Use of Group technology, Cellular layout and other Operations Management Techniques in order to improve Productivity in manufacturing.

1. PRODUCTIVITY IMPROVEMENT
OF GROVER INDUSTRIES
SUBMITTED BY :-
INDERPREET SINGH BEDI
JAGMEET SINGH BAJAJ
JASHANDEEP SIINGH DHILLON
KRITI SHARMA

2. PROBLEMS FACED AND PROJECT GOALS
 Grover Industries is a small scale gear manufacturing company.
 The company has as an inefficient production system which leads to
bottlenecks, rework and scrap and hence leads to lower productivity.
 Goal :- The project aims at increasing the productivity of the
manufacturing process by using the various operational methodology and
techniques.

3. OBJECTIVES
 New effective production layout which would streamline the
manufacturing process.
 Reduce the Non-Value added activities.

4. MACHINERY AVAILABLE
 Four CNC machines for turning and facing operations
 Four Lathe machines for turning
 Four Milling (Horizontal) machines for teeth cutting
 Four Gear Hobbing machines for special teeth cutting (for cutting splines
and cutting sprockets )

5. GEAR MANUFACTURNG PROCESS
SHAFT
CUTTING
TURNING MILLING
GEAR
HOBBING
WELDING
HEAT
TREATMEN
T
FINISHING
PACKAGING
& SHIPPING

6. PRODUCT DESCRIPTION
The company manufactures six types of products

7. PRODUCT CATEGORIZATION
The products were categorized into 3 different part families
Product 1
Product 2 Product 4A
Product 3A
Product 5A
Product 4B
Product 3B
Product 6
Product 5B

8. OLD LAYOUT

9. PRODUCTIVITY IMPROVEMENT
 LAYOUT DESIGN
 WORK REDISTRIBUTION THROUGH WORK METHOD AND TIME STUDY
 BY DECREASING NON- VALUE ADDED ACTIVITIES
 BY APPLYING GENERAL OPERATIONAL MANAGEMENT TECHNIQUES

10. NEW LAYOUT
By using the principle of Group Technology and Cellular Manufacturing, the manufacturing process
was streamlined and was divided into three cells for three part families.
CELL-1
CELL-2
CELL-3

11. NEW LAYOUT - DIFFERENTIATION

12. DIFFERENTIATING BETWEEN VALUE ADDED, SEMI-
VALUE ADDED & NON-VALUE ADDED ACTIVITES
VALUE ADDED ACTIVITIES
SEMI-VALUE ADDED ACTIVITIES
NON-VALUE ADDED ACTIVITIES

13. TIME STUDY

14. LOAD CHART
 There were 17 stations before and the breakdown of the VA,SVA and NVA
is shown below :-
0
10
20
30
40
50
60
70
80
90
100
LOAD CHART _BEFORE
60%
16%
24%
VA,SVA,NVA
1 2 3

15. LOAD CHART
0
20
40
60
80
100
Shaft
cutting 1
Lathe 1 Lathe 2 CNC 1 CNC 2 Miliing 1 Miliing 2 Gear
Hobbing 1
Gear
Hobbing 2
Cell 1
VA SVA NVA
0
20
40
60
80
100
Shaft cutting 2 Lathe 3 CNC 3 Miliing 3 Gear Hobbing 3
Cell 2
VA SVA NVA
0
20
40
60
80
100
Shaft cutting 3 Lathe 4 CNC 4 Miliing 4 Gear Hobbing
4
Cell 3
VA SVA NVA
62%16%
22%
VA,SVA,NVA
VA SVA NVA

16. MATERIAL REQUIREMENT PLANNING
Sample MRP Sheet proposed for raw material purchasing

17. THANK YOU