Lean Manufacturing leads to increase overall efficiency of the workplace and improves the annual profit if tge organization.

1. ‫پروگرام‬ ‫کر‬ ‫نیا‬ ‫کچھ‬
'
،‫بڑھاؤ‬ ‫قدم‬
‫الؤ‬ ‫بہتری‬
'
Lean
Transformation

2. Objectives
• 6S Implementation
• Identification & Calculation of Industrial
Wastages
• Lean Transformation
• Zero Defect
• Continuous Improvement

3. Group 3 –
Change Management
Team Members
• Farhan Shahbaz (Group Facilitator)
• Nasrullah Khan (Group Leader and Line In-
charge RVSCD70)
• Waqas Nawaz
• Irfan Hafeez
• Asim Idrees
• Asif Shahzad
• Mubashir Hussain

4. Audit Zone 3
• Forging Shop
• Electroplating Shop
• Auto-Lathe Shop
• Transfer Line RVS CD70
• Store & its Premises
• Transfer Line Kick
• Development Shop
• Store Office

5. Working
Classification
• Waste Calculation of Transfer Line RVS
CD70
• Lean Transformation, (Identification of
Wastes) Baseline Analysis
• Audit of 3S, Red Tag & BEC Card on
Zone 3

6. What is Lean
Manufacturing?
• Also called Lean Production, is a set of tools and
methodologies that aims for the continuous
elimination of all waste in the production
process.
Lean Manufacturing mainly reduces 8 types of
wastes to ensure cost-effective processes.
• Transportation
• Inventory (Raw Material & Finished good)
• Motion
• Waiting
• Over production
• Over-Processing
• Defect (Reject, Rework)
• Non-utilized Skill

7. Lean
Transformati
on
Transfer-Line RVS CD70

8. Retainer Valve Spring
• The main function of RVS is to retain the engine valve in its compressed
state.
• It ensures the elastic pressure of spring is applied to prevent valve bounce.
• Lead time of RVS production is 89.7sec.
• Monthly Requirement is 1,00,000 Pcs.
• Daily Production capacity of Transfer-line is 4000 Pcs.
• Takt time =6.75sec
• Through put time=48 hours

9. Process Flow Chart
Draw
Press
Cutting
Annealing
Shot
Blasting
Drilling
Deburring
Tapper
Drilling
Forging
Collar Dia
Turning
Facing,
Boring
Heat
Treatment
Final
Inspection
Packing
Initial
Machined
Inspection
Supply
Motion Transportation Inventory Defects Over-processing Waiting Time
Over-production

10. Takt time
6.75 sec
1.8 6.75 13.5 9 13.5 7.9 19.2 16.8
• The operations having cycle time greater than takt time will require more resources
(man/machine) to achieve the required monthly customer demand.

11. Value Stream Mapping
Customer
Demand
Production and
Planning
Forging shop
Drilling
CT= 13.5 Sec
1
Bench Lathe
Deburring
CT=9 Sec
1
Buffing
Taper Drilling
CT=13.5 Sec
1
Bench Drill
IM Inspection
CT=7.7 Sec
1
IQC
Forging
CT= 7.9 Sec
1
Forging
Collar Dia Turning
CT= 16.8 Sec
1
Bench Lathe
Total Length Facing,
Boring and Filleting
CT= 19.28 Sec
1
Bench Lathe
13.5
18 hrs
9
10 Hrs.
13.5
18
hrs
7.7
9.5 hrs
7.9
10 hrs.
16.8
25 hrs.
19.3
25 hrs.
Case Hardening
Heat
Treatment
Final
Inspection
FQC
Supply
Anealing
Daily
shipment
Lead Time=87.68 sec
Through-put Time=48
Hours

12. 87.68
71
PROCESSING TIME
Actual Time study Calculated Time Study
• Current processing time is
87.68sec, While 71sec as per time
study.
• This difference shows that we
have to work on labor, machine
and method to reduce process
time and overall line production
capacity.
DIFFERENCE BETWEEN ACTUAL AND
CALCULATED PROCESS TIME

13. Spaghetti Diagram
Forging
Buff S hop
INV
Store
TL RVS
CD70
Buff shop
Forging
Shop
BL-10
BL-9
BL-8

14. Transportation
Waste
• Monthly time of transportation= 7.67 hours
• Annual no. of hours= 92.14 hours
• Labor wage ____ 100 Rs /-hour
• Annual Transportation waste = Rs.9214.2
Major reason of transportation wastes are
1. Transfer line I/M Deburring

15. Inventory waste
There is no excessive inventory on transfer line, but
a quantity is required for annealing and heat
treatment processes to run the flow of line.

16. Motion waste
Total annual
hours of motion
waste=
24.26Hours.
Major annual
hours of waste
are;
Tapper Drilling=
13.3 Hours.
3.2
13.3
4.1 3.8
0
2
4
6
8
10
12
14
Drilling Tapper
drilling
Collar
Dia
turning
Facing
and
boring
Motion Waste

17. Defect Waste Calculation
Group 3
RVS
CD70
Schedul
e Cost/pc
Propose
d
Revenue
generate
d
50000 40
200000
0
Defects Months
Feb-21 Mar-21 Apr-21 May-21 Jun-21
Avg. monthly Loss
(Rs.)
Height Down 7.80 ~ 8.20 2.89 1.51 44,000
Bore NG 7.20 ~ 7.30 0.92 0.51 14,300
Radius over 0.1 2000

18. Defect Waste
Annual cost of defect waste = Rs. 7,23,600
The top three rejections are as follow:
1. Height Down (7.80-8.20mm)
2. Bore NG (7.10-7.30)mm
3. Radius Over

