Golf Score Business Excellence Revision A October 5, 2007 BE-TL2-006-DRAFT-Golf Score

2 Table of Contents Overview & Scope3 Objective4 Ergonomics Analysis5 Format 6 Procedure7 Examples9 Before & After (Format)12 Kaizen Examples13 ContentsSlide(s)

3 BE-TL2-006-DRAFT-Golf Score Operation being done sideways Operations being done downward motion and awkward height. Operations Ergonomics - Examples

4 BE-TL2-006-DRAFT-Golf Score Overview & Scope Overview Lean and ergonomics can be used in service and administrative functions to increase process effectiveness. This session will emphasize hands-on application of lean and ergonomic tools and techniques..Scope Participants will learn skills to enhance their process effectiveness

5 BE-TL2-006-DRAFT-Golf Score Objective To generate ergonomic tool used to evaluate workstation design from an ergonomics perspective. This will assist in identifying the factors that have contributed to cumulative injuries / illnesses of the operators that will hopefully lead to corrective actions

6 BE-TL2-006-DRAFT-Golf Score Ergonomic Analysis Using GOLF SCORE TOOLS Operation = Motion (Waste) + Work (Value Added) Operation = Motion (Waste) + Work (Value Added) Waste of motion is ergonomic of operators which consist of operation movement,counting,waiting,walking,twisting,stretching, climbing,switching things,climbing, transportation,waiting and etc. To understand motion, 3P is using GOLF SCORE TOOLS to further analyze and improve Ergonomic to meet JIT. A prerequisite before implementing golf scoring method, standard work combination is a must on all station. All waste has to been looked into before implementing the scoring. Golf scoring method is purely motion improvement at a particular station. Motion can be classified upwards,downwards,sideways,non-visible locations, awkward heights and hand being used as fixture. By using this method quality & safety(improve) and fatigue & CT( reduce).

7 BE-TL2-006-DRAFT-Golf Score Golf Score Sheet Format of GOLF SCORE TOOLS

8 BE-TL2-006-DRAFT-Golf Score The procedure as below : Identify a station you want to improve. Take standard work combination sheet as your reference guide. Follow through step by step and define each movement as below. Place a 1 in the “Operation counter” each time an operation is completed as described. The count of all 1’s should equal the total number of operations. Also place 1’s in the “ADDER”columns as appropriate for specific operation. These will adjust the total score.Example if an operations is done in a sideways motion, put a 1 in the operation section for a 3 point score. If same operation is done sideways motion at an awkward height, put a 1 in the operation counter for a sideways motion and a 1 in the AWKWARD HEIGHT ADDER column. The total points for that 1 operation then is 13. How to use GOLF SCORE TOOLS

9 BE-TL2-006-DRAFT-Golf Score Rules for Golf Score Implementation 1) STD WORK COMBINATION SHEET. 2) 7+1 WASTE REMOVED,CREW TO TAKT. 3) APPLY GOLF SCORE(BEFORE). 4) 7 WAYS FOR IMPROVEMENTS(No Cost low cost). 5) APPLY GOLF SCORE AFTER IMPROVEMENT 6) REVISIT THE SCORE AFTER EACH KAIZEN. T/T = 7 hrs. #1 #2 #3 Std. Work Std. WIP Std work combination Sheet KAIZEN

10 BE-TL2-006-DRAFT-Golf Score Operations being done downward and sideways Movement of the operator side to retrieve material and bending down to retrieve material,climbing to retrieve material.

11 BE-TL2-006-DRAFT-Golf Score Using 7 Ways to Improve Process (Reference Only)

12 BE-TL2-006-DRAFT-Golf Score Golf Score Sheet (Before and After)

13 BE-TL2-006-DRAFT-Golf Score Before 2004 Today 2007 Inspection Trolley On Wheels with See Saw table Horse Jig Inspection trolley with 360 O rotation feature eliminates unwanted touches Custom made XY inspection Table Hand Free Inspection Methods XY Table deign for High Density Boards Inspection 360 O inspection Fixture with Flipping Top/ Bottom to ease inspection Sitting Operations Using Hands As A Fixture Kaizen Example Innovation - 7 Ways for Better Inspection Method.

