Basic Internal Logistics

Operation at IMV plant (TMMIN)

August, 2006
Production & Logistics
Control Dept. / GPC / TMC
Our (TOYOTA as Manufacturer) Purpose

We
Wemust
mustproduce
producethe thevehicle
vehicleas
ascustomer
customerrequired,
required,atatthe
theshortest,
shortest,
atatthe
thelowest
lowestcost,
cost,with
withthe
thehighest
highestquality
quality

From Logistics
point of view

“Stable
“Stable&&Flexible”
Flexible”
Logistics
Logisticsthat
thatcan
canfollow-up
follow-up“Real
“Realmarket
marketdemand
demandbasis
basisproduction”
production”

In other words

Cyclic, Small lot, Flexible MP supply (For compact production line)

TMMIN (Karawang plant) case

(Before IMV) From CKD type production line

Separate &
single delivery
route
Local
Fill-up Kanbans
suppliers
Yard / Dock

Fixed
ordering

Port
W/H

Push-in no
consideration of
used qty

X:A
X:Alot
lotofofstock,
stock,X:Long
X:LongL/T
L/Tbecause
becauseofofstagnation,
stagnation,X:Push
X:Pushsystem
system
(After IMV) To PxP flexible production line

e-Kanban

Local Yard / Dock Progress PC Store Baton pass lane ASSY line
suppliers absorption lane

#1
#2
#3 1T 1C 1F
1T 2T 3T
#4
#5
#6
#7
#8
Milk run #9 2T 2C 3C
1C 2C 3C
delivery #10
#11
#12
#13 Supply based
#14 on the
#15 production 1F 2F 3F
3T 3C 3F
#16 progress

Sunter Kanban Room

Inter-process
Kanban

O:Small
O:Smalllot
lotorder,
order, O:Short
O:ShortL/T,
L/T, O:Market
O:MarketOriented
Oriented
 Today’s explanation : Internal Log.flow & Each purpose

(1)P-lane: High-frequency, Small lot supply based on line progress (5)Line supply: Pull system High-frequent Small lot supply

(2)Module stock: Regular volume stock using progress unpacking (6)Empty box sort area: Empty box sorting based on
suppliers
(3)Free location rack: To avoid overflow,keep FIFO (7)Jundate area: Line side space reduction

(4)PC store: To avoid parts shortage, follow type variety change

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Emp.box sort Progress
lane
Free
Location
Module Rack
area

Karawang plant assembly line

 1.Progress
1.Progresslane
lane
~Parts
~Partscarrying
carryingout
outfrom
fromP-lane~
P-lane~

Purpose:High frequency & Small lot parts supply to PC store based on Line progress

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Emp.box sort Progress
lane
Free
Location
Module Rack
area

Karawang plant assembly line

 1) L/O vehicle/ e-KBN order
countdown, and current
lane# indication

10
3
1
2 #2
#3
[Point]
[Point]
2) Start job based on We
[L/O counter] next lane# indication Wemust
mustcarry
carrythe
theparts
partsbased
basedon
onL/O
L/O
counter indication to fit Line progress
counter indication to fit Line progress

6) All Skids were carried out

from current lane#,
pull the cord switch

#1
Course C
#2

#3
#4

#5 [PC store delivery course]

[Progress lane]

C
5) Put the SKID on empty
3) Carry out the SKID
123 dolly using forklift
from indicated lane# PC1-A

[e-KBN]

4) Bring to indicated course

based on e-KBN course#
 [Trouble]
[Trouble]Parts
Partscarrying
carryingout
outwhen
whenline
lineisisstopped
stopped

3
2
1 #3
1) If line is stopped, L/O
counter is also stopped
[L/O counter]

[NG]
Line stopped! [NG]
WeWecan’t
can’tcarry
carryout
outSKID
SKIDininadvance:
advance:
2) Carry out all Skids ItItcauses overflow at PC store
causes overflow at PC store
from lane #3

#1
Course C
#2

#3
#4

#5 [PC store delivery course]

[Progress lane]

3) After carrying out all Skids from

#3,stop his (her) job and wait
 2.PC
2.PCdelivery
deliverycourse
course
~Parts
~Partsdelivery
deliveryto
toPC
PCstore~
store~

Purpose:Parts delivery to PC store in short L/T according to P-lane operation

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 5) Arrange Empty Skids

[Empty skid area]

4) Go to Empty SKID area

6) Separate Empty dollies [Point]

at delivery course [Point]
We
Weneed
need22lanes
lanesper
peraacourse
coursetotodeliver
deliver
efficiently
efficiently(Lane
(Lanefor
forparts
partsdollies/
dollies/
Lane
LaneforforEmpty
Emptydollies)
dollies) PC1-A

