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Chaku Chaku

A chaku-chaku line has a series of machines, each equipped with a hanedashi device, or autoejector. This enables the operator working a chaku-chaku line to

  • walk up and immediately insert the part he is holding into a machine
  • press a start button, and then
  • pick up the previously ejected part.

Because the chaku-chaku operator is running several machines, she relies on jidoka (autonomation). If there is a problem on a machine while the operator is away, jidoka stops production, preventing further defects or damage to the machine.

Chaku-chaku is a Japanese Lean term that translates to load-load. This is in reference to process the operator follows-loading machine after machine in a chaku-chaku line with no need to unload.

Because of the rapid nature of the chaku-chaku cell, it will often be comprised of a number of single-function, right-sized machines.

Lean Tools Needed for a Chaku-Chaku Line:

  • Hanedashi (autoejector)
  • Jidoka (autonomation)
  • Andon lights (to signal machine problems)
  • Standard Work (to specify the process)
  • Kanban (to closely manage the inventory-space for excess inventory may be limited)
  • Visual management/5S (the rapid character of a chaku-chaku line means parts and materials must be in the correct location every time)
  • Kaizen (chaku-chaku lines take a lot of work to complete)
  • Right-sized machines (chaku-chaku cells tend to be single function and compact)

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