Establishment of KODEN production method
Space 1/2 by 5S
STEP of production innovation

Establishment of KODEN production method

Basic spirit of production innovation activities 10 articles

1.Discard the stereotype of how to make it
2.Consider how to do better than the explanation of why you can not.
3.Do not make excuses. First deny the current situation.
4.I will do good things at once. I stop making bad things right away.
5.Do not ask for perfection. Even 50 points are good, so you can proceed anyway.
6.Please fix the moment right away!
7.If you do not mind, you do not have wisdom.
8.Pursue the root cause – why after 5 times how to improve!10ヶ条イメージ
9.Ten wisdom more than one inspiration!
10.Improvement is infinite.

The word is “Have fun working and make money with 4S strategy!”

4S strategy

1.Let’s eliminate the waste of reworking.
2.Let’s eliminate waste of scraps and improve yield.
3.Lose waste of expenses.
4.Let’s stop wasteful capital investment.


1.Do not make too much, let’s not waste too much.
2.Let’s not waste inventory and work in progress.
3.Lost work unbalance, waste.
4.Lose waste of “waiting for hand” due to machine failure.

4S作戦イメージJapan’s top factory 4S作戦イメージ

1.Lose waste of layout.
2.Let’s get rid of unfinished waste.
3.Let’s avoid waste space of unnecessary items and idle facilities.


1.Let’s realize just-in-time strong production.
2.Let’s not wasteful waiting.
3.Let’s not waste the operation.
4.Lose waste of transportation.
5.Lose waste of processing method.
6.Let’s not waste the reserve.

Three principles of production innovation activities

1.Is the employee functioning?
2.Are employees participating in management?
3.Is information sharing being done?


In KODENSHA, a single piece of equipment is the main, but it will escape from the summary making in all process of equipment assembly, part assembly, metal processing, sheet metal and painting.
We are aiming to establish “KODEN Production Method”, a unique production method with high efficiency, pursuing one piece making, one piece flowing.

A thorough 5S
Especially organize, make visible by organizing, aim for space 1/2

Space 1/2 is not simply to make space, but to make waste such as making too much, buying too much, making it quickly!


What did you change today from yesterday?
KODENSHA Behavioral guidelines

Example Expansion of work space by 5S

Sheet metal factory with work space secured by 5S

Example Visualization of work status

Make the dolly visible by the work schedule of the day and the next day

Example Space 1/2 by vertical installation

Reduce space by changing from horizontal to vertical

Example Turret punch mold 5S

Reduction of the time and effort of searching with special storage racks and visualization of mold during use

Example Processing machine chip 5S

Reduction of time spent searching and visualization of chip during use

Example NC lathe claw 5S

Reduction of time spent searching and visualization of claw during use

Example Wiring check jig 5S

Reduce the effort of searching
It is possible to check in-use even from a distant position by diagonal placement

Example Organize measurement instruments and post instructions for use

You can check how to use the equipment that is used for the first time or less frequently by posting, and prevent damage to the equipment due to incorrect use

Example Quality standard sharing

Sharing quality standard recognition by posting examples of good and defective products

Example Securing the passage


Secure passage to prevent accidental accident due to lack of space during busy season

Example Platform division


Worktable size can be changed according to work load
Reduce unnecessary space and improve efficiency

Past 5S examples


STEP of production innovation

Starting STEP – 0, we are implementing 2S thoroughly.

STEP-0 Organize and Organize (2S)
Organize : Separate what you do not need and what you are.
Tidy : Anyone can take out something immediately.

STEP-1 Create a rough flow
· 1 piece making, 1 piece sinking
· Improved from large movements to small movements
· Store creation, gimmicks, shelf making
· Layout change (margin reduction)
· Logistics design

STEP-2 Create a strong flow
· Improvement of setup change
· Multipurpose engineering · Inlining
· Review of internal and external categories
· Review of operated flights (route flights)

STEP-3 Create an accurate flow
· Improvement of packaging (Smaller: reduced to box)
· Thorough leveling
· Improve accuracy of standard work (to rhythmical and smooth movement)
· Maintenance mechanism of abnormality manifestation

STEP-4 Creating a managed flow
· Manualization of KANBAN operation (also expanded to other mechanisms)
· Creating mechanisms for preventive management in QCD
· Enhanced facility preventive maintenance
· Education training manualization
· Establishment of 5S