単発プレス作業時の声掛けルール 目的作業中断の原因では作業者に対する声

単発プレス作業時の声掛けルール
目的
作業中断の原因では作業者に対する声掛けにて未加工が発生する可能性があるため
ルールを明確化する
声掛け側
止む終えずに声を掛ける時は作業工程が終わるまで待って声を掛ける
（作業工程終了：加工済み品を完成箱に入れた時）
作業者確認項目
① 声を掛けられても自工程が完結するまで作業を止めないこと。
（作業を完了させてから対応すること）
② 金型内にセットした製品が無いこと
③ 作業台・金型にチョイ置きが無いこと
※ルールを守らないと・・・
金型内未加工品残り・・・勘違いにより工程飛び品流出に繋がる
恐れがある

2
単発プレス作業の中断・再開ルール
目的
作業中断・作業開始する時に未加工が発生する可能性があるためルールを明確化する
中断ルール
① 異常時は作業を即時停止し管理者に連絡する。止める・呼ぶ・待つの実施
異常とは
設備故障・製品異常・いつもと違う事等
② 声掛けによる場合は声掛けルールに従う
③ 正常に加工が終了して作業を止める場合、加工を作業工程が終了して完成箱に
入れてから金型内に製品残り及び金型周りにチョイ置き無きことを確認し、設備を
離れる事

再開のルール
① 管理監督者に確認し再会すること
確認事項：金型内に製品残り及び金型周りにチョイ置き無いことを確認する
② 声掛けルールに従うこと
③ 金型内に製品残り及び金型周りにチョイ置き無いことを確認して再開する
※ルールを守らないと・・・
金型未加工品残り・・・勘違いによる工程飛び品流出等に繋がる恐れがある




３
プレス作業標準書
段取り時
１． プレス加工する前にブランク入れ・シュートに前製品・異物・異品が
残っていないか確認する
２． 加工前・加工後の製品が明確になっているかを確認する
３． カウンターのスイッチが入になっているか確認する
作業中
１． 製品の落下物を発見した際は必ず赤箱に投入すること
※拾い込みの禁止
２．金型にブランクをセットした状態で席を離れないこと。
セットしたものを加工してから、次の動作に移ること
作業に戻った際に金型の中に製品が残っていた場合
管理者が報告する事。（止める・呼ぶ・待つの実施）
別紙：中断ルール・声掛けルール参照
３．完成品・半完成品の表示を確実にする。
作業終了時
１． 完成品に品番・数量を記入する
２． 類似品は近くに置かないようにする

４
チョイ置き・仮置き品ルール
（１）チョイ置き：工具・サンプル・台車・パレット・手袋等と置くこと
（２）仮置き：製品や材料・空箱等を置くこと
チョイ置き・仮置きの問題点
（１） チョイ置き：使いたい時探す手間が増える
危険な作業状態になり易い
（２） 仮置き：先入・先出等が難しくなり品質・コスト・納期・
安全への影響が出易い
チョイ置き・仮置きの許容状態
（１） チョイ置き：作業状態を明示する「段替え中」・「使用中等」等
明示する
（２） 仮置き：下記の「仮置き品の扱い」に従って「一時仮置き品札」
を掲示して一時仮置きする
仮置き品の扱い
（１） 保管期間は原則１週間以内「一時仮置き品札」を掲示する
（保管期間の書き直しは不可。新規に作成して掲示する）
（２） 通路・トラ線枠内・黄線枠外への一時仮置きは禁止とする
（３） 課長承認を得て掲示・一時仮置きする



５
良い製品品質を作るための実施ポイント
実施テーマ 作業中の心構え 目的 注意散漫作業による工程飛び。誤組付け防止
＝製品品質にどんな影響が発生するか＝
① 作業に集中出来ず、工程飛び・誤組付けと起こす
② 自分だけではなく他の人が工程飛び・誤組付けを起こす
③ 不良品に気づかず流出する
＝客先として＝
① 不良車両を一時保管場所の確保が必要
② 車両より不良品の取り外し及び取付けのムダな費用が生ずる。
③ 販売店への発送遅れ
④ お客様の信用を失う
※全て会社のお金です。
「実施のポイント（カン・コツ）
１． 作業時間内はおしゃべりをしない
必要な話の場合はワンサイクル終了してから応答する。
分からない時や困った時はどんな小さなことでも作業者同士で話しをせずアンドンで管理・
監督者を呼ぶこと
話しかけられた側は受け答えせずにワンサイクル停止後アンドンで管理・監督者を呼ぶこと
２． 作業時間内はよそ見をしない
通路を歩いている人、特に社外者に対しては見てしまう場合があり得る
３． 作業ミスや作業をもたついてしまいリズムが崩れてしまっても、いそがず・あわてず
標準作業通りの作業、確認すること。
４． ライン外者（準直者）は作業中の作業者に声を掛けないこと
必要な話の場合はワンサイクル終了してから話しかける
５． 身だしなみ
帽子を正しくかぶる（製品に髪の毛が咬み込み不良になる）
服装・・・袖のボタン等（機械に巻き込まれ怪我をする）
「実施結果の確認のポイント」
１． 上記を守らない行為が見受けられたらアンドンで管理・監督者を呼ぶ
２． 管理・監督者は作業者の作業状況を観察することを怠らない