19. Over - Processing calculation
Group 3
Part RVS
CD70 Schedule Cost
Proposed
Revenue
generated
50000 10 500000
Months
Over- Processing Feb-21 Mar-21 Apr-21 May-21 Jun-21
Avg. monthly
Loss (Rs)
Burr on collar 5.69 0.51 15,500
Burr in bore 0.79 3,950
Height Over 7.80 ~ 8.20 0.41 2,050
Bore tight 7.20 ~ 7.30 0.29 0.97 3,150
Re PT5 0.37 1,850

20. Over – Processing
Annual cost of over-processing waste = Rs.
3,18,000
The three top rectification (Over-processing) are as
follow:
1. Burr on Collar
2. Burr in bore
3. Bore Tight 7.20-7.30

21. Human utilization
• Under utilization of worker due to poor filling in-process inspection and machine
maintenance check sheets.
• Training and counseling will help to improve the human utilization.

22. Over Production
• “Total Length Facing, Boring & Filleting” is the Bottle Neck
Operation.
• Decrease Down Time (Improve Machine & Tool setting) can increase
production per shift.
• Current production per shift=1400
• Improved production of Bottle-Neck operation per shift will directly
increase the daily Transfer line capacity.

23. Ergonomics • Awkward postures - "Height of BL-07 is down,
need adjustment. Worker may face neck pain
during operation.
• Twisting of the body – While tapper drilling,
piece-clamping requires tightening of the
fixture that causes body-twisting.
• High force - Need to hold fixture for piece
clamping in tapper drilling.
• Repititive Actions - During Tapper drilling
operation, after every 300 Pcs. Worker has to
re-fill the WIP bin.

24. CP, CPK
• In order to maintain the machine, it is bringing in practice to calculate the CP, CPK of
machines weekly (for critical ) and fortnightly(for all).

25. Over all Equipment Effectiveness (OEE)
DAILY PRODUCTION & DOWN TIME CALCULATION Date
sr #
Machine
Name
Process Shift Hours
Production Downtime Conformance
Worker Name
Quanti
ty
Materia
l
Handlin
g (min)
Machin
e
Cleanin
g Time
Drinki
ng
Water
Break/
Wash
room
Tool
Change
/
Machin
e
Setting
Mater
ial
Short
age
Machi
ne
Break
Down
Sum
(If Any)
Total
Downti
me
(min)
Audit Rec. Total Rej Total
MPP
Blank
cutting
8 M. Adil 400
400 4
15 10 25.0
29

26. Audit of 3S Stickers,
RT, and BEC Cards

27. 3S Stickers
Sort
‫اورغیر‬ ‫ضروری‬
‫کو‬ ‫چیزوں‬ ‫ضروری‬
‫کرنا‬ ‫الگ‬ ‫الگ‬
Set in Order
‫دینا‬ ‫ترتیب‬
Shine
‫کرنا‬ ‫صفائی‬
• These are used to highlight the areas that require
simplifications, arrangements and cleanliness regarding
machine, materials, tools & equipment etc.

28. Auto-LatheShop
Sorting , Simplifications and cleaning is
required.
Set in
Order
‫دینا‬ ‫ترتیب‬
Shine
‫کرنا‬ ‫ائی‬‫صف‬
Sort
‫اورغیر‬‫ضروری‬
‫چیزو‬‫ضروری‬
‫ں‬
‫کو‬
‫کرنا‬ ‫الگ‬‫الگ‬

29. Maintenance shop
3S required.
Set in
Order
‫دینا‬ ‫ترتیب‬
Shine
‫کرنا‬ ‫ائی‬‫صف‬
Sort
‫اورغیر‬‫ضروری‬
‫چیزو‬‫ضروری‬
‫ں‬
‫کو‬
‫کرنا‬ ‫الگ‬‫الگ‬

30. Toolingstore
Need Sorting, Simplifications and Shine
Set in
Order
‫دینا‬ ‫ترتیب‬
Shine
‫کرنا‬ ‫ائی‬‫صف‬
Sort
‫اورغیر‬‫ضروری‬
‫چیزو‬‫ضروری‬
‫ں‬
‫کو‬
‫کرنا‬ ‫الگ‬‫الگ‬

31. DevelopmentShop
Forging tools that are under maintenance need
to be sorted in their respective racks and
sections.
Sort
‫اورغیر‬ ‫ضروری‬
‫چیزوں‬ ‫ضروری‬
‫کو‬
‫کرنا‬ ‫الگ‬ ‫الگ‬

32. Setinorder-Forging
Shop
Arrangement of forging tools is required.
Set in Order
‫دینا‬ ‫ترتیب‬

33. RED-TAG
Card
Machines/ Tools/ Equipment/ Material that
are not in use should be removed/disposed/
recycled. This card is applied to highlight them.

34. Transferline Kick
Machine not in use from a certain period of
time. Need to remove/repair.

35. Rejections should be remove timely.
Transferline
Kick

36. Auto-Lathe
Shop
Machines that are not in use should not be
placed in work area.

37. Electroplating
Shop
Barrel not in use.

38. Shot Blasting Shop
Motor need to remove, not in use.

39. Buffing shop
Repair/remove/sell.

40. Development shop
Repair/remove/sell

41. Forging shop
Capstan lathe need to remove/repair.

42. BEC Card
Machines/ Fixtures that are in use but
need a quick maintenance such as oil
leakage or OFF due to some serious issue
for a long time, should be tagged with this
card.

43. Development shop
Machine is under maintenance.

44. Electroplating shop
Rectifier not in use. Remove/repair.

45. Forging shop
Capstan lathe maintenance required.

46. Transferline RVS CD70
Bench Drill requires urgent maintenance.

47. Auto-Lathe Shop
Hydraulic Pump leakage observed.