Course C

[PC store]

[PC store delivery course]

C
C
1) Start indication:All dollies
are full 123
123 PC1-A
PC1-A

[e-KBN]
[e-KBN]
3) Stock parts based on
2) Start delivery confirming e-KBN PC store address
e-KBN course#
 3.Module
3.Modulestock
stockarea
area
~Progress
~Progressunpacking~
unpacking~

Purpose:High frequency & Small lot parts supply to PC store based on Line progress

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 1) Pull system based on
key module Min. stock

019
020
by each container

4) FLR parts are put into

pallets, others are put
[L/O counter] on dollies

TMT SN

SO
[Unpack area]
3) Carry out the module
confirming the module#
ASSB based on L/O counter &
CTL board [Sorting area]
[Module stock]
[Container yard]
Progress unpacking CTL Board
Type Unit 5 10 15 20 25 30 --- 300
2) Prepare Heijunka
Mod# 101 102 103
unpacking plan by SN
each module based Status
on order information
Mod# 50 51 52
SO
Status
Mod# 13 14
ST
Status
 4.Free
4.FreeLocation
LocationRack
Rack

Purpose:To avoid overflow, Keep FIFO

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

(1)Total image of FLR operation 4) Small space parts
are stocked directly
to PC store
1) Container delivery 3) Sort MSP based on
indication based on module parts space at PC store
stock quantity (Pull system)

[Unpack area]

[Container yard] [Module stock] [Sorting area]

2) Module unpacking [PC store]

based on Line progress

5) Big space parts are sorted

into pallet and stocked 6) Change pallets based

in the Free Location Rack
Free Location CTL Board

A-2 B-2 C-2 D-2

Parts CTL Board

Parts
XXXXX-XXXXX
Location
[Free location rack] on pull system from PC
store keeping FIFO
A-1 B-1 C-1 D-1 YYYYY -YYYY Y

ZZZZZ-ZZZZZ
E-2 F-2 G-2 H-2

E-1 F-1 G-1 H-1

(2)Unpacking -> Free Location Rack

4) Stock the pallet to

indicated rack location #
D-3

A-3 B-3 C-3 D-3 E-3

Parts: 11 Parts: 11
B-2 E-2
A-2
A-2 B-2 C-2 D-2 E-2

Parts: 22 Parts: 22
1) Move the pallet to C-1 D-1 E-1
CTL board A-1 B-1 C-1 D-1 E-1

3) Attach one card on pallet, Parts: 33

Parts: 33 [Free Location Rack] and hook another card
on Parts CTL board

A-2 Parts: 44
Parts: 44 Parts CTL Board
[Pick rack]
Free Location CTL Board
[Sorting area] Parts Location
A －３
A-3 B－３
B-3 C－３
C-3 D－３
D-3 E－３
E-3
A-3 B-3 C-3 E-3 E-1
A-3 B-3 C-3 E-3 11111-11111 E-2

A －２
A-2 B－２
B-2 C－２
C-2 D－２
D-2 E－２
E-2 B-2 D-3
22222-22222
A-2 C-2 D-2
A-2 C-2 D-2
33333-33333 C-1
A-1
A －１ B-1
B－１ C-1
C－１ D－１
D-1 E-1
E－１
A-2
A-1 B-1 44444-44444 D-1
A-1 B-1

2) Check Location CTL

board, and take 2 [Location CTL board] [Parts CTL board]
location cards
(3)Free Location Rack -> Pick rack

3) Go to FLR, and
take pallet based on D-3 5) Change pallets
the location card using towing car
A-3 B-3 C-3 D-3 E-3
(W/O Forklift)

Parts: 11 Parts: 11
B-2 E-2
A-2
A-2 B-2 C-2 D-2 E-2

Parts: 22 Parts: 22
C-1 D-1 E-1

A-1 B-1 C-1 D-1 E-1

Parts: 33
Parts: 33 [Free Location Rack]
1) Take pallet Kanban
4) Return 2 location cards and order
to indicated location of
Free location CTL board Parts: 44
Parts: 44 Parts CTL Board
[Pick rack]
Free Location CTL Board
[Sorting area] Parts Location
A －３
A-3 B－３
B-3 C－３
C-3 D－３
D-3 E－３
E-3
A-3
A-3
B-3
B-3
C-3
C-3
E-3
E-3 11111-11111 E-2
E-1
22
A －２
A-2 B－２
B-2 C－２
C-2 D－２
D-2 E－２
E-2 2
B--3 D-3
22222-22222 D
B-2 C-2 D-2
B-2 C-2 D-2
33333-33333 C-1
A-1
A －１ B-1
B－１ C-1
C－１ D－１
D-1 E-1
E－１ B-2
A-2
A-1 B-1 44444-44444 D-1
A-1 B-1

