2. Organization & Products
*
DELHI
GURGAON
MUMBAI
Chennai PlantChennai Plant
CHENNAI
Dharuhera Plant
DHARUHERA
PRODUCTS DHR PLANT
Column Electric
Power Steering
Assy. (CEPS)
Pinion Valve
Assy. (PV
Assy.)
Upper Shaft
Dharuhera Plant
Founded : Jul 2006
1st
. SOP started : Jul 2007
Annual Sales F-10 : 264Cr.
Hydraulic Power Steering Assy.
(HPS)
Gurgaon PlantGurgaon Plant
SKSSL Group(Gurgaon, Dharuhera & Chennai)
3. Products & Customers
Column Electric Power Steering (CEPS)
Hydraulic Power Steering
Customer: Maruti Suzuki India Ltd
Models
Assembly Assembly
Wagon R Alto
Zen Estilo
Customer: Mahindra & Mahindra
Models
Scorpio
Bolero
6. 19695
12278
0
10000
20000
30000
CustomerRequirement line Capacity
Capacity VsRequirementpermonth
Gap :
7417
Nos
Problem Statement
Increase Line
capacity by
investing in
new machines
Increase Line
capacity by
doing kaizens
Option
chosen
HPS line capacity found 44 % less compared to customer requirement for F-15
7. Process Mapping : HPS Group
Understanding Situation
Receipt
store RQA
HPS Assembly
Dispatch
Input Shaft
PV Assembly
Valve Body
Pinion Shaft
Torsion Bar
HPS AssemblyBlockDiagram
12. Action Plan
S.No Activities
Feb-14-Jun-14
Feb March April May Jun July
1 Understanding
Situation
2 Data Collection
3 Analysis
4 Countermeasure
implementation
5 Effectiveness
Monitoring of
Countermeasures
6 Standardization
13. Analysis
Operation Sequence at
Induction Hardening M/c.
Positioning
Tempering
Unloading
Loading
Cooling
Positioning
I.D Heating
Quenching
PositionIng
Slit Heating
Quenching
Sketch Diagram of Induction Hardening M/c
LoadingI.D. HardeningSlit HardeningTemperingUn-Loading
Three operation (ID Hardening, Slit Hardening & Tempering)
performed for each component
14. 37%
63%
Effective Process Time
Non Effective Process
Time (Transfer Time)
Analysis cont..
Non-effective operation Time for Induction Hardening process
S.No operation Time(sec.)
1 Positioning for I.D Hardening 10
2 Positioning for Slit Hardening 27
3 Positioning for Tempering 10
4 Component Unloading 10
Total Non Effective Time 57
Hence brain storming
done to reduce None
Effective Process time
Effective operation Time for Induction Hardening process
S.No operation Time(sec.)
1 Heating at ID hardening station 8
2 Quenching at I.D hardening station 10
3 Heating at slit Hardening station 3
4 Quenching at slit Hardening 5
5 Heating at Tempering station 3
6 Cooling at tempering station 6
Total Effective Time 33
Cycle Time study done and found only 37 % time is Effective for Process but 63 % time is
not effective for hardening Process to achieve product parameter
15. Analysis cont..
Break-up of non effective time
Hardening machine
S.No Non Effective Time Time(sec.)
1 Positioning for I.D Hardening 10
2 Positioning for Slit Hardening 27
3 Positioning for Tempering 10
4 Unloading 10
Total Non Effective Time 57
1 Loader Reverse 2
2 Gripper Loading Station Clamp 1
3 Loader Up 1
4 Loader Forward 2
5 Loader Down 1
6 Gripper Loading Station Declamp 1
7 Job lift Up Id Hardening Station 2
8 Job Lift Down I.D hardening Station 1
9 Loader Reverse 2
10 Gripper I.D Station Clamp 1
11 Loader Up 1
12 Loader Forward 2
13 Loader Down 1
14 Gripper I.D Station Declamp 1
15 Job lift Up Slit Hardening Station 2
16 Rotate for Slit Detection 11
17 Job Lift Down Slit Hardening Station 1
18 Ratate for Heating Position 2
19 Job lift Up Slit Hardening Station 2
20 Job lift Down Slit Hardening Station 1
21 Loader Reverse 2
22 Gripper Clamp Slit Hardening Station 1
23 Loader Up 1
24 Loader Forward 2
25 Loader Down 1
26 Gripper Declamp Slit Hardening Station 1
27 Job lift Up Tempering Station 2
28 Job lift Down Tempering Station 1
29 Loader Reverse 2
30 Gripper Clamp Tempering Station 1
31 Loader Up 1
32 Loader Forward 2
33 Loader Down 1
34 Gripper Declamp Tempering Station 1
S.No. Operation Time
PositioningforI.D
Hardening
PositioningforSlitHardeningPositioningforTemperingComponrntUnloading
16. Analysis cont..
Is this Step Is
necessary ?
