Chaku-Chaku: charging-charging for smooth processes

Chaku-Chaku (着々) is a Lean that focuses on creating a seamless workflow, which literally means "load-loading" in Japanese. The principle is applied in a production cell where machines automatically eject completed parts. As a result, the operator does not have to unload the product, but can concentrate fully on directly loading the next part into the next machine.

How does it work?

In a Chaku-Chaku cell, the arrangement of machines is optimized, usually in a U-shape, to minimize walking distance for the operator. The process is as follows:

1. The operator loads a part into the first machine and starts the process.
2. The machine completes its cycle and automatically ejects the part.
3. The operator picks up the part just ejected, walks to the next machine and loads it directly.
4. Meanwhile, the second machine has completed its cycle and ejected the part, ready to be moved to the next step by the operator.

By adopting this mode of operation, the operator becomes a machine-mover rather than a machine-tender. Time and operations that would otherwise be wasted waiting for a machine or handling finished products are eliminated. The result is continuous, smooth product flow with less inventory between machines and higher overall efficiency.

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