2) Go to Parts CTL
board,
and take location card
[Location CTL board] [Parts CTL board] from left side
(to keep FIFO)
 5.PC
5.PCstore
store
~Parts
~Partspicking
pickingfrom
fromPC
PCstore~
store~

Purpose:Parts picking in short L/T according to parts consumption

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 1) Take Int.KBN/Picking 7) Go to KBN room to
list at fixed time based on take Int.KBN
KBN paging timetable

A B C [Point]
[Point]
IfIfthe
thepicking
pickingisisnot
notfinished
finishedininpremised
premised
time, call T/L to ask relief
time, call T/L to ask relief

[Kanban release box]

5) Pull cord switch when picking
is finished (If picking is delayed,

ask T/L for relief)

DENSO SUGITY Course A:

Course B:

e-KBN Course C:
[Empty dolly area]

[Baton pass lane]

[PC store]

2) Connect empty
6) Sort dollies by
dollies to towing car 4) Change e-KBN and
supply course based
3) Pick parts based Int.KBN and put e-KBN
on Int.KBN course #
on Int.KBN/Picking list into KBN post
 [Detail]
[Detail]Parts
Partsloading
loadingon
ondolly
dolly

DENSO SUGITY

Final Chassis Trimming Final Chassis Trimming

parts parts parts parts parts parts

[PC store] Int KBN

1) Layout is arranged based on e-KBN
suppliers,group is based on
line process
10 1 10
5 5 5
2) Separate dollies
1 10 1
based on line process
or supply course

[F dolly] [C dolly] [T dolly]

Shopping List

# Back # Address KBN # 3) Parts loading based on [Assembly line]

1 474 P1A-01P1 001 supply sequence
2 475 P1A-01P1 001 (Easy to supply)
[Chassis] 1 2 3 4 5 .....….9 10
3 481 P1A-01P1 001
4 486 P1A-01P1 001
5 487 P1A-01P1 001
6 002
[Point] [Trimming] 9 8 7 6 5 .....….2 1
7 488 P1A-01P1 001 [Point]
Picking
8 877 P1A-01P1 001 Pickinglist
listisissorted
sortedbased
basedon
on
line supply sequence
9 189 P1B-06P6 001 line supply sequence 10 9 8 7 6......….2 1
[Final]
[Shopping List]
 [Trouble]
[Trouble]Pick
Pickshortage
shortageKanban
Kanbanoperation
operation

5) If not enough, Parts

tapping from P-lane
4‘) [No parts]
Parts stock check at
Line side

4) [Find parts]
Parts supply to B-lane

#1

#2

#3

#4

[Line side]
[Progress lane] [PC store] [Baton pass lane]
6) Parts supply
Int KBN directly to B-lane

1) Pick-shortage
Kanban returns

3) Picking again at
next cycle
[Kanban room] 2) Kanban Qty
check & record
 [Trouble]
[Trouble]Line
Lineparts
partsshortage
shortageoperation
operation

1) Assy member should write

[Hot call CTL board] shortage parts on CTL board

CTL board & call PC store G/L

2) PC store G/L has to look

for the parts at PC store 3) [Find parts]
Parts supply to B-lane

#1

#2

#3

#4

[Line side]
[Progress lane] [PC store] [Baton pass lane]

4) Parts supply
directly to B-lane
3‘) [No parts]
Kanban Qty check & tap
the parts from P-lane

[Kanban room]
 6.Baton
6.Batonpass
passlane
lane
~Parts
~Partssupply
supplyto
toline~
line~

Purpose:High frequency & Small lot supply to line in fix time unscheduled quantity

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 DENSO NTC

[Supply timer]

[Empty dolly area] [Empty box area]

4) Confirm current job if delayed or not
based on supply timer
6) Separate empty dollies (If the job is delayed, separate empty
at empty dolly area dollies at B-lane, and ask T/L for relief)

5) Arrange empty boxes on

Skids supplier by supplier

[NG]
[NG]
We
Course A: Wecan’t
can’tstart
startsupply
supplybefore
beforeindicated
indicatedtime:
time:
ItItcauses overflow at line side
causes overflow at line side

[Supply CTL ANDON]

Course B:

1) Start supply based on CT-13L1

CTL ANDON indication

Course C: Empty

Delivery List [Line side]

