Complete User Guide

Welcome to Yamazo VAS! Learn installation, activation, and creating your first project.

Installation

Windows Installation

1. Download the Yamazo VAS installer (.exe) from your license email
2. Double-click the installer and follow the wizard
3. Choose installation directory (default: C:\Program Files\Yamazo VAS)
4. Click 'Install' and wait for completion
5. Launch Yamazo VAS from Start Menu or desktop shortcut

macOS Installation

1. Download the Yamazo VAS installer (.dmg) from your license email
2. Open the .dmg file and drag Yamazo VAS to Applications folder
3. On first launch, right-click and choose 'Open' to bypass Gatekeeper
4. If prompted, authorize Yamazo VAS in Security & Privacy settings

License Activation

After installation, you need to activate your license:

First Login

After activation, you're ready to begin:

1. The main dashboard opens with a 'No projects yet' message
2. Click 'Create New Project' to start your first analysis
3. Fill in project details (name, line, station, product)
4. Import your first video file

Understanding Yamazo VAS's data model is key to efficient analysis. Learn about projects, tracks, rounds, and work elements.

Projects

A Project represents a single analysis session. Each project contains:

• One or more video recordings
• Multiple rounds (iterations/kaizen)
• Multiple tracks (operators, machines)
• All work elements, categorizations, and analysis results

Example: 'Assembly Line A - Product X Time Study' with baseline recording and 3 kaizen rounds

Multi-Track System

Tracks represent parallel workflows. This is Yamazo VAS's most powerful feature for modeling real production:

• Operator Tracks: One track for each operator working simultaneously
• Machine Tracks: Automated equipment running in parallel
• Concurrent Work: Model human-machine collaboration accurately
• Unlimited Tracks: Add as many as needed for complex processes

Example: 2 operators + 1 welding robot + 1 testing machine = 4 tracks working in parallel

Multi-Round Analysis

Rounds track improvements over time:

• Baseline Round: Initial state before improvements
• Kaizen Rounds: Each improvement iteration
• Side-by-Side Comparison: See exact time reductions
• Copy Work: Reuse unchanged work from previous rounds

Work Elements

Work elements are the fundamental unit of analysis:

• Time-Bounded: Each work element has start and end times
• Categorized: Station, operator, process, work area, verb
• Classified: 4-Category System - Value-Added Work, Required Non-Value-Added Work (Incidental Work Required), Eliminable Non-Value-Added Work (Incidental Work Avoidable), Waste (MUDA)
• Video-Synced: Click to jump to exact video moment

Master video importing, player controls, and efficient work recording techniques.

Importing Videos

Yamazo VAS supports multiple video formats:

• Supported Formats: MP4, AVI, MOV, MKV, WMV
• Resolution: Up to 1080p (4K support coming soon)
• Frame Rates: 24, 25, 30, 60 fps

Single Video Import

1. Click 'Import Video' in project view
2. Select video file from your computer
3. Wait for video processing (generates thumbnails)
4. Video appears in timeline, ready for work recording

Multi-Video Import

For processes recorded with multiple cameras or clips:

1. Click 'Import Multiple Videos' or use 'Create Project from Path' option
2. Select all video files in chronological order
3. Yamazo creates a unified timeline (virtual concatenation - no physical merging required)
4. Navigate seamlessly across all videos as if they were one continuous recording

Player Controls

Efficient video navigation is critical for fast analysis:

• Frame-by-Frame: J (previous), K (next) - borrowed from professional video editors
• Variable Speed: Ctrl+↑/↓ to adjust speed (0.25x to 2.0x)
• Jump Navigation: Arrow keys (5s), Shift+Arrow (1s)
• Timeline Scrubbing: Click or drag in timeline
• Zoom Timeline: Zoom in/out with mouse wheel for precision

Manual Work Recording

The fundamental workflow for creating time study data:

1. Play the video and observe the work process
2. When a work element begins, press S key
3. When it ends, press E key
4. Categorize in the dialog (station, verb, work area, etc.)
5. Classify with 4 categories: Value-Added Work, Required Non-Value-Added Work, Eliminable Non-Value-Added Work, or Waste
6. Repeat until entire process is recorded into work elements

Smart V2 Motion Analysis — 100% Offline AI

AI-powered automatic segmentation running entirely on your computer. No internet required, complete privacy.

