3. 3
Be lean
In the Lean Management philosophy, all activities in an organization are grouped into two categories:
• Value-added (VA) Activities
• Non-value-added (NVA) Activities.
• In the context of Lean Management, VA and NVA activities are viewed from the customer perspective.
VA activities are those that bring higher value to products and services. Examples are answering customer
queries, entering orders, ordering materials, laying foundation, creating codes, assembling parts, shipping of
goods to customers, etc.
Customers are willing to pay for these improvements which can change the form, fit or function of a product or
service.
On the other hand, NVA activities are tasks that do not increase market form or function.
Examples are filing, copying, recording, waiting, counting, checking, inspecting, testing, reviewing and
obtaining approvals. These activities should be eliminated, simplified or reduced as much as possible.
By tackling waste from an end-to-end business process, not only can your company improve the value of its
products and services, you can also achieve significant cost reduction, strengthen cash flow and emerge from
the downturn with a stronger and more competitive profile.
3
7. 7
Assembly Dismounting (Overhead)
SUB
RHS1
LHS1 LHS2
RHS2
LHS3
RHS3
LHS4
RHS4
LHS5
RHS5 RHS6RHS7
LHS6LHS7
RHS8
STATION ARE CATEGORIZED INTO FOUR DIFFERENT COULOURS
SIGNIFICANCE OF WHICH DETAILED BELOW:-
•STATIONS IN RED COLOUR ARE BOTTLENECKS ON ASSEMBLY LINE &
NEEDS MANAGEMENT INTERVENTION FOR CHANGING THE ASSEMBLY
METHODS.
• STATION IN YELLOW COLOUR CAN BE BALANCED BY TAKING
DEPARTMENTAL BASED DECISIONS RESULTING IN HUGE MANPOWER
SAVINGS
• STATIONS IN GREEN COLOUR WERE BOTTLENECKS ON ASSEMBLY LINE
BUT ACTION HAVE BEEN TAKEN.
•WORKING STATIONS IN WHITE COLOUR CAN BE IMPROVED BY DOING
KAIZENS.
8. 8
Assembly Dismounting (Overhead)
SUB
RHS1
LHS1 LHS2
RHS2
LHS3
RHS3
LHS4
RHS4
LHS5
RHS5 RHS6RHS7
LHS6LHS7
RHS8
slat
LHS1-Angle Bkt& tailor hook
fitment
LHS2- Clutch tie rod &Brake light
switch fitment
LHS3- Fender fitment
LHS4- LH rear wheel fitment
LHS5- LH front wheel fitment
LHS6- Fender seat fitment
LHS7- Water separator fitment
SUB – Fender Sub assy
RHS1- Seat & Strip fitment
RHS2-Horn & timing belt
fitment
RHS3-Fender fitment
RHS4- RT rear wheel fitment
RHS5- Front wheel torquing &
tailor hooking
RHS6-RH front wheel fitment
RHS7-Greasing Filling
RHS8- Oil drain
10. 10
DISMOUNTING ASSEMBLY
CURRENT STATE OF DISMOUNTING ASSEMBLY LINE
DISMOUNTING ASSY CURRENT STATUS TARGET
(10% IMPROVEMENT)
LINE EFFICIENCY 61.5% 67%
TOTAL MANPOWER 73 NO. TO REDUCE 3.5NO.
