MHZ.MOST Workshop summary

Slide 1: B angkok 7 th M ay 2008 Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 2:  Work measurement of universal human body movements as per M aynard Operations S equence Technique (M OS T)  A verage effective working time worldwide = 480 minutes  Combines multi-skilling /multi-stage /multi-functional activity  Pro-active production line speed and workload balancing  F inal customer focused  Continuous improvements in all areas of operations  S elf inspection, self handling and self maintenance by operator team  On going training to update and enhance skills and knowledge of all employees, for sustained continuous performance improvement  E mployee empowerment for process ownership and personnel motivation Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 3: M.O.R.A.L. Cycle: 3.Map 4.Observe 5.Record 6.Analyze 7.Lean A bove cycle is automized using MDA T S oftware (Most Data A cquisition Tool). Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 4: B asic M OS T M ini M OS T Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 5:  Non-intrusive measurement of work brings knowledge without stress  Through knowledge, factual decisions and improvements are made and control exercised  … does not require a stop watch for manual process measurement  . .. does not require performance rating  … can be applied at design and concept stage of a new product, before production begins  ... encourages improvements by motivating personnel  They represent the sequence of events that occurs when an object is moved or a tool is used by an operator  Predefined sequence models represent different types of activities:  General M ove (moved freely through space)  Controlled M ove (movement restricted; attached or in contact)  Tool Use (using common hand tools) Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 6: S ub Operations for S ewing Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 7:  Once processing time has been calculated for each sequence, optimization can begin: ◦ Change tools positioning to limit operator movement ◦ Rationalize supplies and spare parts to stop walking ◦ Change workflow to compress time needed for completing work  Workflow can be automatically recalculated based on an unlimited number of parameters ◦ Operator instructions sheet is printed ◦ Complete production line becomes auto-adaptative and workload balanced Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 8: Crank Shaft Machining Before After No. of Work Centers 20 20 Process Operations 17 17 No. of Operators 17 10 Multi-Machine % 118 % 200 % Max. No. of Machines by One Operator 3 3 CW: Content of Work (Minutes) 52.17 LCW: Lean Content of Work (Minutes) 41.8 Line Speed 15.1 11.82 Production Quantity per Shift (465 Mins) 30 39 Productivity Improvement 121 % Duration for Study 5 Days Duration for Implementation 30 Days Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 9:  Present M ethod and layout  M anpower : 6 Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 10:  New method and layout  M anpower : 2 Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 11: ◦ Typical Through Put Time : Few Days to M onths Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 12:  It is very difficult to apply traditional work measurement tools and technique in long cycle operations and to obtain reliable data  Using computerized systems and knowledge of processes combined with technical specifications along with floor layout, one can easily measure any amount of work involved, with no limited parameters Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 13:  Possible characteristics: ◦ 1. Each Product changes as per customer requirement ◦ 2. Defined sets of product and part variety Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 14:  > 4000 variety of products  B ase template products selected, 20 products represented the others for pilot study  On the basis of these 20 products auto routing of remaining 4000+ products was completed within a week Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 15:  At one of World’s largest manufacturer of Electronic Passive Components  1. Communication to all for General A wareness of M OS T.  2. Training to all employees & A pplicator Training.  3. Process M apping and Elemental data collection.  4. V alidation of elements by applicators.  5. A ctual Implementation.  6. Performance Monitoring.  7. Continual Improvements in Processes by KA IZENs.  8. Revised work content implementation by applicators. Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 16:  Combined with L ean methodology, M OS T is the best tool to easily and scientifically: ◦ S horten production cycles, hence increasing profitability by cost cutting and maximizing resource usage ◦ M akes work easier for operators in labor-intensive manufacturing, increasing personnel motivation and work quality ◦ Provides immediate, measurable ROI  Using computerized systems, one can easily measure any amount of work involved, with no limited parameters  Online productivity KPIs are made available on Enterprise level, in real time Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 17:  Contact M HZ (info@mobilehumanzone.com) for an on-site video audit of a singled-out manufacturing process , previously identified as a resource-consuming bottleneck  V ideo of pilot process is sent to UM A S for analysis  M odelized optimized workflow is sent back to client site for immediate implementation by M HZ  Results are measured and ROI calculated  Upon approval project scope is defined and M OS T roll-out begins with on-site training and remote support Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.

Slide 18: Unique M ost A pplication and S olutions Pvt. L td. in collaboration with M obile Human Zone L td.