# Back # A ddress KBN #
1 474 CT-13L1 001
2 475 CT-13L1 001
3 481 CT-13L1 001
[Baton pass lane]
4 486 CT-13L1 001
P1A-01P1 CT-13L1
5 487 CT-13L1 001

6 002
2) Pull cord switch when 7 488 CT-13L2 001
[Int.KBN]
supply job is started 8 877 CT-13L2 001
3) Supply parts based on Int.KBN/Delivery list
9 189 CT-13L2 001
line address and pick up empty boxes
[Delivery List]
 [Detail]
1) Fixed timing [Detail]Supply
SupplyCTL
CTLANDON
ANDON
announcement

Supply start
Supply CTL Andon
2) When supply member
timing---
pulls the cord switch,
delay display is reset Course Cycle Num ber Delay
A A 38 02
02
03 00

B 38 02
03 00
01
02

B C 38 02
03 01
00

[Supply CTL Andon]

3) Delay time is counted from

fixed timing
(Reset by pulling the cord)

[Baton pass lane]

 [Trouble]
[Trouble]T/L
T/Lrelief
relieffor
forSupply
Supplydelay
delay
[Normal
[Normalcondition]
condition]
2) Supply parts,
Pick empty boxes

[Abnormal
[Abnormalcondition]
condition]
1) Start supply at
fixed timing
[Supply CTL Andon]
Chassis

Trimming

4‘) Separate dollies

& go to next supply
[PC store]
[Empty dolly area]
5) Separate empty Final
dollies
[Assembly line]
[Baton pass lane]
[Supply timer]
6’) T/L arranges
empty boxes 3) Confirm current
job if delayed or
not Delay!

4) Arrange empty 5‘) T/L goes to B-lane

boxes to relieve
[Empty box area] [Kanban room]
 7.Empty
7.Emptybox
boxsorting
sortingarea
area
~Empty
~Emptybox
boxcollecting/Arrangement~
collecting/Arrangement~

Purpose:Empty box sorting for each supplier, box from line process

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 Delivery timer 4) Move empty boxes to stock
area by forklift based on
each SKID’s height
Planned tim e

10:00
Delay
Current tim e

9:55
9:56 00

[Supply timer] DENSO NTC

2) Confirm current job if delayed

or not by timer, If there’s no
delay, go to empty box sort area
[Empty box sort area]
[Line side] Empty

[Point]
[Point]
Arrange
Arrangeempty
emptyboxes
boxesonondolly
dollyininadvance
advance
to sort them easier at empty box sort area 3) Sort empty box supplier
to sort them easier at empty box sort area
by supplier at empty box
1) Supply parts to line side,
sort area
pick empty boxes
 8.Internal
8.InternalKanban
Kanban
~Kanban
~Kanbancollecting/Sorting~
collecting/Sorting~

Purpose:Equal pitch Kanban collecting/Accurate Kanban sorting to pick parts

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 1) KBN collecting
announcement based on
KBN collect 13:30 14:22 14:59 15:36 time table
Pick start 13:55 14:32 15:09 17:51 Kanban collect timing---
Supply start 14:41 15:18 18:00 18:37
3) Start KBN collecting
[KBN collect time table] based on announcement

Course Course Course Course Course

4) Sort Int.KBN based on
A B C D E
picking course

PC PC PC PC PC
1,2 3,4 5,6 7,8 9,10 [Mother post]
PC PC PC PC PC
11,12 13,14 15,16 17,18 19,20
2) T/L moves KBN from
child post to mother post
[KBN manual sort box] based on announcement
6) Put KBN and lists in
the lower box of KBN
release post

7) Move them to upper box

5 min before pick start,
[New KBS] and hand them over to
pick members

Delivery List
Course Course Course
A B C
# Back # A ddress KBN #
1 474 CT-13L1 001

5) Read Int.KBN, then lists 2

3
475 CT-13L1
481 CT-13L1
001
001

are printed out 4 486 CT-13L1 001

5 487 CT-13L1 001

6 002
7 488 CT-13L2 001

8 877 CT-13L2 001

9 189 CT-13L2 001

[Kanban release post]

 9-1.Jundate
9-1.Jundatearea
area
~Sequential
~Sequentialparts
partssetting~
setting~

Purpose:Line side space reduction according to bulky parts sequential supply

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

 6) Carry out the finished 7) Bring next empty child dolly
2) Bring an empty child dolly
child dolly (One pass job flow)
confirming dolly sequence #

01 01 04 01
04

01
01

[Shopping list printer]