MANPOWER
LEAD TIME 85 MINUTES
(13TRCTR/HR)
15 TRCTRS/ HR
(105 TRCTRS/SHIFT)
NO. OF LHS STATION 16
NO.OF RHS STATION 15
NO. OF SUB ASSY STATION 3
TOTAL 34
11. 11
DISMOUNTING RHS STATION
CYCLE TIME
WORKING TIME
AVAILABLE = 240
SECONDS
(90% OF Takt Time)
CYCLE TIME
MORE THAN
TAKT TIME
TIMEINSECONDS
225
150
180
350
230
100
70
150
120
350
180
230
335
300
150
0
50
100
150
200
250
300
350
400
DRIVERSEATFITMENT
HORNTIMINGBELTFITMENT
RT.FENDERFITMENT
TRACTORGREASING
RT.REARWHEELFITMENT
RT.FRONTWHEELFITMENT
OILDRAIN
REARFRAMEFITMENT
FUELTANKSTRAPFITMENT
RADIATORFITMENT
DASHBOARDFITMENT
ELECTRICALCONNECTION
BATTERYSTATION
RT.SHEETMETALFITMENT
SILENCERFITMENT
RHS
12. 12
DISMOUNTING LHS STATIONS
CYCLE TIME
MORE THAN
TAKT TIME
CYCLE TIME
WORKING TIME
AVAILABLE = 240
SECONDS
(90% OF Takt
Time)
TIMEINSECONDS
230
180
200
230
180
120
70
200
180
240
200 200
300
130
220
230
0
50
100
150
200
250
300
350
TRAILERHOOKFITMENT
CLUTCHRODFITMENT
FENDERFITMENT
LT.REARWHEELFITMENT
LT.FRONTWHEELFITMENT
FENDERSEATFITMENT
WATERSEPARATORFITMENT
7PINSOCKETFITMENT
FUELTANKFITMENT
I/PPLATEFITMENT
STG.WHEELFITMENT
DATAPLATEFITMENT
LT.SHEETMETALFITMENT
FRONTGRILLFITMENT
AIRCLEANERMIRRORFITMENT
DIESEL,DIFF.OILCOOLANTFILLING
LHS
13. 13
STATIONS WHERE CYCLE TIME IS MORE THAN TACT TIME
STATION CYCLE
TIME
NVA TIME NVA% MANPOWER
REQUIRED
MANPOWER
DEPLOYED
EFFICIENCY
TRACTOR
GREASING
350 120 42.8% 1.5 2 64%
INSTRUMENT
PLATE SUB ASSY
315 115 36.5% 1.5 2 58.3%
DASHBOARD
PLATE SUB ASSY
280 100 35.7% 1.5 2 51.8%
BATTERY
FITMENT
335 110 32.8% 1.5 2 62%
RADIATOR
FITMENT
350 120 34.2% 2 2 64.8%
SHEET METAL LHS 300 115 38.33% 2 3 37%
SHEET METAL RHS 300 120 40% 2 3 37%
TAKT TIME PER TRACTOR 270 SECONDS
STAGE EFFICIENCY= CT/(NO. OF OPERATORS X TAKT TIME)
14. 14
Production Supervisor
Value Stream Mapping
DISMOUNTING assembly (OVERHEAD CONVEYOR)
1 Shift =480 min.
Lunch = 30 min
Tea break = 10x2=20 min.
CLITA sheet entry= 10 min
Available shift time =
420 min.
PURCHASE
supplier
Mainstores
C/T:
C/T(VA)
:
NET VA
TIME:
OPRTR:
230
150
55%
1
TRAILER HOOK
FITMENT
230
170
63%
1
200
155
57%
1
180
100
37%
1
100
70
26%
1
CLUTCH ROD
FITMENT
FENDER
FITMENT
LT. REAR WHEEL
FITMENT
LT. FRONT
WHEEL FITMENT
180
135
50%
1
230
170
63%
1
100
70
26%
1
350
225
83%
2
95
70
26%
1
225
115
43%
1
150
105
39%
1
C/T:
C/T(VA)
:
NET VA
TIME:
OPRTR:
OIL
DRAINTRACTOR
GREASING
RT. FRONT WHEEL
FITMENT
RT. REAR WHEEL
FITMENT
RT. FENDER
FITMENT
HORN TIMING
BELT FITMENT
DRIVER SEAT
FITMENT
70
45
17%
1
WATER SEPARATOR
FITMENT
120
65
24%
1
FENDER SEAT
FITMENT
CUSTOMER
RHS
LHS
PPC
150 120 7070170155100
115 70170225135105 70
150 52
135
120
150
135 30
120
60
60
810
270
WAITING TIME
VA
15. 15
Production Supervisor
Value Stream Mapping
DISMOUNTING assembly (SLAT CONVEYOR)
1 Shift =480 min.
Lunch = 30 min
Tea break = 10x2=20 min.
CLITA sheet entry= 10 min
Available shift time =
420 min.