Can We
Eliminate ?
Can we
reduce ?
Can we
overlap with
other
activities ?
Conclusion
(Should We
Change it)
1 Loader Reverse 2 P P Yes
2 Gripper Loading Station Clamp 1 P No
3 Loader Up 1 P P Yes
4 Loader Forward 2 P P Yes
5 Loader Down 1 P P Yes
6 Gripper Loading Station Declamp 1 P No
7 Job lift Up Id Hardening Station 2 P No
8 Job Lift Down I.D hardening Station 1 P No
9 Loader Reverse 2 P P Yes
10 Gripper I.D Station Clamp 1 P No
11 Loader Up 1 P P Yes
12 Loader Forward 2 P P Yes
13 Loader Down 1 P P Yes
14 Gripper I.D Station Declamp 1 P No
15 Job lift Up Slit Hardening Station 2 P No
16 Rotate for Slit Detection 11 P P Yes
17 Job Lift Down Slit Hardening Station 1 P No
18 Ratate for Heating Position 2 P No
19 Job lift Up Slit Hardening Station 2 P No
20 Job lift Down Slit Hardening Station 1 P No
21 Loader Reverse 2 P P Yes
22 Gripper Clamp Slit Hardening Station 1 P No
23 Loader Up 1 P P Yes
24 Loader Forward 2 P P Yes
25 Loader Down 1 P P Yes
26 Gripper Declamp Slit Hardening Station 1 P No
27 Job lift Up Tempering Station 2 P No
28 Job lift Down Tempering Station 1 P No
29 Loader Reverse 2 P P Yes
30 Gripper Clamp Tempering Station 1 P No
31 Loader Up 1 P P Yes
32 Loader Forward 2 P P Yes
33 Loader Down 1 P P Yes
34 Gripper Declamp Tempering Station 1 P No
ForTemperingForComponrntUnloading
S.No. Time
Questionnaire
Operation
ForI.DHardeningForSlitHardening
17. Analysis cont..
Problem
Non Effective time is more at Valve body Induction Hardening
M/c
Why-1 Why Non effective (non-Operation) time is more ?
Answer Component Transfer time for different operating is more
Why-2 Why Component Transfer time for different operating is more ?
Answer At a time only single component transfer for different operation.
Why-3 Why single component transfer for different operation?
Answer Process was not optimize for Three component transfer at a time.
Root-cause
At a time only single component transfer for different
operation
Counter measure
At a three component should be transfer for different
operation.
24. Standardization
DATE(Origin) 1/7/2007 CHECKED By PREPARED BY
Rev. No : 0
Rev date : -
NEEDED
UNITS PER
SHIFT
A.K Singh Yogesh kumar
STANDARD IN
PROCESSSTOCK
QUALITY CHECK
SAFETY
Sona
Standard
in process
stock
5
Productionp
er hour
40
STANDARDIZEDWORK
CHART
Part No. D040-5911
Process Valve Body Machining
Takt Time
Cycle Time
90 min
1 2 3
DATE(Origin) 1/7/2007 CHECKED By PREPARED BY
Rev. No : 0
Revdate : -
NEEDED
UNITS PER
SHIFT
A.K Singh Yogesh kumar
STANDARD IN
PROCESS STOCK
QUALITY CHECK
SAFETY
Sona
Standard
in process
stock
5
Productionp
er hour
67.9
STANDARDIZEDWORK
CHART
Part No. D040-5911
Process Valve Body Machining
Takt Time
Cycle Time
53 min
1 2 3
SWC Before SWC AFTER
26. Intangible benefits
1.Customer requirement fulfilled .
2.Capital investment can be deferred .
3.Highly motivated team
4.Motivated workmen force
5.Encouragement to other Teams
26/49