Parts code Number Cell

A 011 1
015 5
017 7
B 013 3
018 8
C 012 2
014 4
016 6
020 0
D 019 9 [Sequence setting area]
5) Parts confirmation
[Shopping list] after Jundate with the list
3) Parts setting based on
shopping list
4) Set e-KBN in child dolly
1) Start job based on
based on Qty/box
shopping list
 9-2.Jundate
9-2.Jundatearea
area
~Jundate
~Jundateparts
partssupply
supplyto
toline~
line~

Purpose:Jundate parts supply based on line progress, reduce dolly change L/T

Progress PC store
lane delivery Assembly
PC store B-lane
course line

Steel pallet
KBN room
Empty Jundate
box area area
Progress
lane

Free
Location
Module Rack
area

Karawang plant assembly line

[Point]
[Point]
Jundate
Jundateparts
partsalso
alsoshould
shouldbe
besupplied
suppliedtotoline
line
according
accordingtotoline
lineprogress
progress

2) Bring finished child dolly

5) Carry the child dollies into line,
take empty dollies from line side
(Mikara operation)

4) Start supply based on parts 10 - 0

stock countdown at line side

[L/O counter]

CT-10 CT-5 CT-1

1) Carry in empty child dollies

3) Mixed delivery based on

parts attachment point
[Sequence setting area]
Review: Internal logistics should be built

(1)The
(1)Theshortest
shortest&&repeatable
repeatableL/T
L/Tlogistics
logisticsoperation
operation

(2)Line
(2)Lineside
sidespace
spacereduction
reductionwith
withHigh
Highfrequency
frequency&&Small
Smalllot
lotsupply
supply

(3)Flexible
(3)Flexiblelogistics
logisticscan
canfollow
followvolume
volume&&T/T
T/Tchange
change
END
END
 1/ 14

Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

VM-NO Explanations

Introduction I am going to explain the basic internal logistics operations at overseas plant using the examples of TMMIN.
▼

2 Purpose of TOYOTA internal logistics is,

▼ to produce the vehicle as customer required, at the shortest, at the lowest cost, and with the highest quality.
▼ From logistics point of view, to put into practice “Stable & Flexible” Logistics. Realize “Real market demand basis production”

▼ In other words, contribute to build the compact production line, that is, cyclic, small lot, flexible Man Power supply.
▼

3 I am going to give a brief explanation of the internal logistics methods before and after the TMMIN IMV model change.
The logistics before IMV model change, the local parts are delivered by suppliers via separate & single route, by using fill-up
Kanban, and transported to the line side via the yard dock.
The import parts are delivered by fixed ordering system, delivered to the line side via the port and the parts dock.
Every routing had large qty stock for productions.
▼ Therefore, TMMIN had many problems and was doing inefficient operations with a lot of stocks, long L/T,
and push system to the market, due to the planned productions.
▼

4 Next, I am going to explain the logistics after changing over to IMV.

The logistics changed to the production progress-based internal logistic style, utilizing e-Kanban, delivery is from suppliers to
the progress absorption lane, via the yard dock with milk-run delivery style. High frequent and small lot. Transport the parts to the
PC store based on production line progress. Transport the parts from PC store to the baton pass lane line side,
utilizing inter-process Kanban and Fill-up method.
▼ Small lot ordering, parts delivery with short L/T, market-oriented productions and logistics based on the line progress are
enabled by e-Kanban introduction.
About each item flow and the purpose, I am going to explain in the next page or later.
▼
 2/ 14

Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

VM-NO Explanations

5 I am going to explain Internal Logistics flows & Each purpose, these are today’s explanation topics.

▼ (1) Progress Lane (Progress absorption lane), High-frequent small lot supply based on line progress

▼ (2) Module stock place - Regular volume stock using progress unpacking

▼ (3) Free location rack - To avoid overflow, keep FIFO

▼ (4) PC store - To avoid parts shortage, follow type variety changes
▼ (5) Line supply - Pull system High frequent Small lot supply

▼ (6) Empty box sort area - Empty box sorting based on suppliers

▼ (7) Jundate area - Line side space reduction

These 7 items are main purposes.
▼

6 ▼ 1. I am going to explain about the progress lane (Parts carrying-out from P-lane).
▼ The purpose is High-frequent & Small lot parts supply to PC store based on Line progress.

▼
 3/ 14

Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

VM-NO Explanations

7 ▼ 1) L/O counter shows the amount of L/O vehicles counting-down, and shows the current carrying-out progress lane No, lane being used.
Currently, remaining 3 L/O vehicles, the progress lane now carrying-out is No2.

▼ Now, 2 Remaining L/O vehicles

▼ Now, 1 Remaining L/O vehicle

▼ The count down shows “10”, and the progress lane No changed to No3.
2) As an example, when production volumes per a day is 240, and there are 24 progress lanes, the production volume per a lane
is 10, when finished 10, the lane No changes to next No.

