of working hour and quantity is conducted for corrective actions. The corrective actions are mainly imposed on those vendors who supply defect components to the assembly lines, for quality improvement. Those vendors are also obligated to receive suggestions from QC department of the company and help improve component quality. The causes of defect components need to be investigated and analyzed by the vendors for corrective actions, furthermore, cause and effect analysis has to be conducted by vendors and then submit corrective actions to QC department in order to achieve quality goal (zero defect), assembly and test (zero failure), elimination of danger caused by rush assembly of defect components to achieve a safety industrial environment (zero accident).
|Appears in Collections:||Thesis|