The Use of Kaizen in Tipper Production Line in Arabian Metal Industries Ltd.

1. The Use of Kaizen in Tipper Production
Line in Arabian Metal Industries Ltd.
King Abdul-Aziz University
Faculty of Engineering - Rabigh
Department of Industrial
Engineering
IE499 Senior Project

2. Students
Eihab R. Garout #1010837
Abdalrahman M. Bahmaid #1007770
Mohammed R. Alharbi #0910779
Advisor
Dr. Hani Shafeek
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3. Agenda
 Arabian Metal Industries Ltd.
 Kaizen
 The Basics of Kaizen
 Methodology
 The Result
 Conclusion
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4. Arabian Metal Industries Ltd.
Arabian Metal Industries Limited (AMI) was establish in 1976
AMI met all challenges by being able to manufacture any product requiring sheet metal
fabrication, welding and machining.
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5. Arabian Metal Industries Ltd.
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6. Arabian Metal Industries Ltd.
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7. Kaizen
• Kaizen is a Japanese word that means continuous improvement.
• Kaizen is intend to be integrate into the normal day-to-day activities
with the focus eliminating waste, creating standards, having a clean
and organized workplace.
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8. The Basics of Kaizen
• The Seven Wastes.
• 5S’s.
• Standard Work.
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9. The Seven Wastes
1. Overproduction
2. Wait time
3. Transportation
4. Over processing
5. Inventory
6. Motion
7. Defects/rejects
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10. 5S’s
1. Sort
2. Set in order
3. Shine
4. Standardize
5. Systematize
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11. Standard Work
• Standard work is the best, most efficient, safest, and most practical
way of doing work.
• It is the process of documenting and standardizing all tasks, so that
authorized, standard procedures are use at all times, on all shifts,
and by all operators.
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12. Standard Work
Examples of standard work are:
• Outline Process Chart
• Time Study
• Cycle Time and Takt Time
• Balancing Time
• Flow Process Chart
• Waste Analysis
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13. Methodology
13
Production line Work In ProgressWastes

14. Methodology
5S’s
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15. Methodology
Standard Work
• Outline Process Chart
• Time Study
• Cycle Time and Takt Time
• Balancing Time
• Flow Process Chart
• Waste Analysis
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16. Outline Process Chart
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Symbol Activity Type of Activity

17. Time Study
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18. Cycle Time and Takt Time
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Takt time is the rate at which
products or services should be
produced to meet the customer
demand.
Cycle time is the total time
from the beginning to the end
of your process.

19. Balancing Time
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Workstation
Seq Work Content Time
Total

20. Flow Process Chart
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21. Waste Analysis
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22. The Result
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Present Proposed

23. Present Situation
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Outline process chart

24. Present Situation
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Present layout

25. Present Situation
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Present Layout

26. Proposed Situation
Present layout
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27. Proposed Situation
Present layout
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28. Present Situation
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Time study

29. Present Situation
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Time study

30. Present Situation
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Balancing time

31. Proposed Situation
Balancing time
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32. Present Situation
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Cycle Time VS Takt Time

33. Present Situation
Cycle Time VS Takt Time
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34. Present Situation
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Flow Process Chart

35. SubjectCharted: Saving
0
0
Activity: 0
0
0
480
Method:Proposed 480.4
Location:AssemblyLine
Operative(s):
 → D  ∆
Partsare Store (Side,Floor,FrontandTail Gate) •
MovingPartstoAssemblyLine 65 8.8 •
MakingAnassemblyforTippers •
Checkingthe Box tipperafterassembly byQC •
MovingTipperbox toSubframe zone 0 0 •
Workingonassemblythe box withthe subframe 10.2 •
CheckingByQC •
movingtoHydrulicZone 50 8.5 •
WorkingonHydrulicAssembly 60 •
Checkingthe tipperbyQC •
MovingtopaintShop 50 0.5 •
Total 165 88 3 4 0 3 1
TipperAssemply Operation  3 3
Transport →
FlowProcessChart
ChartNo.2 SheetNo.1 of 1 Summary
Activity Present Proposed
MakingAssemblyParts Inspection  3 3
Storage ∆
Time (Min) 656.4 176
4 4
Delay D 0 0
1 1
Distance (m) 810 330
Cost
Labor
RemarkDescription
Material
Total
Qty Distance (m) Time (Min)
Symbol
Proposed Situation
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Flow Process Chart

36. Conclusion
• After the comparing between the present and the proposed situation appear that there clarify
different between the present and the proposed of layout, distance and time of the production
line in Arabian metal industry company.
• That we will safe to company around (1681 m) and (690.13 min) in the transportation of tippers
production line.
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37. Conclusion
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38. Conclusion
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39. Thank you for listening
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