Digital KATA Board - APS Improvement Project
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Target Date: Mar 31, 2025
Problem Statement / Current Condition
Current Issue:
VW scrap rate on PFA station is 1.6%, which is above target of < 2%

Root Cause Analysis:
• Material feed inconsistency
• Machine setup variation
• Operator training gap

Impact:
• 15% increase in material waste
• Production efficiency below target
• Quality metrics not meeting standards
1.6%
Current Scrap Rate
85%
Line Efficiency
12
Defects/Day
Before Status
1.6%
Scrap Rate
After Status
0.8%
Target Scrap Rate
Target Condition
Vision:
Achieve consistent VW production with scrap rate < 0.8% by implementing standardized processes and improving operator competency.

Success Criteria:
• Scrap rate reduced from 1.6% to < 0.8%
• Line efficiency increased to 95%
• Zero safety incidents
• 100% operator certification
✓
Complete operator training program
✓
Implement standardized setup procedures
○
Install automated quality checks
○
Achieve target scrap rate < 0.8%
Target Date
March 31, 2025
Process Map / Layout
Current Process Flow:
Material Feed
→
Setup
→
Production
→
Quality Check
→
Output
Identified Issues:
⚠️ Inconsistent material feed causing variation
⚠️ Manual setup process leads to errors
⚠️ Quality checks happen too late in process
⚠️ Operator skill levels vary significantly
Process Observations
Daily Observations (Week 47):
Key metrics tracked hourly, patterns identified in scrap occurrences, correlation between operator shifts and quality outcomes.
📊 Scrap Rate Trend Chart
Interactive chart showing daily scrap rates vs target
Date Shift Scrap Rate Efficiency Notes
Nov 18 A 2.1% 87% Material feed issue
Nov 19 B 1.4% 91% Normal operations
Nov 20 A 0.9% 94% Good day!
Nov 21 C 1.8% 85% Training needed
PDCA Cycles
P
Plan
Week 1-2:
• Analyze current scrap data
• Identify root causes
• Design training program
• Plan process improvements

Target: Complete analysis and training design
D
Do
Week 3-6:
• Implement operator training
• Deploy standardized procedures
• Install quality checkpoints
• Monitor daily metrics

Status: 75% complete
C
Check
Week 7-8:
• Compare before/after results
• Measure scrap rate improvement
• Assess training effectiveness
• Document lessons learned

Next: Weekly review meetings
A
Act
Week 9-10:
• Standardize successful practices
• Scale improvements to other lines
• Update work instructions
• Plan next improvement cycle

Goal: Sustain improvements