Smart V2 Features:

• ROI Selection: Draw a rectangle to focus analysis on specific area
• Scene Type Detection: Automatic context detection (assembly, machining, packaging, etc.)
• Action Recognition: Context-aware action detection based on scene type
• Segment Suggestions: AI suggests start/end times for work elements

How to Use:

1. Open project and click 'Motion Analysis' button
2. Optionally select ROI to focus on specific area
3. Click 'Start Analysis' and wait for processing
4. Review suggested segments in preview
5. Click 'Apply' to create segments or adjust manually

Master these shortcuts to analyze videos 5x faster. Print this page as a reference!

Generate professional reports: SOT, IKF, Yamazumi charts and statistical analysis.

SOT (Standard Operating Table)

SOT breaks down work across multiple dimensions with detailed analysis:

• By Station: Total time per work station and work category distribution (Value-Added, Required, Eliminable, Waste)
• By Operator: Workload per person, efficiency analysis
• By Process: Time per production step, bottleneck detection
• By Work Area: Body regions (left hand, right hand, walk, etc.) ergonomics analysis
• By Verb: Actions (pick, place, squeeze, check, wait, etc.) detailed analysis

IKF (Work Combination Form)

IKF visualizes parallel work with Gantt-style charts:

Yamazumi Charts

Visualize workload balance across stations or operators:

Set up and manage your organization's standard data for consistent categorization.

Stations & Lines

Define your production lines and work stations. These are used to categorize work elements and organize your analysis.

Operators

Manage operator information. Each operator can be assigned to tracks for accurate workload analysis.

Products & Processes

Set up your product catalog and production processes. Link these to projects for detailed reporting.

Verbs & Work Areas

Configure standard work verbs (pick, place, assemble, inspect, etc.) and work areas (left hand, right hand, walking, etc.) for consistent work categorization.

Manage your entire organizational structure: Facilities, departments, lines, and stations.

Hierarchical Structure:

• Facility - Top level, factory or production facility
• Department - Divisions within facility (assembly, welding, quality control, etc.)
• Production Line - Manufacturing lines within department
• Station - Work stations on the line

Features:

• Visual Navigation: Easily navigate through tree structure
• Breadcrumb Navigation: Facility → Department → Line → Station
• Explorer View: See entire hierarchy at once
• Project Linking: Link projects to correct station
• Batch Operations: Create multiple stations/lines
• Import/Export: Share or backup entire hierarchy

Organizational hierarchy is critical for organizing projects and reporting. Each project is linked to a station, enabling aggregated analysis at line/department/facility level.

Identify problems, track improvements, and manage the Kaizen cycle.

Problem Tracking system lets you record issues discovered during video analysis and manage the resolution process:

Features:

• Segment Linking: Link each problem to specific work segment
• Video Integration: Click to see problem moment in video
• Status Tracking: Suggestion → Implementation → Verification → Closed
• Priority Levels: Low, Medium, High, Critical
• Category System: Ergonomics, Quality, Safety, Efficiency, etc.
• Improvement Suggestions: Add solution proposals for each problem
• Multi-Round Integration: Create new round after improvement

Workflow:

1. Detect problem during video analysis
2. Record problem and link to segment
3. Add improvement suggestions
4. Implement suggestion and create new round
5. Verify improvement in new round
6. Close problem and calculate savings

Define durations not included in analysis and calculate net process times.

Skipped Duration is used to define periods in video recording that should not be included in analysis:

Use Cases:

• Breaks: Operator took a break, this time should not be included in net process time
• Stoppages: Machine breakdown, material waiting, etc.
• Setup: Line setup or adjustment times
• Testing: Test runs or trial production
• Interruptions: Interruptions from external factors

Features:

• Multiple Skipped Durations: Define multiple skipped durations in one round
• Reason Specification: Add reason for each skipped duration
• Net Time Calculation: Total time - Skipped time = Net process time
• Visual Display: Skipped durations shown in different color on timeline
• Reporting: Skipped durations shown separately in reports

Compare improvement rounds side-by-side and measure kaizen impact.

