CHAKU CHAKU

The term Chaku-Chaku comes from the Japanese and can be translated with "load load”. Also in general it has become a term for variant of a flow or series production, and the work in it, naturalized, at of all the workplaces involved in the production of a product following each other so that the shortest possible distances between them are possible. Since there must also be space for transport, this is usually a u-shaped or omega-shaped formation.

The basis is multi-machine work: one operator works on several process steps. It is usually his task to load and unload the material. The stations work independently without the intervention of the operator, often simple tasks are taken over by the operators in order to save on machine purchases. In practice, the operators only take over the transport from station to station, sometimes there are “mini” buffers provided at the stations, in which a machined work piece can wait for a short time.

Through the Chaku Chaku production system, also known as flow production, can be different depending on the complexity of the parts to be produced also refrain from purchasing machinery or even dismantling machines. These machine systems are then replaced by mostly simple manual workstations.

In a Chaku Chaku line the operator primarily performs the loading and starting of the stations through. The material is supplied from outside, safety measures to the employees and the ejection of machined parts are automated. The capacity of the line is mostly determined by work distributions of one to three operators flexibly. The advantage of this system is that:

1. thus the usually high acquisition costs for complex interlinking machines

2. and the training time of the workers employed is usually shorter, since the

3. activities are often of a simple nature, and therefore don’t require extensive instructions and

4. there is no training on complex machines.

Also, with the Chaku Chaku principle, the cycle time can be controlled individually, for example, if the pre- and downstream machines run at different speeds, this will be controlled by the operators.

The structure of a Chaku Chaku Line is based on the simplest production principle in which manual labour is the most important factor.

The operator has to fulfill transport, quality control and process monitoring for this. In the manufacturing process, the principle applies that the machine is maintained and not man. Expensive technologies require a high occupancy of machines, are less flexible for fluctuations.

In the simple Chaku Chaku Line it is easy to achieve the required number of units through the design of flexible deployment of operators.

Autounloading

In the lean world “auto unloading” means that every machine is automatically unloading the processed part or component, so that the operator’s task is reduced to only loading the machine. This also refers to the chaku chaku principle. The correct lean term of autounloading is the Hanedashi Principle which is explained here.