3. 3
Harness - Export
Harness - Local
Connectors Devices
1 2
3
4
Fuel Tank Harness
Power Distribution Harness
Missile Harness
Contribution :39%
Customers:GEAS,
Goodrich, Intertechnique
Harnesses for local
defence application
Contribution :
Customers:11%
BEL,GTRE,HAL,CVRDE,,
AEROSTAT.
Various Aerospace and
Defence application
Contribution :32%
Customers :
SAGEM,LITEF,Zollner
Used in various
commercial aircrafts
Contribution :18%
Customers :
Labinal,AIRBUS
VALUE STREAMS
4. 4
Delivery performance, DevicesDelivery performance, Devices
AFTER
To improve this
1,Foot1and OEE monitoring.
2,Cell design based on 3p concepts
3,Introduction of gauge for inspection
4,Kanban system based on MRF.
Before After
DELIVERY PERFORMANCE OF DEVICES
98% 97%
100% 100%
93%
100% 100%
50%
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
Jul-11 Aug-11 Sep-11 Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12
STS% STR%
DELIVERY PERFORMACE OF DEVICES
68%
46%
59%
80%
62%
59%
40%
26% 27%
58%
40%
27%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
Oct-10 Nov-10 Dec-10 Jan-11 Feb-11 M ar-11
STS STR
5. 5
Delivery performance , ConnectorsDelivery performance , Connectors
DELIVERY PERFORMACE OF CONNECTORS
0%
10%
20%
30%
40%
50%
60%
70%
Apr-11 May-11 Jun-11 Jul-11 Aug-11 Sep-11
STR STS
Before
For this remarkable change the steps taken
are:-
1, Level planning.
2, Skill flexibility .
3, Cell design change.
4, Pull system.
5, FOOT1 and OEE monitoring.
Before After
DELIVERY PERFORMACE OF CONNECTORS
0%
20%
40%
60%
80%
100%
Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12
STR% STS
6. 6
Delivery performance, Harness ExportDelivery performance, Harness Export
20%
40%
60%
80%
100%
Mar-11 Apr-11 May-11 Jun-11
STS% STR%
Monitoring of FOOT.
Reduction of non value added activities
Skill flexibility.
Maintaining and correcting jigs by
autonomous maintenance.
Before After
65%
70%
75%
80%
85%
90%
95%
100%
Mar-12 Apr-12 May-12 Jun-12
STS% STR%
7. 7
Improvements
The batch quantity per factory order not
specified.
Parts transferred by piling on trolley all the
parts of one FG in polybags.
Operator needs to sort out again in
production before starting production process.
Not easy for identification or check the
quantity or damage.
BEFORE AFTER
Existing bins and scrap trolley modified for material movement
Trolley
Bin, 5 bins can be accommodated
in trolley. One bin can hold
material in multiples of 5 nos of
one PN.
Supply chain release
FO’s for next week as
per capacity in ,
multiples of 5 every
Wednesday.
SCM WH
Warehouse picks
material next day and
load bins in the
material movement
trolley
PRODUCTION
SHOP
MATERIAL
MOVMENT
TROLLEY
MATERIAL
HOLDING
TROLLEY
IN SHOP
Bins are transferred from
movement trolley to
material trolley in shop. The
empty trolleys taken back.
PRODUCTION
SHOP
Parts verified for qty
and picked as per
requirement
PN in the side
describing FG and
customer PN
MRF
Before After
8. 8
Improvements
Before After
E shelf is a product for Ontic,
goes in to cock pit of aircraft
interfaces between fuel tank and
cockpit indicator.
It consists of Arinc connector in
one end and several round
connector at other end.
During process after connection in arinc
connector before the operations in other side
different limps needs to be identified. This
process is done by 2 operators with mutimeter
Which takes aprox. 20~25 min.
The operation can damage Arinc connector
and manual error causing wrong labels One end inserted to Arinc connector
Other end of probe on free end of
inserted cable
A continuity fixture was developed from scrap
material which consists of mating connector
for Arinc side of Eshelf and a touch pad for
free ends. There is a light indicator which
glows when connection is right. This operation
can be performed by one operator
Arinc end
Free end
Light indicator
1, Reduction of one manpower.
3, Reduction in process time by 25 minutes.
Poke yoke
Before After
9. 9
Improvements
After
Eshelf . Manual Cable cutting for
all cables on form board
with few inches of
cushion in length.
Assembly of arinc
connector.
Bring back to PN
related form board for
final length cutting.
Cut length measures for each
PN’s are specified by blue and
red marking on the form board
during initial cable cutting
Assembly of arinc connector as well
as other end round connectors
Round connector assembly
of other end
For further processes
before Testing and QA
For further processes
before Testing and QA
1,This process modification saves ~30 min/harness.
