1. The document discusses lean manufacturing and value stream mapping for a dismounting assembly line.
2. It identifies various stations on the line where cycle times are higher than the takt time, indicating bottlenecks. One such station is the tractor greasing station.
3. The tractor greasing station currently has a cycle time of 350 seconds with 42.8% non-value added activities and requires 2 operators. Changes are proposed to reduce waste, improve efficiency, and reduce manpower to 1 operator at this station.
This document summarizes the results of 5 kaizen (improvement) projects done on the dismounting assembly line of a tractor manufacturing plant. The 5 kaizen aimed to improve line efficiency by balancing workloads across stations. Kaizen 1-3 involved balancing work between stations like rear frame fitting and tractor greasing. Kaizen 4 combined fender seat and water separator fitting. Kaizen 5 balanced work for instrument plate, cover plate and 7 pin socket fitting stations. Through these changes, line efficiency improved from an initial 59.39% to a final 63.40% while reducing manpower from 73 to 38.
Caterpillar cat 120 g motor grader (prefix 87v) service repair manual (87v000...hhjsekmdmm
This document provides instructions for removing and installing a cylinder head on a 120G motor grader with 3304B and 3306B engines. The removal procedure involves disconnecting various components like fuel injection lines, exhaust manifolds, rocker shafts, and pushrods. Bolts are then removed to lift the cylinder head off the engine block. For installation, a new gasket is used and the cylinder head is placed back on with bolts torqued to specification. Proper cleaning and containment of fluids is emphasized throughout.
Case ih case international 7110 tractor service repair manualfjjsieskekfmmse
This document provides a shop manual for Case/International Magnum series tractors models 7110-7140. It includes an index of components and systems covered in the manual organized by starting paragraph number. It also includes condensed service data tables with specifications for the tractors. The document provides instructions for servicing components of the front axle on two-wheel drive models, including removing and installing front wheel bearings, spindles, adjusting tie rods and toe-in, and removing the axle main member.
This shop manual provides specifications and repair procedures for Ford tractor models 1100-2110. It includes an index listing repair sections by model number. The condensed service data section provides specifications such as engine details, tune-up procedures, fluid capacities, and torque specifications for each tractor model. Dual metric and imperial measurements are provided.
This document contains a table of contents and specifications for parts related to the engine, fuel, exhaust, cooling, air conditioning, and intake systems of a Massey Ferguson TH.8043 130 S3A telescopic handler. It includes over 50 numbered items with descriptions and part numbers for components such as the radiator, muffler, hoses, belts, sensors, and other engine accessories. The parts are grouped into sections for each vehicle system and subsystems.
Claas axos 340 310 (type a22) tractor service repair manualfjkskedmme
1. The document provides step-by-step instructions for removing and refitting the complete engine assembly on an Axos 340-310 tractor. It describes 27 individual operations to remove the engine and additional steps to refit it.
2. Key steps include draining fluids, disconnecting various lines and harnesses, removing accessories like the fuel tank and exhaust, and finally removing the engine by disconnecting it from the front chassis.
3. Refitting follows the removal steps in reverse, ensuring proper reconnection of all components and refilling of fluids.
This document provides a table of contents and specifications for engine parts of a Massey Ferguson 9560 combine from 2012-2014, including the cylinder block, engine and mounting components, fuel lines and filters, and engine electrical systems. It lists over 100 individual parts that make up these engine systems, providing part numbers, descriptions, and other technical details for each component.
Massey ferguson ideal class 7 combine parts catalogue manualfhjsekkemm
This document provides part numbers and descriptions for components related to the engine, starter, alternator, and air conditioning compressor for a Massey Ferguson Ideal Class 7 combine. It includes items such as engine mounts, belts, pulleys, bolts, filters, and the engine itself. The engine options covered include the T4F, ST4 and T3F.
This document summarizes the results of 5 kaizen (improvement) projects done on the dismounting assembly line of a tractor manufacturing plant. The 5 kaizen aimed to improve line efficiency by balancing workloads across stations. Kaizen 1-3 involved balancing work between stations like rear frame fitting and tractor greasing. Kaizen 4 combined fender seat and water separator fitting. Kaizen 5 balanced work for instrument plate, cover plate and 7 pin socket fitting stations. Through these changes, line efficiency improved from an initial 59.39% to a final 63.40% while reducing manpower from 73 to 38.
