Chapters THE MISTAKE-PROOFING REDUCTION EQUIPMENT FOR PACKING PROCESS OF
SUPPLIER AND COST REDUCTION OF PRODUCTION PROCESS DEPARTMENT CASE STUDY: TOYOTA BOSHOKU ASIA CO., LTD.


THE MISTAKE-PROOFING REDUCTION EQUIPMENT FOR PACKING PROCESS
OF SUPPLIER AND COST REDUCTION OF PRODUCTION PROCESS DEPARTMENT CASE STUDY: TOYOTA BOSHOKU ASIA CO., LTD.


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PACKING PROCESS OF SUPPLIER AND COST REDUCTION
OF PRODUCTION PROCESS. DEPARTMENT CASE STUDY:
TOYOTA BOSHOKU ASIA CO., LTD.

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PACKING PROCESS OF SUPPLIER AND COST REDUCTION
OF PRODUCTION PROCESS. DEPARTMENT CASE STUDY:
TOYOTA BOSHOKU ASIA CO., LTD.
Writer Miss Supaksorn Promsan
Faculty Adviser Mr. Vithinut Phakphonhamin
Job Supervisor Mr. Nopparat Amnakmanee
Company’s name TOYOTA BOSHOKU ASIA CO.,LTD.
Business Type/Product Research, development and trading deliver products with value to
customers around the world through our Seats, Interior & Exterior,
Unit Components and Other businesses.
Summary
This cooperative project is a study on the mistake-proofing reduction equipment for packing process of supplier and cost reduction of production process. By studied one supplier which has most miss packing problem around 23.53% of all miss packing problem. The issue is wrong packing and quantity not enough or over demand. So using Visual Control and Poka-Yoke for approve problems and protect miss packing happen again. Result able reduces miss packing of this supplier for 0% of all miss packing. And extend result of activity reduction in issue employee not enough for production by using ECRS for approve. Which able man power reduction and save cost for hire employee around 277,700 baht per year.

Logistics Control



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16
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21
4.3 % 1 2
21
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: : TOYOTA BOSHOKU ASIA CO., LT D. : 801 10250
(+662)329-5000 (+662)186-9788-9
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1.2.2
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Pillars
Kenaf
:
1.4.2 - Audit Suppliers - (P/O) - Invoice - Matching Invoice - Download & Upload PDS -
1.5
Senior Engineer Logistics Control
1.6
1.7
(Quality Problem Report: QPR) (Early Report: ER) – ..2559 17 0.0005%
5 3,519,700 Pillar Trim
B 4 23.53%
2
Visual Control, Poka-Yoke ECRS
2.1 VISUAL CONTROL:
Visual Control (VC) (Productivity) Visual Control line Visual Control “ ” “ ”
Visual Control Visual Control Visual Control Productivity
7
Why ( ) Who () Visual control What () When () Visual Control
Where () Visual Control //
How () Visual Control
2.1 5W 1H
2.1.2 Visual Control

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– – –
8 Visual Control
(: SME HAPPY, 2558, VISUAL CONTROL: [Online], Available: http://smehappy.com/visual-control- .html)
1) (Overproduction) 2) (Waiting) 3) (Transporting) 4) (Inappropriate Processing) 5) (Unnecessary Inventory) 6) / (Unnecessary Motions) 7) (Defect)
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9
o (Eliminate) 7 /
o (Combine) 5
o (Rearrange) 2 3 3 2
o (Simplify) (jig) fixture
(: . , 2552, ECRS [Online], Available: https://cpico.wordpress.com/2009/--ECRS/ [15 2560])
2.3 Poka-Yoke:
POKA-YOKE 2 “Poka” ( -) “Yoke” ( -)
“Poka-Yoke”
2.1 Poka-Yoke
o


3.
1.
3
25 ..2559 28 ..2560
.. 2559 .. 2560

1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1.
2.
3.1
4.1
1
2
3
4
5
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

A
2 2 4 23.53
2 11.76
18 4.1.2
4.2 B
4.1.2.1
4.1.2.2
20 4.1.2.3
21
4.3 % 1 2
1 % 18.37% 2 16.33%

64 18 16
98
34 80 82
98 98 98
22 4.1.3
MAN
MATERIAL
MEDTHOD

4.4
1. 45 - -
2. 13 - -
() - - 5

= 98
1. 45 -
2. 13 -

4.10
4.11
4.12
4.13
30
4.16 Rack 50
4.1.6.3
31

30 58 58 30 88 88 % 65.91 34.09
4.7
4.17 -
1. 45 -
2. 13 -
1 Seatbelt Kanban Kanban Kanban “LH” “RH” Kanban
2 Rack Poka-Yoke Rack Rack 10 5 1 1 Rack 50
3 2 2 ECRS
5.2
2. Kaizen
3.
http://smehappy.com/visual-control-.html [15

56

– 24 .. 2538




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1.
2.