Fsfbglexibility Improvement 06.01,24.pdf

06.01.2024 BAL/BAVA KAIZEN COMPETITION (Q3 : Oct-Dec’ 2023) Slide No. [ 1 of 31]
1
Metalman Micro Turners Plant-1
IATF 16949:2016 & ISO 14001: 2015 & EHS
45001:2018
Certified Company
PLOT NO 17&15, SECTOR 9
IIE, SIDCUL INDUSTRIAL AREA ,PANTNAGAR
WELCOME
TO
ThirdBAL/BAVA Kaizen Competition (2023-24)

Introduction & Products
Overview
Frame Assembly
Frame
Swing Arm
Silencer
Products

Kaizen Theme
Company name
Team Members
BAL/BAVA KAIZEN COMPETITION
Q3 (Oct-Dec’ 2023)
Flexibility Improvement
Metalman Micro Turners, P’ Nagar
S.No. Name Role
1 Mr. Sunil Kandpal Leader
2 Mr. Abhishek Nathani Member
3 Mr. Prem Member

Why
Flexibility
High
Investment
for new
Robots & M/C
Space
Constraint
A big
challenge for
company to
offer a wide
variety of
products to
it’s customer
A big
challenge to
rapidly
increase the
production
level
Business
Development
Theme-Background

KMI,KEI & KPI Linkage with The Kaizen Theme
PLANT VISION/MISSION
KMI(Key Management
Indicators
KEI(Key Effectiveness
Indicators)
KPI(Key Performance
indicators)
Pillar
Vision
Increase Production
OEE Improvement
Equipment Failure Loss
Reduction
PM/KK/QM/DM/JH
To be first choice of customers,
suppliers, employees and stake
holders.
Setup Down Time
Reduction
Tool Change Loss Reduction
Mission
Startup Loss Reduction
(Flexibility Improvement)
Achieve operational excellence by
enhancing plant productivity
through all employee team work,
low cost manufacturing, on time
delivery to customer, high level
quality adherence.
Minnor Stoppages and
Idling Loss Reduction
Speed Loss Reduction
Defects and Rework Loss
Reduction
Production/Hr
Improvement
Line Organization Loss
Reduction
DM/KK
Business Development
Flexibility Improvements on
Line
DM/KK/QM

Approach
Level of
Flexibility
Definition
Development
stage
Product
Level
Common Parts
Level 1
Common parts between different
family of products
DFM
Level 2
Common parts within a product
family
DFM
Common
Dimensions
Level 3
Common location, resting, clamping
& orientation
DFM
Process
Level
Common Tooling's Level 4
Cells capable to manufacture
uncommon component
Process planning
Quick Change Level 5
Cells capable to manufacture
uncommon component with Faster
Set-up Change
Process planning
Approach

Methodology
1-Product wise Mapping for
Flexibility Improvement
2-Stage wise Mapping of
Selected Line for Setup Loss
3-Observe/Record All the
Activity with Time
4.1-Internal to External
Activities
4.2-ECRS 4.3-Series to Parallel
5-Result &
Benefits
6-Effectiveness
Monitoring
7-HD &
Sustenance
Actions
4.4-NVA Elimination

1-Mapping of All Product’s Line
FY2018
1-Platina BS4
2-Pulsar K1 BS4
3-K19 BS4
4-K1R BS4
FY2020
1-K1R BS6
2-K1 BS6
3-K19 BS6
4-Platina BS4
5-Pulsar K1 BS4
6-K19 C
7-K1R BS4
S.No. Product No. of Lines Models
1 Frame 4 7
2 Silencer 1 1
Mapping of finding the scope for flexibility improvement:-
Model at 2018 Capacity (Nos/Day) Model at 2020
K1 BS4 900 K19 BS4 / K1 BS4/K19 BS6 / K1 BS6
K19/K19C BS4 700 K1 BS6 / K19 BS6/K19C
Platina BS4 700 Platina BS6
K1R BS4 700 K1R BS4 / K1R BS6

