Q 464. What is the concept of Hanedashi in Lean Manufacturing? If implemented what type of wastes can it address? Support your answers with examples.

 

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Hanedashi

Hanedashi means for automatized unload of a work item from one process, or it is called an automatic part ejector device.

 

Concept of Hanedashi

Hanedashi concept is used as the means for automatized unloading of work part/item from one process or operation, providing the correct state for the next part/item to be loaded. A key component of Hanedashi device.

 

Usually, the part/item loading of the machine at the beginning is manual. The ejection of the part from machine after the process is completed is automatic.

 

When it is couple of Hanedashi principle equipped machines are placed in sequence, it is called chaku-chaku line which means “load-load”. Because of the auto discharge of the part/item, the operator can run several machines with little waste.

 

Automatic Unloading ( Example )

 

Without a Hanedashi device, the operator would have to set down the new part/item that he would be carrying to the machine, pull out the completed part and set it down, pick up the new part, load it, and then pick up the completed part again.
With Hanedashi Device, the operator will walk up to an empty machine, and would be able to immediately load the new part, pick up the completed part, and move on.

 

What type of wastes can it address?
Waiting: Example - Machine idle time reduce by using Hanedashi device (Unloading time).
Inventory: Example - Buffer inventory between two machine / Process.
Defects: Example -   In a continuous flow system, the products go through the process individually and defects are found in time so that subsequent products can be corrected earlier in the process.
Other Wastes …..

 

 

 

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:

1. Motion - Human movement is reduced as seen in the reduction of the manual steps
2. 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
3. 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
4. Defects - Defects can happen as a result of overprocessing as well as due to handling while removing manually
5. 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’!)

Hanedashi is a Japanese word that means automatic ejection. It is a method where finished components are automatically discharged or ejected. Traditionally, the operator would:

• Pick up the new part or component

• Then walk to the machine  

• Placed the new part operator carrying on the ground 

• Pull out the completed part and place it on the table 

• Pick up the new part and load it into the machine 

• Repick up the completed part

• Move it to the next step in the process

 

Hanedashi would involve the operator picking up a new part, walking up to an empty machine, loading the new part immediately because the finished part was automatically ejected, picking up the ejected part, and moving to the next step or machine. The machine automatically returns to its original position, ready for the next part to be loaded.

 

By placing several hanedashi-designed machines in series, a chaku chaku line (one piece flow or lean work cells) is formed, meaning "load-load." The automatic ejection feature allows the operator to operate multiple machines with less waste, less effort, and in a safer way. The following graph compares a standard line with a hanedashi-based chaku chaku line.

 

 

Hanedashi is a Japanese word that is translated to automatic ejection. A Hanedashi device is designed to automatically eject a part once the process on it is completed.

In order to implement Hanedashi, the process should be reliable and stable. The operator would not need to inspect the finished product.

The diagram below explains how a Hanedashi device reduces waste.

In the above diagram, we can see that without Hanedashi, the operator is required to carry out 4 tasks, however, with Hanedashi this is reduced to 2 tasks.

Chaku-Chaku Line. A chaku-chaku (load-load) line is Handdashi devices placed in a sequence. This enables a single operator to handle multiple machines thereby reducing waste, effort,

Waste Reduction

The wastes that are reduced are “Motion” and “Skills/ Under Utilization of Manpower”.

Motion is reduced as

-       the operator only loads the part on the machine. The machine automatically ejects the part.

-       the operator does not have to walk to the back of the machine to remove the part, this reduces motion and movement.

Skills/ Under Utilization of Manpower is reduced as the same operator will have more time to do other tasks.

References

https://www.isixsigma.com/dictionary/hanedashi/

https://www.velaction.com/hanedashi/

https://training.velaction.com/courses/structuring-standard-work for diagram above

 

Hanedashi

“Hanedashi”, is a Japanese word meaning, “automatic ejection”. The term, “Hanedashi”, is used in lean manufacturing to denote, “a device or arrangement for automatic unloading of a work piece from machinery, at completion of one operation”. A hanedashi device is an automatic part ejector.