Results (English) 1:

Single press work: voice seat rules The purposeBecause of potential work interruption causes an raw in them toRule clarificationVoice hang sideHailing the wait operation down calls to resign at(When you had finished work process end: machined products)Workers check items(1) do not stop working until the complete self-operational procedure also being hailed.(To complete the work from the corresponding)(2) no product set in the mold that(3) that there no Choi put workbenches, dies* Do not obey the rules...Dies in raw goods remaining more misunderstanding... flying process leads to products spillThere is fear2Single press break and resume rulesThe purposeRules to clarify that raw can occur during work interruptions and started working forBreak rules(1) emergency stop work immediately and, to contact the administrator. Stop, call, wait for the implementationAnd the unusualEquipment failure, abnormal products and unusual things, etc.(2) according to them if you follow the voice hung rules(3) when processing completed successfully, stop the work, machining process finished to perfectionFrom putting in the mold in the remaining product and mold around Choi put check, and should not be facilitiesFor me to leaveResume rules(1) review and management supervisors, to reunite.Questions to ask: in the mold in the remaining product and mold around Choi put to verify that no(B) to follow the voice hung rules(3) in the mold in the remaining product and mold around Choi put resume, make sure that no* Do not obey the rules...Mold raw products... by mistake, remaining flying operations may lead to disclosure and other products.3Press work standardSetup:1. Blanks into stamping the front and shoot them before and foreign bodies and different products areTo identify any remaining2. Processing and check processing after the product is in the clear3. See counter switch is on?While you work1. Discovering the product falling always bring in the red box* Includes pick up bans2. That unattended in the State set the blank mould. Move to the following set was processed from If the remained products during mold when you return to work It administrators to report. (Stop and call-waiting for implementation) Appendix: suspend rules and voice hung rules reference3. View of the finished products and semi-finished products to ensure.When you are finished1. Completed written product number and quantity2. Do not place close to similar products4Choy stand, tentatively set products rules(1) Choi put: put and gloves, hardware, sample, Dolly, pallet, etc.(2) provisional position: putting the products or materials, empty boxes, etc.Some problems of temporary place Choi put(1) Choi put: increase the hassle when you want to search. More susceptible to dangerous work conditions(2) provisional position: difficult to preconceived notions, which produced such quality, cost, delivery time,Impact of safety comes out easilyChoi put temporary place of tolerance State(1) Choi put: to specify the task State column refill in and use secondary, etc. You expressly(2) provisional position: according to the treatment of the formal place products below ' temporary provisional place product tags 'Temporary placement place the postTreatment of temporary mounting type(1) storage period principle within one week "temporary provisional place product tags ' to post(Rewrite of the retention period is not allowed. Create a new post,)(2) temporary provisional position to passage Tiger line frame, yellow lines outside to block and(3) getting Manager approval, posted and temporary provisional place5Implementation points for making a good product qualityFly by theme work during preparedness purpose note diffuse work processes. Prevent incorrect AssemblyOr = cause any impact on product quality =(1) could not concentrate on work, causing incorrect assembling and flying operations(2) rather than their own, others cause flying process and assembling errors(C) defective products without realizing, to spill= As a tourists destination =.(A) defective vehicle temporary secure storage needs(B) caused by unnecessary costs of defective vehicle removal & installation.(3) to the dealer shipping delays(D) lose your credit* All company money is."Implementing point (Kang tricks)1. Not chatter during the working hoursFrom one cycle to quit if the story required to respond.In times of trouble, when you don't know what little things without talk among workers and management in Andong,Calling a supervisorWithout the comeback is spoken in one cycle after stopping in Andong call supervisors and management2. Not looking away during the working hoursAnd it may end up looking for people who are walking down the aisle, especially outside of3. Isogazu was halting work mistakes and work and gotten out of rhythm, and calmlyStandard work as work, sure.4. La inn外 by (quasi straight person) is does not bother to work in voiceSpeak to the end if the story required one cycle5. GroomingProperly wear a hat (including MCV hair product becomes defective)Attire... sleeve buttons etc (caught in the machine, injury)Disbursement check points1. If you are found above not defend acts in Andong call supervisors and2. Do not neglect to observe the working situation of workers supervisors and the