Model Flexibility ×
Platina Frame BS6
K19C/K19 BS6/K1 BS6
K1R Frame BS4
K1R Frame BS6
K1 Frame BS4
Model Flexibility
Model Flexibility √
Model Flexibility √
Line-1
Line-2
Line-3
Line-4
Status of Frame Lines
Due to high demand and multiple
variant models of pulsar family, we
selected line no. 4 to make it
flexible line for meeting customer
need.
√
K1 Frame BS6
K19 Frame BS4
K19 Frame BS6

40.0
35.0
10.0 10.0
58.0
20.0
0
10
20
30
40
50
60
70
F-30/40 F-50/60 F-65/70 F-90/100 F-120/130 F-150/160
Frame K19 OBD/K1 OBD to K1 BS4, K19 BS4
Maximum Setup
time 58 Min.
Min.
2-Stage wise Mapping (Understanding of Problem)
Setup time / Occ.
Target -10 Min.
Changing elements in 4M 1T from K1OBD/K19 OBD to K1 BS4 & K19 BS4
Setup
time/Occ.
Stage 4M&T change K1 OBD/K19 OBD K1 BS4 K19 BS4
Material - - -
Method (Robot Programing) - - -
Tool (Fixture Unit) - - -
Material - √ √
Method (Robot Programing) - √ √
Tool (Fixture Unit) - √ √
Material - √ √
Material - √ √
Material - - -
Material - √ √
Material - √ √
Material - √ √
Material - - -
F-150/160
F-170
F-30/40
F-50/60
F-65/70
F-80
F-90/100
F-120/130
F-10/20
Flexibility Level-5
erial - √ √
hod (Robot Programing) - √ √
(Fixture Unit) - - -
erial - - -
hod (Robot Programing) - - -
erial - √ √
erial - √ √
(Fixture Unit) - √ √
erial - √ √
(Fixture Unit) - √ √
erial - - -
hod (Robot Programing) - - -
Material - √ √
Material - - -
Material - √ √
Material - √ √
Material - √ √
Material - - -
F-150/160
F-170
F-65/70
F-80
F-90/100
F-120/130

3-Observe the Activity (Background)
Before
0 5 10 15 20 25 30 35 40 45 50 55 60
1
Store Person remove old material on line
2
Feed the changeover material on line directly
3
All changeover unit/block carry out from Tool Room
for RR unit & Flap bkt 2 nos
4
Fitter dismantle welding units from fixture, open 4
bolts & 2 nos of dowel from base fixture
5
Fitter remove cylinder pneumatic push fittings
6
Remove old units from fixture & placing new units on
fixture
7
Other model fixture units assembly on fixture 4 bolts
& 2 dowels
8
Fitter placing cylinder pneumatic push fittings
9
Re-teaching done on every joint
10
Check the visual welding defect after Re-teaching
Material
Changeover
External Activities
S.No. Changeover Activities Carried Out Internal/External
Stage-120/130 (Time in Min)
Fixture
Changeover
Welding
Program
Setting
Internal Activities
Total Time 58 min

3-Background (Fixture Changeover)
Unit For Changeover
Changeover From K1 Bs6 to K1 Bs4
Step 1:
Pneumatic connection
Dismantling For Input
and Output Pipe
Step 3:
Existing Unit Dismantling Dowell
Bolt Dismantling K1 BS6
Step 5:
New Unit
Assembled K1 BS4
Step 6:
Cylinder Pneumatic Fitting
Step 7:
Reed Switch Mtg in Cylinder
Step 8:
Setup Change
Complete
Step 2:
Reed Switch Dismantling from
Cylinder
Total Set up Time From K1
Bs6 to K1 Bs4 :- 23Min
Step 4:
Vacant Unit

4.1-Internal to External
Activities 4.2-ECRS
4.3-Series to Parallel
4.4-NVA Elimination
4-Brain-storming

