A3 Report - Car Wash Kaizen

1. THEME:- Decrease Car Wash Duration to Contribute to EM Target Duration
Team Name : FAST WASH
DAIHATSU MISR Co., Ltd. ةدوﺪﺤﻤﻟا ﺮﺼﻣ ﻮﺴﺗﺎﻬﻳاد ﺔآﺮﺷ
1. Leader : Mostafa Sherif
2. Sub Leader : Karam Mostafa
Step 1: CLARIFICATION OF PROBLEMStep 4: Cause Analysis
Object: Car Wash Duration
Target: Decrease
Place: Obour Service Center
Purpose: Eliminating wasted time to reach the time that contribute to EM target duration.
Step 2: Investigating Current Situation
Due to the requirements for EM ( Express Maintenance ) target duration
time, We find that car wash took long time.
We investigated our average time for car wash duration to know exactly
which process consume more time.
We find that Wash process took about 45% of the total duration.
Step 5: Setting Up Countermeasures
Step 6: Execution According to Action Plan
Effect Practicality cost evaluation priority
1- VIP Card - Sorting Sign91
2- Specify an ordered Waiting Area (Waiting Lane)XX3 4
3- Define SOP91
4- 2 - Man Operation72
Get extra:-
1.washing machine
2.Vacuum
6- Fix proper amount of water and electric connections63
7- Fix a Clear viewed clock63
8- Hire more washersXX3 4
Countermeasures Action Plan:
No Countermeasure PIC
1VIP card - sorting sign + Numbering Chief Techs 25th of May End of May
2Fix a Clear viewed clock W/S Supervisor 25th of May End of May
a. Define SOP for 2-man operation. W/S Supervisor 25th of May 5th of June
b. Fix more Water and electric connections. W/S Supervisor 25th of May 5th of June
c. Training techs for SOP and practicing.
W/S Supervisor &
Washers
6th of June 15th of June
d. Check for results. W/S Supervisor 16th of June 16th of June
e. Standardizing the SOP. W/S Supervisor 17th of June 20th of June
Step 7: Check Results
Step 3: Target Setting:-
Step 8: Standardization
Facilitator :- Eng. Mohamed Abdul Samad
3
63
Evaluation
5-
No. Counter measurements
Time
Car Wash Process
00:00
07:12
14:24
21:36
28:48
1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 55
Car No.Mins
Car Wash Duration
Average Duration
Day 2 Day 3
Day 1
Vacuum
Wash
Dry
00:00
02:53
05:46
08:38
11:31
14:24
17:17
20:10
23:02
12345678910111213141516
Mins
Vacuum
Wash
Dry
Vacuum
Wash
Dry
00:00
02:53
05:46
08:38
11:31
14:24
17:17
1234567891011
Vacuum
Wash
Dry
40%
30%30%
40%
70%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Wash Dry Vacuum
49%
33%
18%
49%
82%
100%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Wash Dry Vacuum
Current Car Wash Average
Ideal Car Wash Average
EM Requiremen
t
GAP
Long Car Wash
Time
Specify an ordered Waiting Area
(Waiting Lane)
Define SOP
2 - Man Operation
Get extra:- 1.washing machine 2.Vacuum machine
Fix a Clear viewed clock
Fix proper amount of water and electric
connections
Hire more washers
Washer Cant identify car order Washer took too long: 1.Spray water 2.Applying chemicals 3.Vacuum
cars are not sorted
no time frame to follow
no SOP
need to go around car many times
car both sides need processing no extra water and electric connections
only 1 washer only 1:- 1.washing machine 2.Vacuum machine
washer doesn’t know tim
e
no clock to show duration
took too long to start washin
g
Too many Cars
No enough man power
no budget for more washer
s
no proper waiting area (No Waiting Lane) No Sorting Signage
VIP Card - Sorting Sign
GAP
12:11
15:56
14:07
12:44 08:00
08:00
08:00
08:00
05:46
07:12
08:38
10:05
11:31
12:58
14:24
15:50
17:17
EM Idle Average
Poly. (Current Average)
Target
08:00
13:45
00:00
02:53
05:46
08:38
11:31
14:24
Mins
EM Target Duration Current Average
Target
2
1 3
12:11
15:56
14:07
12:44
08:10
08:00
10:10
05:25
04:19
05:46
07:12
08:38
10:05
11:31
12:58
14:24
15:50
17:17
Current Average
Poly. (Old Average)
Poly. (Current Average)
Before:
Average 4 days =
13:44 mins After: Average 4 days = 07:56 mins
1. SOP for car wash process using 2-man operation method. 2. SCM should be informed about the final results so he could announce that the EM target time is achieved. 3. A weekly report about the average car wash duration is announced on the board to keep the results and visually manage it.