Caterpillar cat 120 g motor grader (prefix 87v) service repair manual (87v000...hhjsekmdmm
This document provides instructions for removing and installing a cylinder head on a 120G motor grader with 3304B and 3306B engines. The removal procedure involves disconnecting various components like fuel injection lines, exhaust manifolds, rocker shafts, and pushrods. Bolts are then removed to lift the cylinder head off the engine block. For installation, a new gasket is used and the cylinder head is placed back on with bolts torqued to specification. Proper cleaning and containment of fluids is emphasized throughout.
Case ih case international 7110 tractor service repair manualfjjsieskekfmmse
This document provides a shop manual for Case/International Magnum series tractors models 7110-7140. It includes an index of components and systems covered in the manual organized by starting paragraph number. It also includes condensed service data tables with specifications for the tractors. The document provides instructions for servicing components of the front axle on two-wheel drive models, including removing and installing front wheel bearings, spindles, adjusting tie rods and toe-in, and removing the axle main member.
This shop manual provides specifications and repair procedures for Ford tractor models 1100-2110. It includes an index listing repair sections by model number. The condensed service data section provides specifications such as engine details, tune-up procedures, fluid capacities, and torque specifications for each tractor model. Dual metric and imperial measurements are provided.
This document contains a table of contents and specifications for parts related to the engine, fuel, exhaust, cooling, air conditioning, and intake systems of a Massey Ferguson TH.8043 130 S3A telescopic handler. It includes over 50 numbered items with descriptions and part numbers for components such as the radiator, muffler, hoses, belts, sensors, and other engine accessories. The parts are grouped into sections for each vehicle system and subsystems.
Claas axos 340 310 (type a22) tractor service repair manualfjkskedmme
1. The document provides step-by-step instructions for removing and refitting the complete engine assembly on an Axos 340-310 tractor. It describes 27 individual operations to remove the engine and additional steps to refit it.
2. Key steps include draining fluids, disconnecting various lines and harnesses, removing accessories like the fuel tank and exhaust, and finally removing the engine by disconnecting it from the front chassis.
3. Refitting follows the removal steps in reverse, ensuring proper reconnection of all components and refilling of fluids.
This document provides a table of contents and specifications for engine parts of a Massey Ferguson 9560 combine from 2012-2014, including the cylinder block, engine and mounting components, fuel lines and filters, and engine electrical systems. It lists over 100 individual parts that make up these engine systems, providing part numbers, descriptions, and other technical details for each component.
Massey ferguson ideal class 7 combine parts catalogue manualfhjsekkemm
This document provides part numbers and descriptions for components related to the engine, starter, alternator, and air conditioning compressor for a Massey Ferguson Ideal Class 7 combine. It includes items such as engine mounts, belts, pulleys, bolts, filters, and the engine itself. The engine options covered include the T4F, ST4 and T3F.
The document provides an overview of DTK Group of Industries' manufacturing facilities in Aurangabad and Pune, India. It details the company's vision, facilities, workforce, equipment, processes, quality systems, major customers, and products. Key points include: DTK has over 60,000 square feet of manufacturing space across four facilities, employs over 125 people, and has a wide range of pressing, welding, and machining equipment. The company aims to be a preferred supplier of sheet metal and machined components through continually upgrading its technology and processes.
The document provides information on Total Productive Maintenance (TPM) activities for the Dhampur Distillery department for February 2022. It introduces TPM, outlines its objectives such as zero defects and accidents, and describes the 8 pillars of TPM including autonomous maintenance, planned maintenance, and safety/environmental health. Status updates are provided for various ongoing initiatives within each pillar like number of issues tagged/resolved, kaizen activities, breakdown records, and EHS activities for the past month. Overall the document reports on the department's TPM program aimed at improving productivity, quality and safety.