14 BE-TL2-006-DRAFT-Golf Score Before Kaizen After Kaizen OperationProblem Actions TakenResults At Stamping operation Shinei - Stamping Operation Golf Score before Kaizen Process 10 Too many movement, many operators and operator had to hand carry part weight 7kgs. Example

15 BE-TL2-006-DRAFT-Golf Score P/N: HP AS1, PROCESS 10 Example

16 BE-TL2-006-DRAFT-Golf Score Picture of Process Before and After Kaizen at Stamping Operation Before operator had to bend down and carry part to put into press machine Before After Headcount reduced Used lifter to reduce ergonomic of bending to pick parts weight 7kgs.

17 BE-TL2-006-DRAFT-Golf Score Improvement at Stamping Material supplied in carton boxes from hard tool stamping.Operators had to open the box and retrieve material which is heavy. Material supplied in pallet form; beams supported and separated by polyfoam.Upfront prepared by water spider. Water Spider use material lifter to raise the height of the beam to help operator Before After “NO COST; RECYCLABLE MATERIAL”

18 BE-TL2-006-DRAFT-Golf Score Before Kaizen After Kaizen Operation Problem Actions Taken Results Results : Golf Score Shinei stamping operation Before & After(Process 10) At Stamping operation, Process 10 Too many movement, many operators and operator had to hand carry part weight 7kgs. New std work combination sheet Lifter to reduce ergonomic of bending Reduce head count and fatigue.Improve cycle Time. Example

19 BE-TL2-006-DRAFT-Golf Score P/N: HP AS1, PROCESS 20 Example

20 BE-TL2-006-DRAFT-Golf Score P/N: HP AS1, PROCESS 30 Example

21 BE-TL2-006-DRAFT-Golf Score Before Kaizen After Kaizen Operation Problem Actions Taken Results Results : Golf Score Shinei stamping operation Before & After(Process 20 & 30) At Stamping operation, Process 30 Too many movement, many operators and operator had to hand carry part weight 7kgs. New std work combination sheet Lifter to reduce ergonomic of bending Reduce head count and fatigue.Improve cycle Time. Example

22 BE-TL2-006-DRAFT-Golf Score Asyst Singapore: Lean Progress 2x4 full factorial DOE shows that material load is constant. A relief is defined for horizontal assembly Kaize n Before Kaizen After Kaizen Before Kaizen After Kaizen Before Kaizen After Kaizen Kaizen Tools can’t be found and different stations sharing assembly tools Add tools and allow technicians to visually manage availability of tools Leg used as jig thus causes assembly to be complicated Jig used to hold assembly in place, 12.5% reduction in cycle time Distributed load cause different distortions at different lengths if assembly done vertically and horizontally Kaizen Not Rigid but heavy load Assembly done horizontally with alignment needed causing “Over- Par” Golf scoring (at 13 points for this operation) Golf Score: 1 point

23 BE-TL2-006-DRAFT-Golf Score Kaizen Example Before Kaizen After Kaizen Golf Scoring: 77% Impv Score13 points (Par 1) Score3 points (Par 1) Temporary Jig for assembly Hand as jig required for assembly Completed Jig for “no-hands” assembly

24 BE-TL2-006-DRAFT-Golf Score Kaizen Example Jigs for Hands Free Assembly Before Kaizen After Kaizen Golf Scoring: 77% Impv Score13 points (Par 1) Score3 points (Par 1) No jig available for assembly Hand as jig required for assembly Jig fabricated for hands-free assembly for test Only horizontal screw mounting required

25 BE-TL2-006-DRAFT-Golf Score Kaizen Example Kaizen Activities (Standing Operations) After Productivity : 7.8 % Capacity  Sitting operation Standing operation Before Stool for better comfort