Development of Material Handling Equipment in a Paint Factory with Karakuri Kaizen
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Abstract
From the current condition of a case study of paint factory, there are the seven materials handling points in the paint process. Generally, the material handling activity is a Non-value-added (NVA) activity but necessary. The objective of this paper is to design the vertical material handling equipment by means of the Karakuri Kaizen principle and to propose points of caution in such design. The karakuri-kaizen principle is the use of basic mechanisms to create a simple and energy-saving semi-automatic movement mechanism. In this research, the most important problem is picked up and solved by designing the material handling equipment that has to take the material from the 2nd floor down to the 1st floor and then go back up to wait for the material on the 2nd floor again. The two models are designed. The advantages, weaknesses, and costs of the two models were compared to select only one suitable model. After that, we create and test the materials handling equipment. Finally, the distance is reduced by 77.60% while the time is reduced by 89.47%.
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