In this case, finished L/O for 10 vehicles, start the parts carry-out from the lane No3.

▼ 3) Carry-out the parts from the corresponding progress lane (No3).

▼ 4) Confirm the e-Kanban carry-out course No, and bring to the corresponding PC course. (This time the course C)

5) Put the parts on the empty dolly that bound for the course C.

▼ 6) When carried out all parts from the progress lane (In this case No3), pull the cord switch to indicate operation is completed.

▼ The key point: Carry-out based on the L/O counter instructions without fail, to keep up with the line progress.
▼

8 ▼ Trouble handling : I am going to explain how to carry-out the parts when a line is stopped.

▼ 1) Line A is stopped, and L/O counter shows there is 1 vehicle remaining. When the line is stopped, L/O counter is also stopped.

▼ 2) Carry out all parts from the lane currently used lane. (In this case, Lane No3).

▼ 3) Stop after finished the parts from the lane No 3, wait for next instruction by the L/O counter.

▼ Point: We can’t carry-out SKID in advance to avoid PC store overflowing.

When the line is stopped, parts are build up inside the progress lane.
▼
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9 ▼ I am going to explain “2. Carry-in course to PC store”. (Parts carry-in to the store)

▼ Purpose :Parts delivery to PC store, in short L/T according to P-lane operation

▼

10 ▼ 1) Confirm all dollies are full of parts.

▼ 2) Confirm the Kanban carry-in course (in this case, course C), and start delivery.

▼ 3) Carry-in the parts to the PC store address that written on e-Kanban. (In this case, PC1-A)

▼ 4) Go to the empty skid area.

5) Arrange empty skids.

▼ 6) Detach empty dollies at the original carry-in course.

▼ Point: We need 2 lanes per a course to deliver efficiently (One lane for parts dollies / One lane for Empty dollies)
When the line is stopped, parts cannot be carried-out from the progress lane, no parts overflow at PC store.
▼

11 ▼ 3. I am going to explain the module stock area (progress unpacking).

▼ The purpose:High frequent & small lot parts supply to PC store based on Line progress.
▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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12 ▼ 1) Devan at the ordering points for each container group (Signal Kanban). Check the module Minimum stock.

▼ 2) Prepare Heijunka unpack plan for each module, based on order information, on monthly scheduling timing.
In this case, when completed 5 SN L/O, unpack module #101. When completed 15 L/O, unpack module #102.

▼ 3)When L/O counter shows the instructed vehicle qty (In this case 20), unpack the target modules. (SO, module #51)

L/O counter is count-up.

▼ 4)Put the FLR target parts on the pallet, and separate other parts using the dollies for each course.
When the line is stopped, unpacking is not done, no parts are sent to PC store FLR, so no parts overflow.
Besides, the ordering point Kanban (triangle Kanban) is not detached, so module carrying-in from containers is also stopped.
▼

13 ▼ 4) I am going to explain the FLR (Carry-in / out ).

▼ Purpose:To avoid overflow of MSP (Multi Source Parts=Imported parts), Keep FIFO (First In First Out)
The target parts are large parts and parts with wide type variations.
▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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14 ▼ At first, I am going to explain the total image of FLR.

▼ 1) indicate fill-up delivery based on module stock quantity.

▼ 2)Module unpacking based on Line progress.

▼ 3)Sort MSP for PC store or for FLR.

4) Carry in small space parts directly to PC store FLR and stock.

▼ Big space parts are sorted into special pallet and stocked in Free Location Rack.

So far, I explained the same contents a while ago.

▼ 6) Change pallets based on pull system from PC store, keeping FIFO and using fill-up Kanban (Triangle Kanban).

These are the total image of parts carrying in and out, utilized FLR.
FLR is to keep FIFO and to handle the type variations. If we have no FLR, the wider PC store spaces are necessary,
or a lot of overflowing parts have to be kept in PC store.
▼

15 ▼ I am going to explain from the module unpacking to FLR stocking.

The upper and in the center is FLR. The lower left is Location CTL Board. The lower right is Parts CTL Board
▼ 1) When finished putting the module-opened parts on the pallet, move the pallet (Part No 44) to FLR CTL Board.

▼ 2) Take 2 location cards, both small and large, from the FLR CTL Board (In this case, “A-2”),
attach the large location card on the pallet.

▼ 3) Attach the small location card on the corresponding Part No place, on Parts Control Board (Part No 44) from the right.

▼ 4) Stock the pallet to FLR as indicated on the FLR card. (Rack A-2)

▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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16 ▼ I am going to explain unpacking to pick rack.

