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Kostal Production System Essay

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The Kostal Production System (KPS) is in addition to employees, material, and equipment - the central component of the production areas within the KOSTAL Group describes, how the processes within the production areas are to be designed, implemented and maintained guides during the production of parts/articles and gives an orientation for daily work standardizes the main instruments within the production network internally and externally

The implementation of KPS is carried out in six phases: Project preparation Orientation of mindset Basic processes Advanced processes Achieving results and improving
The core tasks of the Department are to develop local implementation plans and continually monitor the progress of KPS projects. It also …show more content…

Preventive and corrective maintenance is done based on the criticality of that equipment. The production processes and products are designed in such a way to achieve a fault-free production and increase the quality and reliability of the products.

The employees are trained on the basic methods of preventive quality assurance and in each production area there are additional employees who have in-depth knowledge about early stage error prevention. Kostal uses poka-yoke mechanism, it is a mechanism used in lean manufacturing processes to help the equipment operators avoid mistakes. The aim of this mechanism is to get rid of product defects by preventing, correcting or drawing attention to human errors as they occur.
The advantages of implementing poka-yoke are: Time spent on training workers is very less Most cost-efficient method to avoid and identify errors Unburdening of operators from repetitive operations Increases safety of operators as errors are avoided Reduction in defective parts and increase the quality to the

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