The document summarizes a Kaizen event held from March 24-28, 2008 to improve processes in the hard dies work area. The 11-person team achieved their goals of implementing 9 safety improvements, improving 5S by 1 point, reducing setup times for brake presses and plasma cutting, and reducing work-in-process levels. Standard work was also developed. Next steps include additional equipment, posting standard work, backup press programs, addressing press repeatability, and identifying spare parts.
This case study describes how MTM tools and Lean principles were used to improve the efficiency of an outdoor cooking appliance production line. The production line originally had 4 operators working in separate workstations with significant wait times. MTM analysis was used to measure task times and identify opportunities. The line was rebalanced into a U-shape with tasks grouped by zone. Operators now push carts between zones, completing full product cycles. This reduced waste and improved flexibility. MTM databases were created to standardize times and enable balancing for new products. The result was a 99.6% balanced line with 4 operators, increasing productivity by 34.68%.
This document provides a proposal for establishing a new ISO-9001:2000 certified spring manufacturing plant. Some key points:
- The plant would manufacture 75,000 springs annually for railway rolling stock. It would have 460 employees and require an initial investment of Rs. 120 crores.
- The plant would have various machinery for spring production including furnaces, coiling machines, tempering furnaces, and testing equipment.
- Quality objectives include meeting production targets while minimizing rejections and improving employee skills. Quality policies commit to meeting customer requirements and legal compliance.
- The proposal outlines the production process, machinery, staffing needs, and requests assistance to address bottlenecks like outdated equipment and improve communications.
Internship at HONDA MOTOR CYCLE SCOOTER INDIA LIMITEDsgrsoni45
The document discusses the benefits of a co-op education model for students, industries, and institutions. It provides details about a training program for a student named Sagar Soni at Honda Motorcycles And Scooter India Limited. The training involves learning about various production processes and machine shop layouts. It also discusses parameters for crank shafts and their effects, preventative maintenance of gauges, and ways to reduce rejections and engine noise.
This document provides information about planning and scheduling for a metro rail project in Hyderabad, India. It includes details about various project managers and consultants involved in the project. It then discusses the advantages of planning and scheduling, different project phases, knowledge areas, and tools used for planning like Primavera, Microsoft Project, and Excel. It also covers work breakdown structures, resource and organization breakdown structures, activity costing, scheduling techniques, progress measurement, and variance analysis. Overall, the document outlines key concepts and processes for project planning and control used for large infrastructure projects.
Hyundai r35 7 mini excavator service repair manualfhsejkdkmem
This service manual provides maintenance and repair instructions for the machine. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repairs for individual machine systems. Proper maintenance following the schedules and procedures in the manual is important to ensure the long life of the machine and prevent failures.
Hyundai r35 7 mini excavator service repair manualfhsjekkdkem
This service manual provides maintenance and repair instructions for the machine. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repairs for individual machine systems. Proper maintenance following the schedules and procedures in the manual is important to ensure the long life of the machine and prevent failures.
Hyundai r35 7 mini excavator service repair manualidkkdmmdd
This service manual provides instructions for maintenance and repair of the excavator. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repair/replacement of parts. Proper maintenance is important to ensure long life of the machine and prevent failures. The manual aims to help effectively carry out necessary repairs by providing accurate product descriptions and correct repair procedures.
Hyundai r35 7 mini excavator service repair manualsoeldksejdksem
This service manual provides instructions for maintaining and repairing an excavator. It outlines the machine's components and systems, inspection and maintenance procedures, and troubleshooting guides. The manual explains that proper maintenance is crucial to ensuring the long life of the machine and preventing failures. It also provides part numbers and specifications to aid technicians in repairs.
Hyundai r15 7 mini excavator service repair manualfjjskekdmmse
This service manual provides maintenance instructions for machine serial number HY1570001~. It details inspection, repair, and replacement procedures for the machine's various components to help technicians efficiently service the equipment. The manual covers safety procedures, component outlines, hydraulic and electrical systems, troubleshooting guides, and maintenance schedules.