Results (English) 2:

One-shot press work during voice credit rules
purpose
for raw is likely to occur in voice credit for workers in the cause of the interruption of the work
to clarify the rules
and voice credit side
is working process when you put a voice to not finished cease Wait until the end multiplied by the voice
(working process end: when put into a complete box the processed goods)
worker confirmation item
that ① beyond the hung also own process does not stop the work until completion.
(It corresponds from to complete the work)
that there is no product that was set in ② mold
③ The work table that there is no place Choi to mold
※ do not abide by the rules and ...
die in the raw goods remaining ... leading to the process jump goods outflow by misunderstanding
fear is 2 to suspension and restart rule of one-off press work purpose to clarify the rules since there is a possibility that raw occurs when to start work interruption and work interruption rules ① abnormal When I contact immediately stopped administrator work. to stop, call-waiting of implementation is an abnormal thing, etc., different from the equipment failure and products abnormal, always the case due to the ② voice credit to follow the voice credit rules if you stop ③ work was completed successfully processed, the working process is complete the processing and the complete box to make sure that the defunct Place Choi from putting into the mold around product remaining and mold, the equipment that leave resumption of rules ① managers and supervisors to Check and reunion to be sure matters: the mold product remaining and it is confirmed that there is no place Choi around mold ② thing to follow the voice credit rules resume to make sure that in the ③ mold no place Choi around product remaining and die if you do not abide by the rules ※ · ... there is a risk that lead to process jump goods outflow due mold raw goods remaining ... misunderstanding 3 press work standard manual setup during 1. The previous products and foreign matter, different goods to blank holder shoot before you press working to ensure that no remaining 2. It is checked whether the product after processing before and processing has become clear 3. Make sure the counter of the switch is turned ON work in one. When you have found the product of falling objects can be turned always to red box ※ pick-inclusive ban 2. Do not leave the seat in a state of setting the blank mold. After processing those set, it proceeds to the next operation when the remained product into a mold when it is returned to the work that the administrator reports. and (stop-call-wait for implementation) Attachment: interruption rule voice credit rules reference 3. To ensure the display of the finished goods and semi-finished products. Work at the end of 1. To fill in the part number and quantity to finished product 2. Similar products is to not place near 4 Choi Place, temporarily placed goods rules Place (1) Choi: placing the tool sample truck palette gloves, etc. (2) temporary placement: products and materials and empty boxes, etc. that put Choi Place, temporary placement of problems Place (1) Choi: Find effort increases when you want to use easy to become a dangerous work state (2) temporary placement: the first-in, first-in first-out, etc. is difficult becomes quality, cost and delivery time - out effect on the safety easy Choi Place, temporary placement of permissible state (1) Choi Place: demonstrate a working state "during the stage sort", "use moderate", etc. demonstrate (2) temporary placement: the following "provisional Place goods handling "according to the" temporary temporary placement goods bill " to it to temporarily temporarily placed posting of temporary storage goods treatment (1) storage period principle within one week to post a "temporary temporary storage goods bill" of (storage period rewrite is not allowed. to post Create new) (2) Pauses temporarily placed to the passage-tiger-ray frame within-yellow line outside the framework shall be prohibited to post-one o'clock temporarily placed to give a (3) manager approval 5 good enforcement point for making the product quality flew step by mental attitude purpose distraction work of implementation theme in work. Mis-assembled prevention = product or = What effect occurs in quality can not concentrate on ① work, causing the process jump-mis-assembling other people not only ② yourself cause jump-mis-assembly process ③ defective outflow to not notice the = as customer = ① need to secure a bad vehicle a temporary storage location removal and installation of the waste of defective than ② vehicle cost occurs. ③ shipping delay to the dealer lose ④ your credit ※ It is all the company money. "Point (Kang tips) of implementation within 1. working time not talking in the case of necessary story to respond to from the end of one cycle. when when Ya in trouble you do not know the story by workers each other also every little thing management and in Andon and without it it will be referred to the supervisor side that has been spoken it is referred to as the managers and supervisors in one cycle after stopping Andon without comeback within 2. working time not to look away people who are walking down the aisle, especially outside person for the case is there get to become seen even got collapsed rhythm 3. would tangled working mistakes and work, and hurry not, panic not work a standard work street, make sure to that. 4. out-of-line person (quasi-direct) who can not call out to workers in work talk to from the end of one cycle in the case of necessary story 5. grooming made ​​to wear a hat correctly (narrowing hair with the product bite bad ) Dress ... sleeve buttons and the like (caught in the machinery of injury) "check point of the implementation result" 1. Call the managers and supervisors in Andon Once act that does not abide by the above seen 2. Managers and supervisors to neglect that to observe the work situation of the worker

