This document summarizes the co-op experience of Nimish Yadav at an automotive manufacturing plant. It outlines their educational background in industrial engineering and production engineering. It then describes lessons learned around communication skills, leadership, responsibility, and teamwork. The document provides an overview of projects involving waste reduction, cycle time analysis, root cause analysis, and lean manufacturing tools. Specific kaizen events and improvements to production cells are then detailed. Finally, additional proposed solutions and opportunities for further improvement are presented.

1. Co-op Fall 2015
Nimish Yadav

2. Introduction
• My education and experience
– Industrial Engineer (MS, Clemson University)
– Production Engineer( B.Tech, VIT, India)
• Lean Six Sigma Green Belt and
application.
• Dr. Deming Philosophy.

3. Lesson Learned
• “Look at things from a zoom out view”
• Communication Skills.
• Leadership skill.
• Responsibility and Accountability.
• Team work.

4. Lesson Learned
• Minitab.
• Cognos Reporting.

5. Projects Overview
• Waste Detection, Documentation and Elimination.
• Cycle time study.
• Root Cause Analysis.
• Kaizen.
• 5S
• Job instruction manual changes.
• DDS Board & Enablers

6. Area of Concentration
• Automotive PED
• HPE Weld Cells

7. Kaizen W2411
• Moving 2 operators to 1.
• Addressing Sparks problem.
• Ergonomic- placing Ergo Mats

8. Kaizen W2955
• Implementing 5S
• Labeling the bins and making Checklist for items
• Addressing spark Problem

9. W6404
• Layout change- Standardized placement of bins.
• Moving Shelf to restrict motion.
• Moving Button press to ergonomic location
• Moving Light curtains to reduce motion.
• Marking Area for affordance

10. W6404

11. W6404

12. HPE & Rework Station
• Layout change to reduce material
handling.
• Reduce Dependency on Forklift trucks
• Better floor utilization.

13. HPE & Rework Station

14. Proposed Solutions
• Forklift Standardization
• Work undertaken for W2011, W2996.
• Removal of railing and modifying Light Curtains.
• Implementing 5S on all the Automotive PED cells.
• Started with W2955 and can be repeated in the similar fashion for other
machines.
• Removal of Hoists from W6404 for better floor utilization.
• Easier to move the bins and can help reduce dependency on Forklift drivers.

15. Proposed Solutions
• Labelling and colour coding bins on W2411 to avoid
confusion.
• Improve complicated fixture on W6401.
• 24 seconds to just load the part. ( side A)
• Have to use mallet.
• No Constraints or affordance.
• Economic use of power.
• Switch off fans and lights.
• Movement detection sensors in the storage area for lights.
• Use of Natural light.

16. Proposed Solutions
• Availability of Manual Forklift
• To transfer finish parts from one cell to another in HPE.
• Better design for Light Curtains
– Gallery Method Brainstorming session
– New design for W2519 and Programming change for W2480

17. Improvement Recorded

18. Opportunities for SSP
• Making Continuous Improvement a priority everyday.
• Improve communication to avoid missing target dates.
• Cultural change is difficult and the it is hardest change, but we have
to start thinking about improvement.
• Positive thinking is the key.
• Need to employ more Co-op every semester (career fair) for fresh
ideas.
• Dr. Deming – Process (lean) and Quality will go hand-in-hand.

19. Thank you