Time in minutes
PURCHASESupplier
Mainstores
200
180
66%
1
7 PIN SOCKET
FITMENT
200
190
70%
1
240
160
59%
1
180
160
59%
1
200
95
35%
1
FUEL TANK
FITMENT
I/P PLATE
FITMENT
STG. WHEEL
FITMENT
DATA PLATE
FITMENT
280
180
64%
2
230
220
81%
1
335
255
62%
2
300
180
22%
3
150
110
40%
1
150
90
33%
1
350
230
85%
2
SILENCER
FITMENT
RT. SHEET
METAL FITMENT
BATTERY
STATION
ELECTRICAL
CONNECTION
DASHBOARD
SUB ASSY
RADIATOR
FITMENT
REAR FRAME
FITMENT
130
60
22%
1
FRONT GRILL
FITMENT
300
185
23%
3
LT. SHEET METAL
FITMENT
CUSTOMER
RHS
LHS
250
185
68%
1
DIESEL, DIFF. OIL
COOLANT
FILLING
220
95
35%
2
AIR CLEANER
MIRROR
FITMENT
120
95
35%
1
FUEL TANK
STRAP FITMENT
PPC
TESTING
AND
INSPECTION
160
C/T:
C/T(VA)
:
NET VA
TIME:
OPRTR:
C/T:
C/T(VA)
:
NET VA
TIME:
OPRTR:
160 190 95 185 9560 185180
90 95 230 140 220 225 180 110
405 200 100 135 135 135 270 305
135 135
135 0 0 0
270
16. 16
STATION
TRACTOR GREASING
STATION CYCLE
TIME
NVA TIME NVA% MANPOWER
REQUIRED
MANPOWER
DEPLOYED
EFFICIENCY
TRACTOR
GREASING
350 120 42.8% 1.5 2 64%
TYPES OF WASTE OBSERVED:-
• TRANSPORTATION.
• DEFECTS.
• MOTION.
• MANPOWER UNDER UTILISATION.
17. 17
STATIO
N
TRACTOR GEASING
STANDARD WORK COMBINATION
CHART
DATE 1.7.14
C/T(SEC) 350
MODELS 735, 834, 724, 843. TAKT(SEC) 270
DOC.NO.
s.no Work Sequence
Operation
time JOB TIME IN SECONDS
Manu
al Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 325 330 335 340 345 350
1
REMOVING OF
OLD CAPS 60
2
PICK GUN MOVE
TO TRACTOR 5
3
GREASING ALL
POINTS 125
4
CLEANING EXTRA
GREASE 40
5
PLACING THE
GUN BACK 5
6
MOVE TO PICK
NEW CAPS 5
7
PLACING CAP ON
GRESE POINTS 105
8
MOVE BACK TO
STAGE 5
TOTAL 350
NON VA%= 34%
18. 18
Production
Supervisor
Value Stream Mapping
DISMOUNTING assembly (TRACTOR GREASING)
1 Shift =480 min.
Lunch = 30 min
Tea break = 10x2=20 min.
CLITA sheet entry= 10 min
Available shift time =
420 min.
Time in minutes
PURCHASE
Supplier
Mainstores
GREASE STORAGE
TRACTOR
GREASING
FORK LIFT FROM STORE
Before- 450 Mtr.
After-250 Mtr
TYPES OF
WASTE
19. 19
TRACTOR GREASING STATION
STORE USE TO FEED THE GREASE DRUM TWICE A WEEK.
WE HAVE CALCULATED THE DISTANCE & IT CAME 450 METERS FOR FEEDING ONE GREASE DRUM
- SO FORK LIFTER MOVMENT /MONTH WILL BE:-
450X8 = 3.6 KM/MONTH
PROPOSAL IS TO CHANGE THE LINE STORAGE LOCATION OF GREASE DRUM & FEEDING THE GREASE FORTNIGHTLY.
AFTER CHANGING THE FEEDING LOCATION FORK LIFTER DISTANCE WILL REDUCE TO 250 METERS /15DAYS.
-SO FORK LIFTER MOVMENT /MONTH WILL BE:-
250X2 = 0.5KM/MONTH.
THEREFORE TOTAL FORK LIFTER MOVEMENT WILL REDUCE FROM 3.6KM TO 0.5KM.
DEFECTS GENERATED DUE TO DELAY IN FEEDING WILL ELIMINATED.
20. 20
1st round
Grease Cap removal
2nd round
Tractor greasing
3rd round
Extra grease cleaning
and grease cap fitment
TRACTOR GREASING STATION
19 No. Grease
point on tractor
2 No. operator
required
TYPES OF WASTE
21. 21
TRACTOR GREASING STATION
OUR TARGET IS TO REDUCE THE MANPOWER FROM 2NO. TO 1NO., REDUCING DEFECTS,
IMPROVING AESTHETICS OF TRACTOR.
