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Defects on TA (2.2%)

Theme:. Name: Company:. Toyota Business Practices (TBP) ■ Problem Solving Flow Chart. The division you belong to: Paint shop in the assembly operations division

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Defects on TA (2.2%)

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  1. Theme: Name: Company: Toyota Business Practices (TBP) ■ Problem Solving Flow Chart The division you belong to: Paint shop in the assembly operations division The background of the job: ▼ New paint floor will be established in June 2006, which will increase the production. Currently the incidence of outflow of paint defects has increased. 　　　　 ▼ Before establishing the paint floor, we have to decrease the defects without major capital expenditure. Step 1 Clarify the Problem Step 2 Break Down the Problem 【Ultimate Goal】 Having 0 painting defect. 【Process】 By defects categories Units without defects Flow out from Paint shop Units bought off By final paint inspection Units painted & Baked in top coat Units prepared For painting Units primed Contribution Runs & Sags (42%) 【Ideal Situation】 (Should be Situation) 2 % or less of vehicles leave assembly hall with paint related defects that require repair. 【Break Down】 By part Thin paint (34%) Step 3 Target Setting By car Tail gate (57%) 【Prioritized Problem at point of occurrence】 Defects on HILAY (8 %) 【Target】 Paint defects occur Reduce paint defects Dirt (24%) 【Problem】 Door interior left (17%) Paint defects leaving assembly hall need to be reduced by 4 % Defects on TA (2.2%) Door interior right (22%) Step 4 Root Cause Analysis Defects on CORLA (2%) Machine is inappropriate Staff’s performances are poor Painting materials are poor Painting methods are ineffective 【Current Situation】 Currently 6 % of vehicles leave assembly hall requiring paint related repairs Other area (4%) Defects on RUX (2.1%) Difficult tasks to do Skills are poor Staffs do not have capacity to learn There is a no skill development training for staffs 【The points that you cannot fit in the PS steps, The researched data that were not apply for breakdown (Incl. Division Points)】 【Countermeasures】 【Root Cause】 . Conduct a training that can improve staffs’ skill development . Make a poster that reminds staffs not to produce paint defects and put it to a wall Step 5 Develop Countermeasures

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