On the basis of the situation as seen form three points of view, D made the following Seiton system improvement policies.
Improvements for Component safety Seiton system
1) Parts and materials which are assembled by the deadline in the amount indicated in the operation order form, will be taken and placed on a cart, taking as few loading trips as possible, and prepared for transporting (in accordance with the operations of the next process).
2) The next process will, in accordance with the deadline on its own operations order form, transport for the components from the assembly process, and place them in a spot which will make it easy to work. Components will not be unloaded. Both 1) and 2) will decrease the number of times components have to be handled reducing chances of injury.
3) Empty carts and containers will be returned to the assembly process when the next trip for components is made.
Increasing safety transportation containers for components
1) Protective equipments will be attached to containers according to the shape of components and the presence of danger
2) These containers will be used, in delivery box style specifically for inter process use. These will be placed on a small cart, and assembled products will be placed in the containers.
3) These will be designed after a survey shapes and amount of components is made.
Establishing a work in progress component storage area and person in charge:
1) Components from the assembly workshop which have been placed in safety containers and loaded onto a small cart will be transported along with the item form indicating the place to be delivered and left in the storage area which is labeled as such, and workers will notify the next process and wait for them to be received for transporting.
2) A group leader will be designated as the person in charge of the safety area for the assembly workshop who will check the number of products, check to make sure delivery is made, contact the next process, check along with the recipient to make sure of amount and make safety checks.
Establish workshop operational control system:
1) To produce the amount required, when required, in the required quantity, for minimal unfinished products, and deliver it to the place that requires it, a structure will be established which will plan, assign operation, conform and evaluate what is accomplished and process the set amount for the four production elements.
2) With the above, we will create a system which will fulfill the control items: production (P), quality (Q), cost (C) delivery (D), safety (S), morale(M).
Of the four improvement themes above D decided to attempt the two would accomplish accident prevention as well as improve efficiency.
The Main Improvement Point for Seiton system with Emphasis on Components:
Of the themes in item (2) above, the following two were chosen, and the main improvement points designed.
Main improvement points for component safety Seiton system (steps):
1) Seiton system for assembly workshop According to the operations form order and the operational schedule, the workers bring the transportation containers and small carts from the component delivery storage area to the work table, making sure of safety equipment. Components which have been processed will, according to safety operation and safety rules, be put into safety containers prepared for components of that size, the safety productive equipment fastened, then the worker will make communication to the next process that delivery preparation is complete and wait for them to be received for transporting.
2) Seiton system for the next process: Workers will, according to the operation order from and operational schedule, go to the storage area for processed and assembled items when contacted, accept the components for their process, take them back to their workshop and store them temporarily in the order in which they are to be used. For assembly processing, workers will go to the temporary storage area, remove the safety protective equipment from the components, carry them in containers to the work table, take the components from their storage containers and begin operations.