IN ORDER TO ACHIEVE ABOVE TARGET WE HAVE TO DO FOLLOWING WORK:-
•SOP TO BE MODIFIED
- PLANNED TO MODIFY THE TOOL FOR FACILITATING CAP REMOVAL & GREASING IN ONE GO.
TOTAL DISTANCE MOVED IN 3NO. ROUNDS=21 METER/TRACTOR.
AFTER MODIFICATION IT WILL COME TO 14 METER/TRACTOR.
• IN ORDER TO BRING THE PROCESS UNDER TAKT TIME WE NEED TO OFFLOAD SOME OF THE
CLOSED GREASING POINTS TO VENDOR END, E.G:-
- CROSS TIE ROD.
- LONGITUDINAL TIE ROD.
- TOP LINK.
THIS WILL REDUCE GREASING POINTS FROM 19 NO. TO 13 NO.
•IMPROVING GREASE COUPLER QUALITY, DOING TRIAL FOR 4 JAW COUPLER INSTEAD OF 3
JAW COUPLER IN ORDER TO CONTROL EXTRA GREASE WHIPPING PROBLEM.
22. 22
TYRE FITMENT
TYPES OF WASTE OBSERVED:-
• TRANSPORTATION.
• DEFECTS.
• MANPOWER UNDER UTILISATION.
• OVER PRODUCTION.
23. 23
STATION REAR TYRE FITMENT
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 230
MODELS 735, 834, 724, 843.
TAKT(SEC
) 270
DOC.NO.
s.no Work Sequence
Operation time
Manual Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
1
TYRE CLAMPING AND MOVEMENT
TOWARDS THE LINE 35
2
MOVING AND POSITIONING OF
TYRE 45
3
NUT AND WASHER
TRANSPORTATION 10
4
NUT AND WASHER PLACEMENT
WITH HAND 15
5 NUT TIGHTENING AND TORQUING 50
6
RETURNING OF CLAMP MACHINE
FOR NEXT CYCLE 15.
7 WAITING TIME FOR NEXT CYCLE 60
TOTAL 230
NVA%= 36%
24. 24
STATION FRONT TYRE
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 100
MODELS 735, 834, 724, 843.
TAKT(SEC) 270
DOC.NO. WC/02
s.no Work Sequence
Operation
time JOB TIME IN SECONDS
Manua
l Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95100 105 110 115 120 125 130 135 140145 150 155 160 165 170 175 180 185190 195 200 205 210 215 220 225 230
1
PICKING OF BOLTS AND MOVE
TOWARTDS TRACTOR 5
2 PLACING OF BOLTS ON HUB 15
3
TAKING OF NUTS AND TYRE
TOWARDS TRACTOR 15
4 POSITIONING OF TYRE 10
5 PUTTING NUTS ON BOLTS 25
6 PICKING OF GUN 5
7 TIGHTENING OF NUTS 25
TOTAL 100 OPERATION TIME 100 SECONDS
NVA%= 40%
25. 25
TYRE STORAGE
YARD
TYRE FITMENT
Value Stream Mapping
DISMOUNTING assembly (TYRE MOVEMENT AND FITMENT)
TYPES OF WASTE
RIMSTORAGE
REAR WHEEL ASSY
FRONT WHEEL
ASSY
TOTAL MANPOWER-9NO.
26. 26
SCOPE OF IMPROVEMENTS
1. THE TRACTOR PROVIDED CAN LOAD ONLY 7 REAR TYRES OR 46 FRONT TYRES AT A TIME
DISTANCE FROM TYRE STORAGE YARD TO TYRE ASSEMBLY SHED IS 250METERS TO & FRO.
-52 ROUNDS FOR REAR TYRES
-8 ROUNDS FOR FRONT TYRES
TOTAL 60 ROUNDS
•SO TRACTOR MOVMENT FOR 184 TRACTORS/DAY WILL BE:-
250X60 = 15KM/DAY.
•WEEKLY CONSUMPTION OF DIESEL FOR TRANSPORTING TYRES IS APPROXIMATELY 90 LITRES
•SO ANNUAL CONSUMPTION OF DIESEL IS 52X90 =4680 LITRES.
•APPROXIMATELY ANNUAL COST FOR DIESEL CONSUMPTION IN TYRE MOVEMENT IS
4680X58 = Rs271440
2. DUE TO TRANSPORTATION OF LIMITED NO. OF TYRES AT A TIME THERE ARE ALWAYS CHANCES THAT TYRES FOR SOMES SPECIFIC
TRACTOR MODELS ARE NOT REACHED ON TIME AS IT TAKES 5 TO 7 MINUTES TO BRING TYRES AT ASSEMBLY AREA.