Massey ferguson 1760 m compact tractor parts catalogue manualfjjskejdmdn
The document is a table of contents and service manual sections for a Massey Ferguson 1760M compact tractor. It includes sections on the engine and fuel systems, steering, drivetrain, brakes, hydraulics, electrical systems, cab, chassis, decals, wheels, implement lift system and accessories. Each section includes detailed part listings, diagrams and specifications for repairing and servicing the tractor systems.
Review W 26 & Plan Week 27 2022_MUM.pptxssuserb71d4d
The document contains a production review and plan for Week 26 and Week 27 at the JOB SITE BAS – TANJUNG ENIM site for PT MANGGALA Engineering Department. It includes production data from all pits, equipment allocation and availability, productivity analysis, and production projections showing expected overburden removal of 143,585 BCM for Week 27. Safety topics and schedules are also included.
Hyundai r15 7 mini excavator service repair manualfjjsekdmme
This service manual provides maintenance and repair instructions for the HY1570001 excavator. It outlines inspection and maintenance procedures, including checking fluid levels, lubricating parts, inspecting wear items, and adjusting components. The manual emphasizes performing repairs correctly using the proper tools, materials, and techniques. Maintaining the excavator according to the schedules in the manual will help ensure long life and prevent failures.
Hyundai r15 7 mini excavator service repair manualfhsjejkdmem
This service manual provides maintenance and repair instructions for the HY1570001 excavator. It outlines inspection and maintenance procedures, including checking fluid levels, lubricating parts, inspecting wear items, and adjusting components. The manual emphasizes performing repairs correctly using the proper tools, fasteners, and techniques. It also provides troubleshooting information and specifications to aid technicians in efficiently servicing the excavator.
The document provides an overview of DTK Group of Industries' manufacturing facilities in Aurangabad and Pune, India. It details the company's vision, facilities, workforce, equipment, processes, quality systems, major customers, and products. Key points include: DTK has over 60,000 square feet of manufacturing space across four facilities, employs over 125 people, and has a wide range of pressing, welding, and machining equipment. The company aims to be a preferred supplier of sheet metal and machined components through continually upgrading its technology and processes.
The document provides information on Total Productive Maintenance (TPM) activities for the Dhampur Distillery department for February 2022. It introduces TPM, outlines its objectives such as zero defects and accidents, and describes the 8 pillars of TPM including autonomous maintenance, planned maintenance, and safety/environmental health. Status updates are provided for various ongoing initiatives within each pillar like number of issues tagged/resolved, kaizen activities, breakdown records, and EHS activities for the past month. Overall the document reports on the department's TPM program aimed at improving productivity, quality and safety.
The document summarizes a Kaizen event held from March 24-28, 2008 to improve processes in the hard dies work area. The 11-person team achieved their goals of implementing 9 safety improvements, improving 5S by 1 point, reducing setup times for brake presses and plasma cutting, and reducing work-in-process levels. Standard work was also developed. Next steps include additional equipment, posting standard work, backup press programs, addressing press repeatability, and identifying spare parts.
This case study describes how MTM tools and Lean principles were used to improve the efficiency of an outdoor cooking appliance production line. The production line originally had 4 operators working in separate workstations with significant wait times. MTM analysis was used to measure task times and identify opportunities. The line was rebalanced into a U-shape with tasks grouped by zone. Operators now push carts between zones, completing full product cycles. This reduced waste and improved flexibility. MTM databases were created to standardize times and enable balancing for new products. The result was a 99.6% balanced line with 4 operators, increasing productivity by 34.68%.
This document provides a proposal for establishing a new ISO-9001:2000 certified spring manufacturing plant. Some key points:
- The plant would manufacture 75,000 springs annually for railway rolling stock. It would have 460 employees and require an initial investment of Rs. 120 crores.
- The plant would have various machinery for spring production including furnaces, coiling machines, tempering furnaces, and testing equipment.
- Quality objectives include meeting production targets while minimizing rejections and improving employee skills. Quality policies commit to meeting customer requirements and legal compliance.
- The proposal outlines the production process, machinery, staffing needs, and requests assistance to address bottlenecks like outdated equipment and improve communications.