▼ 1) Detach the pallet Kanban (Signal Kanban) and order when picking the parts. (In this case, Part No 22)

▼ 2) Go to Parts CTL board, and take target parts location card (Part No 22) from the left side. (In this case, B-2)

▼ 3) Take pallet from B-2, based on the location card.

▼ 4) Put 2 Location Cards together, and put back on the FLR Control Board. (The place for B-2)

▼ 5) Attach the signal Kanban (Part No 22) on the pallet, bring to PC store, and change the pallet.

I am going to explain the FLR CTR Board and Parts Control Board.
When the location card is attached on Free Location CTR Board, that means the place is empty. When there are no location card,
we have some parts stocks. Parts CTR Board shows which parts are put on which racks.
Use from the left of Parts CTR Board, the parts FIFO can be kept.
FLR, 3-dimensional, and can be used freely, so the necessary PC store space can be reduced.
▼

17 ▼ I am going to explain about PC store (Parts picking from the store).

▼ Purpose:Parts picking in short L/T according to the parts consumption results at the production line.

▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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18 ▼ 1) Take Internal KBN and Picking list from Kanban release post at fixed time based on KBN paging timetable.

2) Connect empty dollies to towing car inside empty dolly storage place.

▼ 3) Pick parts based on Internal KBN and Picking list.

▼ 4) Change e-KBN of the picked parts with Internal KBN, put e-KBN into KBN post, and attach internal KBN on the pallet.

▼ 5) Pull the cord switch when picking is completed. If picking is delayed, ask for relief.

6) Sort dollies by supply course based on Internal KBN course No. (Course A, B, and C)

▼ 7) Go to KBN room to take Internal KBN and pick list. Repeat these (1) to (7) operations.

▼ Point: If the picking is not finished in premised time, call Tam leader to ask relief
▼

19 ▼ Next, I am going to explain how to load the parts on dollies.

▼ 1) In TMMIN, the layout is arranged based on suppliers, group is based on line process.
Layout is, DENSO final parts, chassis parts, and trim parts. Layout in PC store differs company by company.

▼ 2) Separate dollies based on line process, Final, Chassis, or Trim

▼ 3) Parts picking based on supply sequence (Easy to supply to the line side). Output the picking list in the picking sequence.
▼ When supplying from left to right and load the parts to the final line, pick the part 1 first, that has the late supply sequence.
▼ As the second, pick Part 5.

▼ Lastly, pick Part 10.

▼ For chassis line, pick the parts in the order of 10, 5, and 1.

▼ For trim line, pick the parts in the order of 1, 5, and 10.

▼ [Point] Picking list is sorted based on line supply sequence or not.

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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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20 ▼ I am going to explain “[Trouble] Pick shortage Kanban operation”. (No parts in PC store)

▼ 1) “Pick shortage Kanban” returns,

2) Register the “pick shortage Kanban” qty.
▼ 3) Pick again at the next cycle. (There are safety stocks at the line side)

4) If there are parts in PC store, supply the parts to the baton pass lane.

▼ 4’) If there are no parts in PC store, confirm the stocks in the line side.
▼ 5) If the line side parts are not enough, take out the parts from the Progress lane,

6) Directly supply the parts to Baton pass lane.

▼

21 ▼ Next, I am going to explain “[Trouble] Line parts shortage operation”.

▼ 1) Assy member should write shortage parts on CTL board & call PC store G/L.

▼ 2) PC store G/L has to confirm the parts are there in PC store.

3) If there are some parts, supply the parts to Baton Pass lane.

▼ 3’) If there are no parts, check Kanban Qty & take out the parts from P-lane.

4) Parts supply directory to Baton Pass lane.

▼

22 ▼ Next, I am going to explain Baton pass lane. (Parts supply to the line)

▼ Purpose: High frequent & Small lot supply to the line in fix time and unscheduled quantity.
▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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23 ▼ 1) Start supply based on CTL ANDON indication.

2) Pull cord switch when supply job is started

▼ 3) Supply parts based on Internal KBN line address (CT-13L1 ) and delivery list, pick up empty boxes.

▼ 4) Confirm whether current job delayed or not, based on supply timer. If delayed, separate empty dollies at B-lane, and ask T/L for relief.

▼ 5) If there is no delay, arrange empty boxes on skids, supplier by supplier at the empty box area.

6) Separate empty dollies at empty dolly area.

▼ NG (No Good): We can’t start supply before indicated time, it causes overflow at line side.
▼

24 ▼ I am going to explain the information from Supply CTL ANDON.

▼ The Supply CTR ANDON No. changed to 3.