-THEREFOE CAUSING WRONG FITMENT OF 10NO. TYRES ON AN AVERAGE/DAY.
- ALSO IF WE ARE TO INCRAESE THE CAPACITY /PRODUCTION & TO MAKE TRACTOR DEFECT FREE WE ARE TO WORK TO INCREASE
TYRE CARRYING CAPAPCITY/ROUND.
3. TYRES ALSO GET FILLED WITH RAIN WATER, THEREBY WE ARE DEPLOYING 1NO. MANPOWER FOR DRAINING WATER FROM THE
TYRES.
27. 27
PROPOSED SOLUTIONS
TO REDUCE TRACTOR’S UNNECESSARY MOVEMENT:
• WE CAN SETUP A LOCAL INVENTORY FOR MOST FREQUENTELY USED TYRES(ON THE BASIS OF SIZES, TRACTOR MODELS, etc.)
NEAR THE TYRE ASSEMBLY SHED.
* THIS WIL REDUCE TRACTOR MOVEMENT FROM 60NO. ROUNDS TO 30NO. ROUNDS
*DIESEL CONSUMPTION WILL ALSO REDUCE TO 50%.
IN ORDER TO INCREASE THE PRODUCTION CAPACITY:-
• FOR THE MOVEMENT OF TYRES FROM THE MAIN TYRE STORAGE, A TRACTOR TROLLEY CAN BE USED WHICH CAN EASILY
CARRY 25-30 TYRES AT A TIME. THIS WILL HELP IN REDUCING NO. OF ROUNDS AND HENCE THE DIESEL CONSUMPTION TO A
GREAT EXTENT.
TO ACHIEVE THIS FOLLOWING WORK NEEDS TO BE DONE:-
- DESIGNING & FABRICATION OF TROLLEY.
- FORK LIFTER FOR LOADING TYRES ON TO TROLLEY OR LOW FLOOR TROLLEY WITH AIR SUSPENSION/HYDRAULIC
CYLINDER ARRANGEMENT.
- FOR UNLOADING WE CAN GIVE ROLLER ARRANGEMENT ON THE TROLLEY WITH SLIGHT TILT SO THAT OPERATOR CAN
EASILY UNLOAD THE TYRE.
*IF TRIAL WILL BE SUCCESSFUL THIS ALSO WILL HELP TO REDUCE
- TRACTOR ROUNDS FROM 60NO. TO 15NO.(75% SAVING IN DIESEL) IN MOVING THE TYRES.
- AND DIESEL COST WILL REDUCE FROM 2.5LAC (APPROX) TO 63 THOUSAND P.A ONLY.
SAVING OF 1.87LAC P.A.
TO CONTROL THE LINE SIDE TYRE INVENTORY:-
• A GRAVITY CONVEYOR CAN BE SETUP TO TRANSPORTING FRONT TYRES FROM THE ASSEMBLY SHED TO THE ASSEMBLY LINE.
ALSO THERE WILL SAVING IN 1NO. MANPOWER FOR FRONT TYRE MOVEMENT.
31. 31
PROBLEMS IDENTIFIED
•EACH SEAT WEIGHS AROUND 20KGS. THEREFORE IT IS DIFFICULT TO LIFT IT AND TAKE FOR THE
FITMENT ON TRACTOR.
TOATL LOAD CARRIED BY OPERATOR/SHIFT =20X92 =1840Kg.
•ALSO THERE IS SOME UNNECESSARY MOVEMENT OF THE OPERATOR.
BOTH OF THE ABOVE MENTIONED FACTORS RESULT IN HIGH FATIGUE TO THE OPERATOR, THEREBY
LOWERING THE EFFICIENCY OF THE OPERATOR.
DUE TO THIS OPERATOR USE TO REFUSE TO DO WORK ON THIS STAGE.
PROPOSED SOLUTION
- WHETHER BUDGET IS ASSIGNED FOR THE PROVISION OF MANIPULATTOR BUT WE HAVE SOME PLANS
TO DO TRIAL WITH SOME TACKLE ARRANGEMENT & LIFTING WITH PNEUMATIC HOIST.FOR THIS
OVERHEAD STRUCTURE NEEDS TO BE CLEARED & BALANCER NEEDS TO BE INSTALLED FOR DRIVER SEAT
LIFTING & FITMENT.
