Tuesday, July 14, 2009

principles of Chaku-Chaku

Chaku-Chaku is a takt flow job in which the operator moves the parts to be processed from one machine to another, walking a fixed path loading and unloading the machines.

In this example, the operator walk around the cell and unloads-loads the machines (automatic or semi-automatic) in the order of sequences 1 to 6.

The principle of Chaku-Chaku is to design the layout of necessary machines and equipment in the order of the work sequence, the closest from one another as possible.
The operator loads the part to be processed and walks to the next machine, and so on. If the machines do not unload themselves automatically, unloading will remain part of operator's job.

The parts don't dwell anymore in front of the machines, neither are they moved in batches, but are processed in a streamline, with a drastic reduction of leadtime.

Another highlight of this approach is the full responsibility given to the work cell for the entire production cycle and therefore a better management of deliveries, quality and traceability.

The key to line or cell Chaku-Chaku efficiency is the synchronization between operations and the operator path, in order to maximize his occupation. The U shaped cell is very suitable for this usage.