Round Comparison lets you compare two rounds in detail and visualize improvement impact:

Comparison Metrics:

• Total Time Difference: Baseline vs. After improvement
• Work Category Change: Value-Added, Required, Eliminable, and Waste work change analysis
• Segment Count: Work step increase/decrease
• Net Process Time: Excluding skipped durations
• Waste Elimination: How much reduction in Eliminable Non-Value-Added Work and Waste times
• Efficiency Improvement: Percentage improvement
• Side-by-Side View: Two round timelines side by side

All metrics presented with visual charts in comparison dialog.

Create and reuse segment templates for recurring work.

Segment templates let you quickly use recurring work steps in similar projects:

Features:

• Automatic Template Creation: Templates automatically created during project copying
• Manual Template Definition: Create your own templates
• Quick Application: Apply template to new round/project
• Mapping: Map template segments to new segments
• Library: Manage all your templates in one place

Usage: Use 'Create from Template' option when creating new round.

Define and track occupational health and safety risks per segment.

OHS Risk Tracking lets you record potential health and safety risks for each work element:

Features:

• Risk Level: Low, Medium, High
• Risk Category: Ergonomics, Chemical, Physical, Biological, Psychosocial
• Segment Integration: Define risk for each segment
• Work Object: Specify risky object (machine, chemical, etc.)
• Notes: Describe risk details
• Reporting: Generate OHS risk report

Usage: Fill in 'OHS Risk' field when creating or editing segment.

Dedicated track type for Single Minute Exchange of Dies analysis. Reduce changeover time systematically.

Creating SMED Track

1. Click 'Add Track' button in project view
2. Select 'SMED' as track type
3. SMED track appears in timeline with timer icon

Setup Types

SMED distinguishes between two types of setup work:

• Internal Setup: Work that can ONLY be done when the machine is stopped. Goal: Convert to external or reduce time.
• External Setup: Work that CAN be done while the machine is running. Goal: Move as much work here as possible.

Operation Types

Each setup entry can be classified by operation type:

• Manual: Operator hand work (adjustments, connecting, etc.)
• Automatic: Machine or tool operation (calibration cycles, etc.)
• Walking: Movement between locations (fetching tools, parts, etc.)

Recording SMED Entries

1. Select the SMED track in timeline
2. Press E key to create entry at current time
3. Select Setup Type (Internal/External)
4. Select Operation Type (Manual/Automatic/Walking)
5. Add description and save

SMED Report

Visual pie chart and detailed table on the SMED page:

• Navigate to /smed page from project menu
• Color coding: Internal (blue shades), External (green shades), Walking (red)
• Pie chart shows time distribution by setup and operation type
• Identify opportunities to convert internal to external setup

Excel Export

Export SMED analysis to Excel for further analysis and reporting. Includes all setup entries with times, types, and descriptions.

25-criteria work evaluation form. Score operator movements across 5 categories for systematic motion analysis.

Temotoka (Is Degerlendirme Formu) is a standardized work evaluation methodology. It assesses operator motions across 25 criteria in 5 categories.

5 Evaluation Categories (25 Criteria)

• Body (4 criteria): Back rotation angle/frequency, bending/squatting angle/count
• Foot (2 criteria): Walking step count, walking deviation
• Hand-Arm (9 criteria): Equipment touch, part pickup distance/frequency, assembly height/distance, orientation angle, hand changes
• Tool (6 criteria): Tool distance/height, assembly distance/height, position changes, hand switching
• Eye (4 criteria): Part search, tool search, verification, control point count

Temotoka Analysis Features

• Visual score cards for each entry
• Category breakdown with subtotals
• Round comparison for improvement tracking
• Color-coded entries in timeline

Comprehensive ergonomic risk assessment. Identify musculoskeletal disorder risks and improve workplace safety.

WERA (Workplace Ergonomic Risk Assessment) provides comprehensive ergonomic risk evaluation to identify and prevent musculoskeletal disorders in the workplace.