Tackle with Challenges to make the Line Flexible
We need to make the line flexible for new models. We have following challenges which are
given below:-
• Few quantity of
material are kept inside
the cell before the setup
Commonize the material
in both model through
raising DFM
•To reduce Setup Time
through design change
of the fixture’s unit for
quick changeover
• Separate program for
each model (Master) are
made and interlocked
with master call
• Poka Yoke done on
fixture
Man: Wrong part
welding due to
same appearance
of few parts
Method: Setup
loss due to robot
re-teaching after
model changeover.
Material: Feeding
of model wise
material inside the
cell Mix up of
material due to
same appearance
and same profile
Tool: Setup Loss
due to change in
fixture’s unit.
Challenge
Action-1 Action-2
Action-3
Action-4

Action Taken
S. No. Changeover Before Condition Activity
Total
Time
(Min.)
Action Plan Status
Current
status
(Total
time in
Min.)
1
Material
Changeover
Store person Remove existing Material from line .
Remove
Activity
10
Kept next model
material in plastic bin
(Qty.- 20 Nos) before
setup change
Done 0
2 Feed the changeover Material on Line Directly
Fixed
Activity
3
Fixture
Changeover
All Change-Over Unit/Block carry out from Tool
Room for RR unit & Flap Bkt. 2 nos.
Remove
Activity
10
Stage wise place given
for RR unit & Flap bkt.
Units
Done 0
4
nos bolts & 2 nos of Dowell.
Remove
Activity
5
Common Bolting block
designed for easy
bolting for other model
Done 0
5
Fitter removes cylinder pneumatic Connectors &
Reed Switch .
Remove
Activity
5
6
Removing old units from fixture & Placing New
units on fixture. Fixed
Activity
3
Done 8
5
7
Other model Fixture units assembly on fixture 4
Bolts & 2 Dowels
8
Fitter placing cylinder pneumatic push Fittings,
Provide Reed Switch in Cylinder.
Fixed
Activity
5
9
Welding
Program Setting
Re-teaching Done on Every Joint
Fixed
Activity
10
Separate Welding
Programs for each
model Only Master
calling
Done 2
10
Check the Visual Welding defect activity after Re-
teaching
Inspection 5
Total Time - Before 58 min Total Time - After 10 min
Internal
to
External
NVA
elimination
Elimination of 4
& 5 no. activity
and Combine
the base block

Action
Changeover From K1 Bs6 to K19 Bs6
Step 1:
Units For Changeover
Step 3:
Changing the master block
makes changeover flexible
and easy for different units
Step 2:
Replacing the changeover
block by newly designed
Master Dummy Block.
Master Block
for Changeover
Total Set up Time From K1
Bs6 to K1 Bs4 :- 8 Min

5-Activity of Setup Change (After)
Before
After
0 5 10 15 20 25 30 35 40 45 50 55 60
1
Store Person remove old material on line
2
Feed the changeover material on line directly
3
All changeover unit/block carry out from Tool Room
for RR unit & Flap bkt 2 nos
4
bolts & 2 nos of dowel from base fixture
5
Fitter remove cylinder pneumatic push fittings
6
Remove old units from fixture & placing new units on
fixture
7
Other model fixture units assembly on fixture 4 bolts
& 2 dowels
8
Fitter placing cylinder pneumatic push fittings
9
Re-teaching done on every joint
10
Check the visual welding defect after Re-teaching
Material
Changeover
External Activities
S.No. Changeover Activities Carried Out Internal/External
Stage-120/130 (Time in Min)
Fixture
Changeover
Welding
Program
Setting
Internal Activities
Total Time 10 min
Flexibility
Level-4

1-Receiving of Drawing 2-Process feasibility Study
3A-If Process Feasible
3A-Go For Development
3B-If Process difficult to Feasible
3B-Raise DFM (Difficult
for Manufacturing)
Sharing of Problems for
Part manufacturing
Deviation from Customer
Part develop as per DFM
Methodology for Flexibility Level-4 to 1
Accepted
Not accepted