- FOR TRAILER HOOK WE HAVE PLANNED SOME CYLINDER & TACKLE ARRANGEMENT.
AFTER PROVIDING THE ABOVE SOLUTIONS 1NO. MANPOWER WILL BE SAVED.
32. 32
SHEET METAL
STATION CYCLE
TIME
NVA TIME NVA% MANPOWER
REQUIRED
MANPOWER
DEPLOYED
EFFICIENCY
SHEET METAL LHS 300 115 38.33% 2 3 37%
SHEET METAL RHS 300 120 40% 2 3 37%
FRONT GRILL 130 40 30.77% 1 1 48.15%
TYPES OF WASTE OBSERVED:-
• DEFECTS.
• MOTION.
• MANPOWER UNDER UTILISATION.
33. 33
STATION
SHEET METAL LHS
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 300
MODELS 735, 834, 724, 841, 843OSM.
TAKT(SEC) 270
DOC.NO.
S.no Work Sequence
Operation
time JOB TIME IN SECONDS
Manual Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300
1
PLACING PANEL FROM
TROLLEY TO TABLE 5.
2 PASTING STICKER ON PANEL 10
3
PLACING PANEL BACK TO
TROLLEY 5
4
HANDLE PLACEMENT ON
OANEL 40
5
PLACING IT BACK ON
TROLLEY 5
6
BOLT PLASTIC WASHER ASSY
9NO. 20
7
PICK HEADLIGHT
FROMTROLLEY 5
8
HEADLIGHT FITMENT ON
TRACTOR 30
9
RUBBER GROMET FITMENT
ON TRACTOR 20
10
PICK PANEL MOVE TO
TRACTOR 5
11
PANEL LOOSE FITMENT ON
TRACTOR 30
12 PICK GUN 5
13
TIGHTENING OF FRONT
FRAME BOLT 10
14 MOVE BACK TO PICK SHIELD 10
15
SHIELD LOOSE FITMENT ON
TRACTOR 30
16 PICK GUN 5
17
TIGHTENING OF PANEL AND
SHIELD 50
18 PASTING OF STAR ATICKER 5
19 TIGHTENING OF TOP TIE NUT 10
TOTAL 300 OPERATION TIME 300 SECONDS
NVA%= 17%
35. 3535
STATION FRONT SHEET METAL
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 130
MODELS 735, 834, 724, 843. TAKT(SEC) 270
DOC.NO.
s.no Work Sequence
Operation
time JOB TIME IN SECONDS
Manual Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
1 FRONT GRILL ASSY 30
2
PICKING MATERIAL AND
MOVING TO TRACTOR 10
3 FITMENT AND TIGHTENING 30
4
MOVING AND PICKING NUMBER
PLATE 10
5 FITMENT AND TIGHTENING 20
6 MOVING LHS TO RHS 10
7
PICKING MATERIAL AND
MOVING TO TRACTOR 10
8 TIGHTENING OF BATTERY COVER 10
TOTAL 130
FRONT SHEET METAL
36. 36
STICKER PASTING STAGES TIME IN SECONDS MANPOWER DEPLOYED
FENDER LHS 15 1(+FENDER LIGHT FITMENT)
FENDER RHS 15 1(+FENDER LIGHT FITMENT)
DASHBOARD AND CHASIS STICKER 40 1(+DATA PLATE PUNCHING)
SHEET METAL LHS 15 1(+SHEET METAL FITMENT)
SHEET METAL RHS 15 1(+SHEET METAL FITMENT)
TOTAL 100 SECONDS 5
FOAM PASTING STAGES TIME IN SECONDS MANPOWER DEPLOYED
SHEET METAL LHS 30 1(+SHEET METAL FITMENT)
SHEET METAL RHS 30 1(+SHEET METAL FITMENT)
DUST COVER 40 1(+ DUST COVER & DATA PLATE FITMENT)
TOTAL 100 SECONDS 3
37. 37
SCOPE OF IMPROVEMENT:-
IT IS CLEAR THAT DIFFERENT STICKER ARE BEING PASTED AT DIFFERENT STAGES
* BY ASSEMBLY LINE OPERATORS AT FENDER, CHASSIS, DASHBOARD & SIDE PANNELS.
* BY CONTRACTOR MANPOWER(2NO.) SIDE PANNEL-724XM, 841XM & 834XM MODEL,SINGLE HOOD-843XM
& 735XM, DASHBOARD.