Internship at HONDA MOTOR CYCLE SCOOTER INDIA LIMITEDsgrsoni45
The document discusses the benefits of a co-op education model for students, industries, and institutions. It provides details about a training program for a student named Sagar Soni at Honda Motorcycles And Scooter India Limited. The training involves learning about various production processes and machine shop layouts. It also discusses parameters for crank shafts and their effects, preventative maintenance of gauges, and ways to reduce rejections and engine noise.
This document provides information about planning and scheduling for a metro rail project in Hyderabad, India. It includes details about various project managers and consultants involved in the project. It then discusses the advantages of planning and scheduling, different project phases, knowledge areas, and tools used for planning like Primavera, Microsoft Project, and Excel. It also covers work breakdown structures, resource and organization breakdown structures, activity costing, scheduling techniques, progress measurement, and variance analysis. Overall, the document outlines key concepts and processes for project planning and control used for large infrastructure projects.
Hyundai r35 7 mini excavator service repair manualfhsejkdkmem
This service manual provides maintenance and repair instructions for the machine. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repairs for individual machine systems. Proper maintenance following the schedules and procedures in the manual is important to ensure the long life of the machine and prevent failures.
Hyundai r35 7 mini excavator service repair manualfhsjekkdkem
This service manual provides maintenance and repair instructions for the machine. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repairs for individual machine systems. Proper maintenance following the schedules and procedures in the manual is important to ensure the long life of the machine and prevent failures.
Hyundai r35 7 mini excavator service repair manualidkkdmmdd
This service manual provides instructions for maintenance and repair of the excavator. It includes sections on safety precautions, machine outlines and specifications, maintenance schedules, troubleshooting, and repair/replacement of parts. Proper maintenance is important to ensure long life of the machine and prevent failures. The manual aims to help effectively carry out necessary repairs by providing accurate product descriptions and correct repair procedures.
Hyundai r35 7 mini excavator service repair manualsoeldksejdksem
This service manual provides instructions for maintaining and repairing an excavator. It outlines the machine's components and systems, inspection and maintenance procedures, and troubleshooting guides. The manual explains that proper maintenance is crucial to ensuring the long life of the machine and preventing failures. It also provides part numbers and specifications to aid technicians in repairs.
Hyundai r15 7 mini excavator service repair manualfjjskekdmmse
This service manual provides maintenance instructions for machine serial number HY1570001~. It details inspection, repair, and replacement procedures for the machine's various components to help technicians efficiently service the equipment. The manual covers safety procedures, component outlines, hydraulic and electrical systems, troubleshooting guides, and maintenance schedules.
Massey ferguson 1760 m compact tractor parts catalogue manualfjjskejdmdn
The document is a table of contents and service manual sections for a Massey Ferguson 1760M compact tractor. It includes sections on the engine and fuel systems, steering, drivetrain, brakes, hydraulics, electrical systems, cab, chassis, decals, wheels, implement lift system and accessories. Each section includes detailed part listings, diagrams and specifications for repairing and servicing the tractor systems.
Review W 26 & Plan Week 27 2022_MUM.pptxssuserb71d4d
The document contains a production review and plan for Week 26 and Week 27 at the JOB SITE BAS – TANJUNG ENIM site for PT MANGGALA Engineering Department. It includes production data from all pits, equipment allocation and availability, productivity analysis, and production projections showing expected overburden removal of 143,585 BCM for Week 27. Safety topics and schedules are also included.
Hyundai r15 7 mini excavator service repair manualfjjsekdmme
This service manual provides maintenance and repair instructions for the HY1570001 excavator. It outlines inspection and maintenance procedures, including checking fluid levels, lubricating parts, inspecting wear items, and adjusting components. The manual emphasizes performing repairs correctly using the proper tools, materials, and techniques. Maintaining the excavator according to the schedules in the manual will help ensure long life and prevent failures.
Hyundai r15 7 mini excavator service repair manualfhsjejkdmem
This service manual provides maintenance and repair instructions for the HY1570001 excavator. It outlines inspection and maintenance procedures, including checking fluid levels, lubricating parts, inspecting wear items, and adjusting components. The manual emphasizes performing repairs correctly using the proper tools, fasteners, and techniques. It also provides troubleshooting information and specifications to aid technicians in efficiently servicing the excavator.
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