Yamazo Studio product tour films
Two short tours with real Yamazo Studio screens. The data on screen is demo data; each film’s page lists the key moments and the full transcript of its captions.
Watch the film · 30 sShort tour: Yamazumi, line balancing and the report
Real Yamazo Studio screens, recorded with demo data: the most loaded station in the Yamazumi chart and how the time splits by work type, line efficiency and the number of stations needed in line balancing, and finally the reliability report of the measurement.
Watch the film · 60 sAdvanced tour: measure, balance, approve
Beyond the Yamazumi, line balancing and report of the short tour: a new allowance type in Master Data goes to a second person for approval in Airlock, the approval is signed and recorded, and Studio uses only the approved list. The data on screen is demo data.
Yamazo series: Find your second factory
One line, one story, six films: the improvement story of demo line A2, from measuring it on video to the standard work sheet. The numbers come from Yamazo Studio's demo data, not from a customer.
Watch the whole series on YouTube · The film loads from YouTube when you press play.
The Second Factory
Under every line runs a second factory: it runs every shift and produces nothing. On demo line A2 that is 47.23 seconds in every product and 4.6 hours every day of work nobody wants. Waste measured station by station from shop-floor video is removed with kaizen, then the work is redistributed: five stations are enough, and the sixth is freed up for new work.
Episode 1: Film the line first
Film the line once, measure it at your desk. The video is linked to its facility, department and line, and the start and end of every work element are marked in the video. One cycle at A2-02: twelve work elements, 75.12 seconds. Performance rating and allowances give the standard time, and the line's six stations appear, each at its standard time.
Episode 2: See the waste
Every work element falls into one of four classes: Value Added, Required Work, Avoidable Work, Waste. Of A2-02's 83.74 seconds, only 43.74 add value; four elements are waste, 17.68 seconds. Takt time is 79 seconds and two stations are above it; at both, the waste is larger than the overrun. The problem goes into the A3 report with the measured numbers.
Episode 3: Kaizen and proof
Kaizen starts with the countermeasures in the A3. A second cycle is filmed at the same station and the two cycles are compared side by side: at A2-02 the four waste elements are gone, the value-added share rises from 48.3% to 57.7%, and 49 seconds of waste per cycle disappear. Both stations drop below takt, and the result of the second measurement goes into the A3.
Episode 4: Balance the line
All six stations are under takt, but their loads differ. Total work divided by takt, rounded up, gives at least five stations. No work element starts before its predecessors finish, so only the leading work elements move to the station before. The result: five stations under takt, efficiency up from 88.8% to 91.6%, balance loss down from 11.2% to 8.4%, and the same demand met with one station less.
Episode 5: Write the standard
The new layout is tried on the line and measured over eight cycles. The three work elements from A2-03 are now at A2-02; every step, in order and with its time, sits in one table, and the total cycle time of 52.9 s is under takt. The measured time comes from the video, the key point and reason from the engineer. The draft is reviewed first, then approved, and reviewer and approver cannot be the same person. The sheet downloads as a PDF and opens on a phone by QR code.
How to use Yamazo Studio
A short video for every screen of the app. The numbers on screen are Yamazo Studio's demo data, not a customer's.
Watch all videos on YouTube · The film loads from YouTube when you press play.
Getting started with Yamazo Studio: dashboard and first study
When you first open Yamazo Studio, the video time study software, the dashboard shows the next step: start your first study in a few minutes.
Set up facility, department, line and stations
Before a time study, describe your plant: facility, department, assembly line and stations are added in turn, so every measurement lands on the right station.
How to do a time study: stopwatch and time table
Time study from video or with a stopwatch: in the time table every row is a work element and every column a cycle, and the cycle time is worked out as you measure.
Read about the topicCycle report: does the cycle time fit the takt time?
The cycle report answers one question: does the cycle fit the takt time, and if not, where does the time go? See value added, required work and waste on one page.
Read about the topicElement times and standard time table
Review measured element times cycle by cycle: category split, cycle time spread and a standard time table with its confidence interval.
Read about the topicHow to read a Yamazumi chart
The Yamazumi chart stacks station load as value added, required work and waste, and warns you when a partly recorded cycle drags the average down.
Read about the topicLine settings: choose the primary study for each station
Before balancing the line, give each station one primary study; missing ones are flagged and you choose which cycles count.
Read about the topicLine Yamazumi chart: compare station loads with takt time
The line Yamazumi chart shows every station's load next to the takt line, so the bottleneck station and the imbalance stand out at a glance.
Read about the topicHow to balance an assembly line
Line balancing: see station loads side by side, move work elements between stations and compare scenarios to clear the bottleneck.
Read about the topicCompare time studies: before and after
Put measured studies side by side: compare times before and after an improvement element by element, and show the gain in numbers.
Read about the topicCreate a standard work combination sheet
The standard work combination sheet is built from the selected station's measured elements: manual work, machine, walking and waiting against the takt line.
Read about the topicCreate work instructions from a time study
Turn a measured project into a standard work instruction step by step: each step with its key point, reason, quality note and measured time.
Read about the topicWorkforce planning: how many operators per station?
Work out from demand, shifts and standard times how many people each station needs; the bottleneck and the staffing gap are flagged in the table.
Read about the topicSMED analysis: reduce changeover time
Cut changeover time with SMED: separate internal and external setup steps and see which work done while the machine stands could move outside.
Read about the topicCreate a value stream map (VSM)
A value stream map shows material and information flow on one map: start from a template and get takt and lead time calculated live.
Read about the topicValue stream map: from current state to future state
The map calculates takt and total lead time live and marks the process above takt; copy the current state, design the future state and compare the two.
Read about the topicMotion efficiency analysis: score motion losses
Each piece of work is scored on an assessment form; body, foot, hand, tool and eye losses are deducted from 100 points, and the costliest motion stands out.
Read about the topicWERA ergonomic risk assessment
Assess ergonomic risk at the workplace with WERA: shoulder, wrist, back, neck, legs, force and vibration are scored and high-risk tasks are flagged.
Read about the topicMotion Memory: all measured cycles in one place
Motion Memory gathers the work cycles of your measured studies as cards; find similar work and add an improvement idea to any cycle.
Read about the topicSkill matrix: which operator can do which task?
The skill matrix shows each operator's level on each task by colour; suggestions come from observed cycles and a supervisor confirms them.
Track improvements across all projects
Collect the problems and improvement ideas of every project in one list; open and resolved items are grouped by project.
Read about the topicWrite an A3 report with a review workflow
A3 problem-solving report: background, current condition, target and benefit calculation on one page, with draft, review and approval steps.
Read about the topicOpEx cockpit: the state of every project on one page
Operational excellence cockpit: estimated savings, approvals waiting, open improvements and the share of reliable studies, as of today, on one page.
Lean manufacturing calculators: takt time, OEE and more
Ready-made forms for takt time, OEE and other everyday lean calculations; add the results to a project and export them to Excel.
Read about the topicCustomer management for consultants
If you consult for several companies, keep each customer's data apart; facilities not yet linked to a customer are flagged.
Export and restore facility data
Export your facility data as one package, encrypt it if you like, and restore it on another computer from that same package.
Master data: products, variants and equipment
Facilities, departments, lines, stations, products, variants, equipment and work definitions in one place; gaps are flagged and an Excel template fills them in bulk.
License management and browser registration
Your license state, user and video allowance, update channel and what the license is bound to on this computer, on one screen; register a browser or transfer the license from here.