Leaderboard

Hanedashi: Auto-Eject / Auto Unloading / Automatic Ejection This technique provides automation for machines to remove finished parts from the process. Below is a typical example of manual and automatic unloading of the finished product. Manual Unloading: Automatic Unloading: Manual effort is just put in loading and not in unloading. Hanedashi is crucial for "Chaku Chaku"/"Load-Load" Line. In Chaku-Chaku, operator picks and loads the finished part from Machine A to B, to complete the cycle. If Hanedashi is used, machine can itself unload and load the parts with out operators effort. Thus Hanedashi can effectively eliminate the below wastes in a lean manufacturing setup. Transportation: Wasted time in moving materials unnecessarily Motion: Wasted time and efforts due to unnecessary movements by operators Waiting: Wasted time in waiting for finished product to complete next steps Some of the benefits of Hanedashi: At same time, operations in Multiple machine is possible Operator productivity improvement Improved working condition due to better ergonomics

Hanedashi is a Japanese term referring to automatic ejection of a part from a machine, once the processing is completed. Let me discuss this concept with reference to a compression molding operation. In this example, the processing is done using a molding press and a pre-formed job needs to be loaded into the heated mold in the press. In a traditional set up (without Hanedashi), the following would be the typical set of activities: 1. Carries the preformed job from the previous process 2. Places it near the compression molding press 3. Inserts his hand inside the mold and pulls out the completed job 4. Places it on the table 5. Picks up the preformed job 6. Loads it into the mold 7. Picks the completed job and moves to the next machine If Hanedashi is implemented, then the press will be equipped with an automatic ejection mechanism for the finished job and the machine will also make itself ready to receive the new input. Then, the set of activities with the same scope as we saw earlier would be: 1. Bring the preformed job 2. Place in on the mold 3. Pick the finished job and load it for the next process, as applicable Hanedashi is an important methodology in Lean Management, and the type of wastes that are addressed will be: Motion - Human movement is reduced as seen in the reduction of the manual steps Waiting - The job need not wait inside the machine until an operator attends to it. Similarly, the new job need not wait for the earlier job to be removed. Hence the throughput increases Over processing - Excess time inside the machine may sometimes make the job over processed. Results in wastage of energy as well as prone for defects Defects - Defects can happen as a result of overprocessing as well as due to handling while removing manually Unutilized talent - The operator will be able to handle multiple machines and hence more resources need not be deployed for the same operation, thus resulting in better utilization of talents Apart from the above, Hanedashi also addresses operator safety. For the example discussed, many instances have occurred, where the operator might get injured (some times loss of fingers) if the machine gets activated while moving the job manually. Hot molds could cause burns. It may be interesting to note that if there is a sequence of machines with the application of Hanedashi across, then it is often referred to as a ‘Chaku-Chaku’ (Japanese term) line. (meaning ‘Load-Load’!)