The use of Hanedashi concept ensures waste removal in lean manufacturing, as an operator is not required to exert-- to unload the finished part & to check quality of finished tool. As such, the operator would load a fresh piece to machine assembly, pick the finished tool & move to next machine in production line, repeating production steps.

Facilitation of Hanedashi machines in succession order, within periphery of little distance, allows operator to load different pieces to manufacturing set-up, in rapid succession.

The use of Hanedashi machines in quick-succession, in an alphabet U-shaped or inverted U-shaped arrangement, lead to creation of Single piece flow production lines referred to as “chaku-chaku” (Japanese word meaning “load-load”) line. Chaku-Chaku lines eliminate the need of expensive precision guided machines, capable of loading parts to production assembly. The human labour without getting distracted, is better utilized in Chaku-Chaku lines, as targeted activity, is located in close sphere.

Chaku-Chaku lines permit application of hard Yoka-poke system, in lean manufacturing. Yoka-poke means “the avoidance of unfortunate errors”, and can be implemented as

a.       hard Poka-Yoke actions check and balances, that directly avoid mistakes and,

b.       soft Poka-Yoke actions check and balances, that eliminate potential error.

Utilizing Chaku-Chaku lines, an operator is only required to attend to fitting work piece correctly to a machine after finished tool is automatically removed by hanedashi device.  As such, operator may attend a next machine with finished load from one machine, and return to previous machine after automatic ejaculation of the finished part. Due to nature of complexity and speed of production process, hard Yoka poke can be implemented; where, operator is accountable for the correct processing of a part of the production assembly.

To avert faulty production, or lower grade quality in finished tools, provisions to halt manufacturing automatically, is added in production assembly, referred to as, “Jidoka” (Japanese word meaning-Automation with Human Intelligence).  Jidoka, sensors-based monitoring system, was introduced for the first time by Toyota, in their production systems, where-in the production in entire assembly was totally stopped, at the first occurrence of error in production. The clear benefits of this Automation included elimination of root cause defects, with augmented benefits such as, defect free production &, win-over the episodes of work in progress.

Karakuri/LCA (Low-Cost Automation) is a new innovation to Hanedashi devices, where, there is no dependence upon compressed air, drives, electricity, sensors to implement automation in transformation cycle. Example Profile Tube System D30 is a work bench-- material provisioning and picking system, used in lean manufacturing, that depends upon law of gravity and mechanics to being automation jidoka to production assembly.

 

 

  

 

 

Hanedashi is a Japanese word meaning automatic ejection. It is also defined as a device for automatized unload of a work item from one process or operation, given that the accurate state for the next work item to be loaded. The Hanedashi standard of the automatized unloading and orientation for the next process is frequently used in automated production systems that operate according to the Chaku-Chaku standard.

 

Once several Hanedashi-designed machines are placed in sequence, they form Chaku-Chaku line, means “load-load.” Because of the automatic discharge functionality, the operator can run multiple machines with less waste, less effort and in a safer manner.

 

Implementing the Hanedashi in manufacturing line, it would eliminate the Wait time (Delay), Motion and Defects wastes exists in the manufacturing unit.

 

Difference between traditional Set up and Hanedashi Set up:

 

Traditional Set Up:

 

 

Hanedashi Set Up:

 

 

 

The only manual operation involved in Hanedashi principle is to insert the work piece. The processing and afterwards the discharge is fully automated, work piece than can be transported to the next machine or handed over to the next operator.

  

Difference between traditional Set up and Hanedashi Set up:

 

 Example of Hanedashi:

 

One of the largest auto battery manufacturers in the world traditionally used a single operator to load, run and unload their machines which was costly, time-consuming and frequently unsafe process. After visiting another plant in Japan, the plant manager decided to copy the Japanese branch work ways and install a Chaku-Chaku line using Hanedashi automatic ejectors.

 

Productivity increased intensely because the operator could now simultaneously run four machines. Safety improved because the operator no longer had to reach to the machine to pull out a completed part or movement around to load it. 

 

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 

Mohamed has highlighted the maximum number of wastes that might get addressed by implementing Hanedashi and hence his answer is the best.

 

Also review the answer provided by Mr Venugopal R, Benchmark Six Sigma's in-house expert.

 

PS - I believe Hanedashi can help us address all 8 wastes except for Over Production