PROPOSED SOLUTIONS
1. SO IF WE DO STICKER PASTING CENTERALISED BY OFFLOADING ALL THE STICKER PASTING & FOAM
PASTING ON SHIELDS & PANNELS ACTIVITIES TO CONTRACTOR :-
*WE CAN REDUCE 1No. MANPOWER FROM THE ASSEMBLY LINE.
*QUALITY OF STICKER WILL IMPROVE AS THEY WILL PASTE ALL STICKER WITH LIQUID SOLUTION
RESULTING IN NO AIR BUBBLE LEFT.
2. STAGE EFFICIENCY WILL ALSO IMPROVE.
38. 38
TRACTOR ELECTRICAL FITMENT
STATION CYCLE
TIME
NVA TIME NVA% MANPOWER
DEPLOYED
EFFICIENCY
HARNESS AND
TIMING BELT
150 45 30% 1 55.5%
INSTRUMENT
PLATE S/A
315 115 36% 2 58.3%
COVER PLATE S/A 280 100 55.5% 2 51.8%
DASHBOARD
FITMENT
240 80 33.33% 1 88.8%
ELECTRICAL
CONNECTION
230 10 5% 1 85.1%
7 PIN SOCKET 200 20 10% 1 74%
TOTAL 1415 370 26% 8 65.5%
TYPES OF WASTE OBSERVED:-
• DEFECTS.
• MOTION.
• IDENTICCAL JOB OF ONE TYPE IN VERY
LESS TIME.
• MANPOWER UNDER UTILISATION.
39. 39
STATION
CHASIS HARNESS & FAN BELT
FITMENT
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 150
MODELS 735, 834, 724, 841, 843OSM.
TAKT(SEC) 270
DOC.NO.
S.no Work Sequence
Operation time JOB TIME IN SECONDS
Manual Walk 5
1
0
1
5
2
0
2
5
3
0
3
5
4
0
4
5
5
0
5
5
6
0
6
5
7
0
7
5
8
0
8
5
9
0
9
5
1
0
0
1
0
5
1
1
0
1
1
5
1
2
0
1
2
5
1
3
0
1
3
5
1
4
0
1
4
5
1
5
0
1
5
5
1
6
0
1
6
5
1
7
0
1
7
5
1
8
0
1
8
5
1
9
0
1
9
5
2
0
0
2
0
5
2
1
0
2
1
5
2
2
0
2
2
5
2
3
0
1 HARNESS HORN SUB ASSY 20 VA
2 MOVING TO TRACTOR 10 NVA
3 HARNESS FITMENT ON TRACTOR 60
3 MOVE TO PICK BELT 5
4 BELT FITMENT ON TRACTOR 15
5 PICK GUN 5
6 TIGHTENUNG OF BELT 30
7 BACK TO STAGE 5
TOTAL 150 OPERATION TIME 150 SECONDS
TRACTOR ELECTRICAL FITMENT
41. 41
STATI
ON
DASHBOARD PLATE SUB ASSY
STANDARD WORK COMBINATION CHART
DATE 1.7.14
C/T(SEC) 350
MODEL
S
735, 834, 724, 843.
TAKT(SE
C) 270
DOC.NO. WC/03
s.no Work Sequence
Operation
time
Manua
l Walk 5101520253035404550556065707580859095
10
0
10
5
11
0
11
5
12
0
12
5
13
0
13
5
14
0
14
5
15
0
15
5
16
0
16
5
17
0
17
5
18
0
18
5
19
0
19
5
20
0
20
5
21
0
21
5
22
0
22
5
23
0
23
5
24
0
24
5
25
0
25
5
26
0
26
5
27
0
27
5
28
0
1
PICK ALL METER5S FROM
TROLLEY 20
2 DISASSEMBLE SWITCHES 35
3 TROLLEY MOVEMENT 10
4
DASHBOARD TROLLEY TO
TABLE 5
5
OPENING COVER
PLATE 25
6 MOVE BACK TO TABLE 5
7 SWITCH FITMENT IN PLATE 60
8 HARNESS CONNECTIONS 120
TOTAL 280 OPERATION TIME 280 SECONDS
42. 42
52 minutes
2-3m
2-3m
1-2m
C/T =150
VA =105
NETVA=39%
OPERTR =1
HORN TIMING
BELT FITMENT
DASHBOARD
SUB ASSY
DASHBOAD SUB
ASSY
Production
Supervisor
PPC
Supplier
Value Stream Mapping TRACTOR ELECTRICALS
C/T =280
VA =180
NETVA=64%
OPERTR =2
C/T =280
VA =180
NETVA=64%
OPERTR =2
43. 43
SCOPE FOR IMPROVEMENT
- ELECTRICAL HARNESSES, ELECTRICAL S/A AND ELECTRICAL FITMENT ARE CURRENTLY
PERFORMED AT DIFFERENT LOCATIONS ON DISMOUNTING LINE BY DEPLOYING 7NO.