Body Region Evaluations

Evaluate key body regions for ergonomic risk:

• Shoulder: Posture and movement assessment
• Wrist: Flexion, extension, deviation
• Back: Bending, twisting, lateral flexion
• Neck: Flexion, extension, rotation
• Leg: Standing, walking, squatting posture

Risk Level Classification

Automatic risk classification with color-coded indicators helps prioritize ergonomic improvements:

• Low Risk (Green): Acceptable posture, continue monitoring
• Medium Risk (Yellow): Further investigation and improvements recommended
• High Risk (Red): Immediate ergonomic intervention required

WERA Analysis Features

• Body region score breakdown
• Risk level visualization with colors
• Detailed factor analysis
• Round-based comparison for improvement tracking

Share your entire organizational structure (facility, department, line, station) and master data.

Facility Export/Import lets you export/import organizational hierarchy and all master data as ZIP file:

Exported Data:

• Facility → Department → Line → Station hierarchy
• Operators, Verbs, Work Areas
• Products, Segment Types
• All metadata and relationships

Import Features:

• Conflict Resolution: Skip/overwrite/merge on conflicts
• Hierarchy Consistency Check: Missing references automatically detected
• Multi-step Import: Step-by-step import
• Preview: Preview data before import

Usage: Use 'Import/Export' buttons on Explorer page.

Share your analysis with stakeholders through professional reports and data exports.

PDF Reports

Generate comprehensive PDF reports including SOT analysis, IKF charts, and Yamazumi diagrams. Perfect for presentations and documentation.

Excel Export

Export detailed work element data to Excel for further analysis, custom calculations, or integration with other tools.

Project Import/Export

Share complete projects with colleagues or backup your work. Project files include all videos, work elements, and configurations.

Industry-tested workflows for maximum efficiency and accuracy.

• Record stable processes: Ensure the process is running at normal pace before recording. Avoid recording during training or ramp-up periods.
• Capture multiple cycles: Record at least 3-5 complete cycles to identify variations and calculate reliable averages.
• Use high frame rates: 30 fps or higher ensures smooth playback and accurate time measurements.
• Master keyboard shortcuts: Keyboard shortcuts can reduce analysis time by 5x compared to mouse-only operation.
• Be consistent with categorization: Use the same verbs and work areas across similar projects for comparable results.
• Review and validate: Always review your work elements after recording. Use the video sync to verify accuracy.
• Document assumptions: Add notes to your project explaining any special circumstances or assumptions made during analysis.
• Start with AI analysis: Begin with hybrid mode automatic segment suggestions, then manually correct. Saves 40-60% time.
• Define skipped durations: Define skipped time for breaks, stoppages, and interruptions. Critical for accurate net process time calculation.
• Use problem tracking: Record every problem you detect and track improvement process. Makes Kaizen cycle systematic.
• Set up organizational hierarchy: Create facility/department/line/station structure before starting projects. Forms foundation for reporting and organization.
• Use multiple rounds: Always create new round after improvement and compare. Show Kaizen impact with concrete data.
• Backup videos: Regularly backup video files. Video relink feature prevents video loss but backup is safest.

Discover the latest features and improvements in Yamazo VAS version 1.3.0.

Move Projects Between Stations

Easily reassign projects between stations. When your production layout changes or projects need to be reorganized, you can seamlessly move projects to different stations without losing any analysis data.

Periodic Work Support

Handle periodic tasks that don't occur every cycle. Mark work elements as periodic to accurately represent tasks like quality checks, tool changes, or maintenance activities that happen at intervals rather than every production cycle.

Custom Station Ordering

Customize station order in charts and reports. Arrange stations in the order that makes sense for your production flow, making Yamazumi charts and reports easier to read and analyze.

Offline License Activation

Activate your license without an internet connection. For secure environments or facilities with limited connectivity, offline activation ensures you can get started without network access.

Flexible License Tiers

Choose the license tier that fits your needs. Different tiers offer various feature sets to match your organization's requirements, from basic time studies to advanced ergonomic assessments.

Solutions to common issues and where to get help.