Ensure Production Capacity of 10M sets Comp Ensure Production Capacity of 10M sets Comp TDR Final Report TDR Final Report Contents 1. Final report 2. Best practice Capacity of 10M sets Comp TDR TDR Final Report Ensure Production Capacity of 10M sets Comp Theme Team 众志成城 Category P/I Index Sales logic Current Goal Result Big Y Issue 00Y Comp. Production/Sale 9M Sets 150M＄ 200M＄ 200M＄ Current(‘04) KPI Biz Perfor_ mance Major Objective Current W. Best Goal Result ’00Result: 7,000,000*21.5=150M＄ ’00Target: 9,000,000*22.2=200M＄ ’00Expect: 9,000,000*22.2=200M＄ Assembling T/Time Productivity 4.8sec 675EA/Hr 81% 3.0sec 4.0sec 800EA/Hr 86% 4.0sec 950EA/Hr 800EA/Hr 86% Oper. Rate Lessons Learned (Best Practice) Member Problem Improvement Improve malfunction of Air Tool to tighten bolt Electric Tool substituted for Air Tool Increase electric pole and extend the tunnel for drying Improve painting T/Time Improve machining T/Time Figuration once of C/Shaft F-Up System Regulated program and reduced loss of PJW line Control T/Time of squad once a month Control Defect Rate once a week New TDR start because of parts lacking and line defect New method for piston honing Improve quality of machini ng Add magnet in jig to improve quality of protector PJW Period BIG-Y Issue Supply Capa `00年 COMP要求数量 TTL：9,000KEA 2521 Unit:KEA 生产能力 (’00 TDR目标 2348 Over 2314 10,000K 9,000K Comp. K 要( 1821 Shortage 生产能力 (’0 7,200K JAN MAR JUN SEP DEC 1/4 2/4 3/4 4/4 Major Objective Big-Y Little-y KPI Innovation Unit:Sec 4.8 ?组装 ?组装 -全体 工程 165工程中 55工程 T/Time 改善 -全体 工程 165工程中 55工程 T/Time 改善 4.0 20% -F/Test工程 T/T改善 4.7S → 3.9S -F/Test工程 T/T改善 4.7S → 3.9S TR-COMP --涂装Line涂装Line TT/T/T 44.7S.7S →→44.0S.0S -中频 加热 装置 改善 -中频 加热 装置 改善 -Bolt紧固 工法 改善 -Bolt紧固 工法 改善 --COCO22焊焊机机TT/Time/Time &&品品质质改改善善 -烘道 T/Time & 干燥温度 最佳化 -烘道 T/Time & 干燥温度 最佳化 TR-COMP `00 675 `00 1000万台 1000万台 ?组装 ?组装 850 Unit:台/Hr 生产能力确保 生产能力确保 800 -T/Time 改善 -T/Time 改善 -组装 Line Lay-Out变更 -组装 Line Lay-Out变更 -Drop 不