MANPOWER & AT SOME STAGES THERE IS IMPROPER UTILISATION OF THE SAME.
-WORK IS UNEVENLY DISTRIBUTED, AT SOME STAGES WORK EFFICIENCY IS VERY HIGH AND
SOMEWHERE IS VERY LOW.WORK NEEDS TO BE BALANCED.
- 4NO. OF BOLTS UNWANTED DISMANTLING ACTIVITY CAN BE ELIMINATED.
- AND IT IS VERY DIFFICULT TO DIAGNOSE & RECTIFY THE ELECTRICAL PROBLEM DUE TO
HUGE COMPLEXITY.
TRACTOR ELECTRICAL FITMENT
44. 44
PROPOSED ACTIONS
•IN HIGH EFFICIENCY STAGES LIKE ELECTRILCAL CONNECTIONS THERE IS HUGE SCOPE OF GOING FOR COUPLER
CONNECTIONS RATHER THAN EACH WIRE CONNECTIONS. AND INPLACE OF TIGHTENING OF SCREWS AT SOME
STAGES LIKE ALL INSTRUMENT PLATE METERS WE CAN GO FOR MALE/FEMALE THIMBLES.
- WITH THIS FITMENT TIME WILL REDUCE.
- LOOSE CONNECTION PROBLEM WILL BE ELIMIATED.
- 1NO. OPERATOR DEPLOYED FOR ELECTRICAL CORRECTION WILL BE REDUCED.
- WARRANTY FAILURE DUE TO ELECTRICAL PROBLEMS WILL REDUCE.
• RECEIVING OF DASHBOARD & DASHBOARD PLATE SEPARATE .
•PROPER UTILISATION OF MANPOWER CAN BE ACCOMPLISHED IF WE CLUB ALL THESE STAGES(INSTRUMENT
PLATE, DASHBOARD PLATE ELCTRICALS, ELECTRICAL CONNECTIONS ONLINE, REAR VIEW MIRROR FITMENT) INTO
ONE SUB ASSEMBLY STAGE.
• WE CAN GET SOME OF THE ELECTRICAL COMPONENTS IN ASSEMBLED FORM FROM VENDOR END LIKE SUB ASSY
OF 7 PIN SOCKET, STARTING SWITCH ETC.
-THERE WILL BE SAVING OF 1NO. MANPOWER.
- DEFECTS DUE TO LOOSE CONNECTIONS WILL REDUCE.
AT ZAHEERABAD IN OUR PLANT
TRACTOR ELECTRICAL FITMENT
45. 45
DASHBOARD NVA REDUCTION & INVENTORY CONTROL
BEFORE AFTER
*NVA OF OPENING TIME OF 25SECONDS SAVED
*PAINT QUALITY IMPROVED.
*5S IMPROVED ON THE STAGE
47. 47
MATERIAL
STORAGE
RACK
TABLE
Value Stream Mapping
DISMOUNTING assembly (Fender Fitment )
BEFORE
TYPES OF WASTE
FENDER TROLLEY
FENDER TROLLEY
FENDER TROLLEY
FENDER TROLLEY
PROBLEM FACED
•EXTRA MOVEMENT & FATIGUE OF OPERATOR
•2 NO. MANPOWER REQUIRED TO LIFT THE FENDER
•CHANCES OF ACIDENT
48. 48
MATERIAL
STORAGE
RACK
TABLE
Value Stream Mapping
DISMOUNTING assembly (Fender Fitment)
AFTER USING
MANIPULATOR
FENDER TROLLEY
FENDER TROLLEY
FENDER TROLLEY
FENDER TROLLEY
RESULTS AFTER USING MANIPULATOR
•EXTRA MOVEMENT & FATIGUE OF OPERATOR REDUCED
•OPERATOR MOVEMENT SAVED 16 METERS PER TRACTOR
•NOW 1 NO. MANPOWER REQUIRED FOR FENDER FITMENT