▼ 1) Fixed timing announcement,

2) Pull the cord switch to start. Course A is fixed time start, so 0min delay.

▼ B and C, 1 min delay.

▼ Course C starts 1 min after. If pull the cord on the start timing, the delay time can be reset.
▼ Course B hasn’t be started yet, 2 minutes delayed.
3) Delay time is counted from fixed timing.
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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25 ▼ I am going to explain Team Leader relief for supply delay

▼ In normal condition.
▼ 1) Pull the cord, and start supply at fixed timing.
▼ 2) Supply parts, pick the empty boxes.
▼ If there’s no delay, 4)Arrange empty boxes at the empty box sort area.
▼ 5) Separate empty dollies at empty dolly area.

Those are the operations on the normal condition.

▼ Next, I would like to explain the delayed case.

▼ 1) Pull the cord, and start supply at fixed timing.

2) Supply parts, pick the empty boxes. Delayed here.

▼ 3) Check the delay using Supply CTR timer.

▼ 4’) Separate dollies at Baton pass lane, and start next supply.

▼ 5’) T/L goes to Baton pass lane for relief.

6’) T/L arranges the empty boxes.

These are T/L relief due to supply delay.

▼

26 ▼ Next, about “7.Empty Box Sorting Area (Empty box collecting and arrangement) ”.

▼ Purpose: Empty boxes sorting for each supplier that withdrawn from line process.

▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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27 ▼ 1) Supply parts to the line side, pick empty boxes.

▼ 2) Confirm current job if delayed or not by timer. If there’s no delay, go to empty box sort area.

3) Sort empty boxes supplier by supplier at empty box sort area.

▼ 4) Move empty boxes to the stock area by forklift, based on each SKID height.

▼ [Point] Arrange empty boxes on dolly in advance in the empty box sort area, to sort them easier.

28 ▼ I am going to explain “8.Intra-process Kanban (Kanban collecting/sorting).

▼ Purpose:Equal-pitch Kanban collecting/ Accurate Kanban sorting to pick parts accurately
▼

29 ▼ 1) KBN withdraw announcement based on time table.

▼ 2) T/L moves KBN from child post to mother post based on announcement
▼ 3) Kanban staff starts KBN collecting based on announcement.

4) Sort the withdrawn intra-process KBN based on picking course.

▼ 5) Read intra-process KBN, then shopping lists and delivery lists are printed out. (TMMIN is using scanner)
6) Put intra-process KBN and lists in the lower box of KBN release post.

▼ 7) Move them to upper box 5 min before picking start, and pick members start picking using intra-process Kbn and delivery lists.

30 ▼ 9-1. I am going to explain Jundate area (Parts setting).

▼ Purpose:Line side space reduction according to bulky parts sequential supply.

▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

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31 ▼ 1) Start job based on shopping list.

Study the output way for easier Jundate handling, no picking movement backward and forward, no mistakes.
Study the print out method in order not to cause mistakes. TMMIN outputs based on the parts sequential No.
▼ 2) Bring an empty child dolly confirming dolly sequence #

3) Set the parts on dollies based on shopping list.

▼ 4) Set e-KBN in the pocket of child dolly based on Qty/box

▼ 5) After Jundate, Parts confirmation with the list.

▼ 6) Carry out the finished child dolly to the designated place, after parts confirmation.

7) Bring next empty child dolly and start the Jundate operation. (One pass job flow)
▼

32 ▼ I am going to explain 9-2. Jundate area (Jundate parts supply to the line).
▼ Purpose:Jundate parts supply based on line progress, reduce dolly change L/T
▼

33 ▼ 1) Carry in empty child dolly

2) Bring finished child dolly

▼ 3) Mixed delivery based on parts attachment points, such as mixed delivery but chassis process only
(Do not mix chassis parts and final parts)
▼ 4) Start supply based on parts stock countdown at attachment points. (Line progress)

5) Carry the finished child dollies into line, take empty dollies from line side (Mikara operation).

▼ Point : Jundate parts also should be supplied to line according to line progress.
▼
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Course Name Internal Logistics Lecture name Basic Internal Logistics Operations at overseas plant

VM-NO Explanations

34 Review: Internal logistics should be built

▼ (1) The shortest & repeatable L/T logistics operation

▼ (2) Line side space reduction with High frequency & Small lot supply

▼ (3) Flexible logistics can follow up volume & T/T change

These are important items should be build.

▼

35 That’s all for explanation of “Basic Internal Logistics Operations at overseas plant”.

Best Internal Logistics differs depending on the capability of companies and suppliers, or various conditions.
Lastly
Understand the basic concept, and try to take efforts to construct the best internal logistics suitable for each company and plant.