Results (English) 3:

Discrete time of press working rules aimed at work at the voice of the cause for the operator to the voice in the unprocessed when there is a potential for clarification of rules to stop at the side end of the voice in the voice on the working process to wait for voice on completion of work process: process work until its processed products to get a complete box to check items, including voice
① operator to stop. The product can not be set at the inside of the mold ）
② corresponding to finish the work atWhether the working table and the mold, and not just on the estimation of no choice rules in rough mold at rest, by mistake, there is a possibility that the time of interruption / resumption at the aim of rule 2 may be connected to a single press working process and outflow to fly work work starts not working for clarification of rules at the
① abnormal interruption rule manager to work for an immediate halt to contact. Such things at different embodiment at the stop and wait for the call to equipment failure and abnormal when productsWhen the process is completed
③ according to the normal rules to stop working when processing the voice by the voice, the machining process is completed without placing too make sure product and mold in the mold around the rest into the box at the completion of the items to be checked again confirmed. It is well to leave the resumption of
① rule at the facility management to the supervisor: according to the voice
② rules in place to die and mold product Choi around no restEstimation of rules to check whether the mold in the mold and the rest put Choy products around that cannot be protected with the rest of the mold is not processed in time. It is the third book press work standard at the setup steps can be exported by a fly press to shoot before putting the blank before the foreign products, and products that make sure no 2. 3. To make clear before and after processing products are at the counter of a switch that checkWhile working at the first discovery of the product when it falls into the estimation is always up in the red box ban, such that the die seat is placed in the blank. From the process to set to work at it, and move on to the next operation to report cases of management products left in the die when I returned. To stop the call waiting for execution, including: break the rule, the voice Annex 3 rules refer to ensure finished products and semi-finished products. At the end of the work.1.2 to fill in the number and volume of the finished product to the similar products are not well placed near the place and temporarily placed at the four rules (1) product Choi Choi: put a sample truck tool palette and gloves, etc. (2) of the temporary resting place: materials and box such products and put at the place of the temporary Choi Choi (1): 2. When you want to use to search for the more dangerous working condition to be temporarily placed at the left): easy to difficult first-in, quality, cost, delivery, etc. the safety effect.The temporary resting place too permissive condition (1): the choice to change in working state "stage" and "to" in use, etc. (2): "a temporary resting place" in the following article deals to the temporary placing post according to the temporary resting time "product notes (1993). Put (1) treatment of temporary storage of the storage period of the rewrite period within one week of the temporary resting principle" temporary post card "products. A new ）
（ 2 post) to create a path within the yellow line tiger line outside the temporary place and temporarily ban.(3) approved by the manager, it is time to put a temporary post 5 for making good quality products at work attitude for distraction of points in implementation process theme.
① work can focus on what effects in preventing erroneous assembling quality products,
＝ = need a secure place to temporarily store the defective vehicles
①
＝ customers to other people to fly and erroneous assembling process without noticing
③ in defective products; not only
② myself and fly and erroneous assembling processWhether the vehicle is generated by removing the mounting cost of waste and defective. To
③ shop shipping delays
④ lose your credit estimation of all the company money. From the point of
「 responsive to one cycle is completed, and if necessary, including the inside story of how great a task (no time to talk. I don't know, at the time when in trouble, however small it may work in Dong to tell others to call the manager and director.2 in that after one cycle in response to stop the andon side call management supervisor in time without looking at passage 3, a person walking there can be seen as particularly with respect to the outside to have lost it one to miss work, work and work rhythm of work and live in it. 4 line outside the (quasi linear operators who work in that it is not.In the case of the story is from 5 to one cycle is completed, the need to wear a hat (at the right hair grooming products, including being caught in bad dress, sleeves, etc., do not forget to button 2 person management and supervision in the management and supervision to the andon calls you there were not the result of an example ）
「 injury involved in the machine 1 point (1993) above the act of workers working conditions.