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 the 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 inventory because the space for excess materials may be limited when machines are placed close to each other)
• 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)