1P Improvement Case Study.pdf

Copyright © 2015 by Unicharm India Pvt. Ltd. All rights reserved Confidential Document

1P ImrovementProduction Dept. K.Onishi & Team

Case Study

Unicharm India Pvt. Ltd. Nitin Jain 2

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What do you think about these photos?Hearing….Answer1. Poly is on the electric socket. Chance of short circuit. 2. Tape Dispenser is daily required at this process. So why it is kept like this. 3. We daily replace tapes. And we know this is the part of our job. Then why kept like this.


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What do you think about these photos?HearingAnswers,1. Tools are kept after use like this. Can you find it for next use? 2. Scissors are kept on the machine. We are not providing pouch to keep in?3. Why this much space? Clarify the purpose?? Do we have too much space?

1. We are already running out of space for FG. If we have some space, save it.


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What do you think about these photos?Hearing…Answers,1. WIP are the heart of work.. with out these we can’t do operation. We all know it is base of our recipe of making 1P. So why no place for these WIP to store/keep?


What do you think about this picture?Hearing…Answer…Box Keeper is pushing the poly to close the box. Poly are coming with lot of air inside it.


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Now, this is very interesting one… Can anyone tell, why this machine is stopped?

All people are tearing diapers.. machine is stopped. Is this there relax time… Some of you will say it is machine break down… Am I correct?If so, then where is the operator????

Unicharm India Pvt. Ltd. Nitin Jain

Operator→What she is doing???

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Oh! Operator is over there? What she is doing over there??


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Oh! Great!! They are now looking for material… ???This is Unicharm thinking??Material is finished… Go to material storage area to get the material.


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This generated MUDA… Waiting Muda..


Our Target!

290cs* per shift

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*Target is as per current sales requirement and is for 1P machine from CHINA. Demand will increase with the increase of supply.


What are the Problems

• ? • ? • ? • ? • ? ……

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Let’s hear what is in there mind…Are they think abnormality as abnormality or not..


Kaizen Ideas?

• ? • ? • ? • ? • ? ……

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In case they really think that as a problem.. they will have idea…


Problems• 2S is not done • WIP place and Qty. is not decided • Porter is not assigned • Preparation of material • Layout • SOP’s etc., • Machine speed is not enough

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1. 2S is not followed in the floor. Before taling about 3S/5S or 6S, start with 2S please.. It is SEIRI and Seiton..2. It is not decided what is the WIP qty as per the required qty i.e, as per CT3. Operator and other people are moving here and there.. Porter is not assigned for three machines.4. It is not clear system of preparing the material.5. We think that layout is not easy to work. And is generating many MUDA.6. SOP are not available at the floor. We doubt people know their responsibilities.


KAIZEN idea• Implement 2S activity.

• Can assign the leader among worker responsible for the day/week/month!

• Train workers “Thoroughness of 3S” • Calculate the CT and decide the pallet/hour for WIP • Making of Job Instruction Sheet with Standard Work Chart for Porter

• Teaching the importance of material preparation. MUDA • Need to make the layout easy to use and effective • Need to make JIS,SWC and SOP

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Neraime..1. Need to follow at least first 2 S of 6 S. We need to start the practice and need to train people. 2. Need to decide the WIP pallet / hour based on the C/T per machine3. Since, people are moving here and there… we need to stop the MUDA of Movement by assigning the porter.4. MUDA in case material in not prepared. What is that? Train them with the MUDA elimination . 5. Make the easy to work and MUDA less layout.6. Let’s assign the people’s job once again.


KAIZEN1. ? 2. ? 3. ? 4. ? 5. ? 6. ?

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We all need to start working and make all these KAIZEN happen. Please implement and come with actuals to Onishi San.

We will write the KAIZEN here….


Effect of KAIZEN1. ? 2. ? 3. ? 4. ? 5. ? 6. ?

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Let’s share the effectiveness of the things you have done.. Let’s pen down your own contribution to the company! #feelproud

What was the effect of those.. KAIZEN

1P Improvement Case Study.pdf

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