2, Savings of $500/Annum
Kaizen
Before After
10. 10
Improvements Training method
Earlier method of qualifying the operators was:
Give induction training
for 1hour
Put them on the job
under senior
operator
Update skill
matrix as per
supervisor feed
back . An OJT
record is
maintained
Main concerns were frequent quality concerns and
inflexibility to move operators to different process and
restriction in multi skilling of a operator.
The following method is derived to improve the qualification
process:
New operator joins and his record
getting updated in OJT sheet. All
the initial training will be given
by group leader or shift engineer.
Enters in C level (Red)
Completes 20 hr gen training,
scores min 80-% mark moves
to B level (YELLOW) in any
line or process. Here the
operator can go to any line or
process as per shift engineer
decision.
Completes 3 months training needs
to scores 80% mark (any skill which
shift engineer/GL require as per
load), move to A level (Blue). Here
he needs to score 80% in each skill
of any line to be considered as
perform with out supervision.
Completes 2 yrs and needs to score
90% including training skills. So he
moves to A+ (Green) who can train
and perform
If scored less than 80%
If scored
less
than
80%
If scored
less than
90%
1, Process based qualification (flexibility to move from one line
to other line)
2, Multi skilling
3, Productivity improvement (1% over all)
Standard Work
Before After
11. 11
GPS IMPROVEMENT
Improvements
Right power distribution cable is a product we
manufacture for Goodrich .We make wire
harness for right and left distribution box, Which
are used in Flacon 7X aircraft.
Each cable take almost 6~7 shifts for completion.
So in this process a section requires specific number of
cables need to routed through different sections and also
through varied color of tubing's.
Earlier we don’t have specific chart mentioning this cause
time for newly inducted operators to understand and learn
also can cause wrong routing even by experienced
operator.
A specific chart has been developed with color coding
for wires, which needs to be routed through different
tubing's
1, Improved training method.
Visual factory
12. 12
Microdot connector assembly is highly skillful
process , It is 100% handmade connector
involving potting and high voltage testing.
One high runner PN 1466123 was having high
rejection due to the process.
The process demands connector shell needs to
be tapped with tapping tool in both sides
Then a helicoil spring needs to be inserted.
After this the actual process starts. So 1 of 20 nos
get rejected (Shell, helicoil,washer). So per month
rejection go upto 10%.
Finished product
Improvements Poke yoke
Scrap was 10%
1,No scrap from last 5 months.
Before After
13. 13
August 8, 2012page 13 /
Kaizens
Before After
Savings
.
Earlier cable bundling process as per the form board, was a time
consuming process which involved manually holding the cable
bundle as per the form board & install the band ties. Repeatability &
Reproducibility of the shape of the harness was not able to attain
Installed 2 nails as per the form board shape , by which operators
are able to easily route the cable bundle in between them. Quality
improved with respect to repeatability & reproducibility.
1, Improved Quality of the part.
2, Savings of $ 250/Annum
14. 14
August 8, 2012page 14 /
Kaizens
Before After
.
Two operators were involved in the testing (continuity & cross
continuity) with the use of multimeter by manually checking each
limbs (9 Limbs & 13 contacts). Labels were inserting by checking so.
No reworks were possible as the length of the harness is exact.
Customer complaint (1No) & rejection (Scrap) at final inspection
happened due to wrong label orientation & wrong continuity
Development of a new semi automatic tester which enables to test
(continuity & cross continuity) the harness before potting & acts as
a fixture for label insertion with only 1 operator..
1, Reduction of one manpower.
15. 15
PIDG, pre insulated diamond grip is used as terminals in wire harness. The insulating material is PEEK which is tough material to
crack. In ADM plant we make this type of assembly ~350-400K every month in various PN’s (different AWG identified by colors).
The process is as follows:-
There are 3 parts to assembly PEEK,
sleeve and ring terminal
Making bell
mouth of PEEK
Inserting the
sleeve in to PEEK
Inserting Ring
terminal in to
sleeve
Pressing the whole
assembly to fix
terminal
Final assy
There was high scrap rate 20 % due to
this issue.
Due to the criticality of manufacturing
this items the suppliers were not able
to support.
In normal process the part
get rejected as shown in
picture.
In PN’s related grey color was
having problem in this area of
process due to tolerance clash of
sleeve and ring terminal.
To overcome this problem we came up with
low cost solution.
A metal block machined with a hole. A pin
according to sleeve dia is machined and
inserted in the hole
Metal block
Pin
The whole assembly is then fixed on a
toggle press as shown in picture. The non
conforming assemblies is then mounted on
the pin and gently pressed with the toggle
After
Before
Kaizens
16. 16
KaizenKaizen
Local Harness
Local harness is based on project but harness look similar.
Time consuming and Confusion in relating product to the
different projects .
No board, tables were placed against the wall.
Before After
The lines were divided in 3 lines with identification.
And meeting board established with line identification to the board.
1,Visibility and identification.
2,Improved 5S+1.