Understanding of Problem
Problem:-Main Step fixture changeover time is more at F-60 during changeover from K1
OBD to K19 BS4
Background:-Part (Main Step) profile is common and locating hole’s CD are different
43 mm
46 mm
Setup time from K1 OBD to K19 BS4 is
30 min

Why-Why Analysis, Root Cause & Kaizen Idea
Why-1
• Setup time is more for main step
Why-2
• Changing in Main step Fixture’s unit
Why-3
• Main Step Bush CD is different from other
model
Root Cause:-Main Step Bush CD is different from other model
Kaizen Idea:- Commonize the bush CD of K1 & K19 model

Before/After Comparison
Before After
Main Step Bush CD-43 mm in K1 OBD and
46 mm in K19 BS4
Main Step Bush CD-46 mm which is
common in both model K1 OBD & K19
BS4
43 mm
46 mm
46 mm
K1 OBD
K19 BS4
Common Part in both model in
K1 OBD and K19 BS4
Countermeasure:-Commonized the bush CD with dimension 46mm in both model (K1 and K19).

Theme: To reduce the Setup loss at F-60 Stage in K1 Line Implementation Date
Present Status: Main Step fixture changeover time is more at F-60 during changeover from K1 OBD to K19 BS4 11/07/2023
BEFORE AFTER Result:
ANALYSIS:
W1: Setup time is more for main step
W2: Changing in Main step Fixture’s unit
W3: Main Step Bush CD is different from other model
Kaizen Idea :Commonize the bush CD of K1 & K19
model
Countermeasure : Commonized the bush CD with
dimension 46mm in both model (K1 and K19)
Root Cause :Main Step Bush CD is different from
other model
Benefit: Productivity improved
H.D.: .: NA Sustenance : Check point added in PM Sheet
Kaizen-03
30
0
0
10
20
30
40
Before
After
Fixture unit Setup
Time
100%
Min
43 mm
46 mm
K1
OBD
K19
BS4
46 mm
Flexibility
Level-1

Results of set-up time activity
40
35
10 10
58
20
3 3 4
7
10
3
0
10
20
30
40
50
60
F-30/40 F-50/60 F-65/70 F-90/100 F-120/130 F-150/160
Frame Pulsar K19 OBD to K1 BS4/K1 BS6/K19 BS4
Before
After
Setup
Time/Occ.
Min.
82% setup
time
reduction

Results & Benefits
P
Productivity
improved by
25%
Q
Sustain
C
Reduce Improved
D
Timely Improved
M
S
Line-4 Before Flexibility After Flexibility
Models K1 BS4
K1BS4
K19 BS4
K1 BS6
K19 BS6
Capacity/Day 900 1200
Capacity/Month 22500 30000

Effectiveness Monitoring
Validation Report for RR Unit & flap bkt’s fixture elements Sample Inspection Report for Main Step Bush

Kaizen Applicability Summary & HD Status
Kaizen Summary at K19 Line
Sr. No. Stage F - 30 F-40 F-50 F - 60 F - 70 F - 80 F - 130 F - 140 F - 150 F - 160 F - 170
1
Place provided for
keeping fixture
elements at
welding stage.
a x a a a a a a x x a
2
Provided common
base for both
models changing
blocks
x x x a x a x a x x x
3
Common parts
between different
family of products
and within a
family of product
x x x a x x x x x x x
Legend: Applicable a Not Applicable x
Horizontal Deployment:-K1R Line

Sustenance Actions
Point added in PM check Sheet

Learnings
TEAM
SPIRIT
UNDERSTANDING EACH
OTHER
SKILL
IMPROVED
SELF
CONFIDENCE
LEARNINGS
PROBLEM SOLVING
TECH.
COMPUTER
SKILL
COMMUNICATION
PRESENTATION
SKILL

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