IRJET- Productivity Improvement in Manufacturing Industry using Lean Tools
project ppt
1. 1
PROJECT REPORT ON INDUSTRIAL TRAINNING
IN
FIAT INDIA AUTOMOBILES LIMITED
Submitted By:-
Parwinder Singh
Karamjit Singh Nagra
Mandeep Singh
AJAY KUMAR NIGAM
Assistant General Manager
Trimming Plant Head
Power Train Division, FIAT.
Submitted To:-
B-19, Ranjangaon MIDC Industrial Area, Pune
2. INTRODUCTION:-
FIAT is one of the leading Automobile Industry in the world. The
Engines and Transmissions produced by FIAT has been appreciated globally
in terms of its quality, performance and efficiency. It is said that every third
car in the world has FIAT’s Engine.
The plant capacity is to produce 3.5 lacs power train and 2.5 lacs car per
annum. Though the manufacturing system is highly automated with highly
skilled manpower, the FTQ (First Time Quality) percentage is 97.89% that
means there is a rejection of around 2.11%.
Our project is solely related to Introduction of New Product (EURO-5
ENGINE) and to reduce the Bottleneck time of Trimming Assembly line, to
reduce N.V.A (Non Value Added) activities and Insaturation present in line
and to increase the overall production. Simultaneously reducing the cost per
engine.
The Company has defined some targets in terms of quality and
performance, so that every single unit has to pass through various quality
checks to assure the quality of the product delivered. So keeping in mind all
these targets we tried to reduce as much waste time as we could.
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4. LIST OF ABBREVATIONS:-
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N.V.A.A Non Value Added Activity
S.V.A.A Semi Value Added Activity
V.A.A Value Added Activity
BN Time Bottleneck Time
TWTP The Way to Teach People
HERCA Human Error Root Cause Analysis
PDCA Plan Do Check and Act
OPL One Point Lesson
5W1H Who, What, Where, When, Why,
How
5. PLANING OF ACTIVITIES:-
Keeping in mind the vastness of the activities it was important to go for
procedure which would fetch us the most desired results efficiently and
effectively. We tried to considered all the factors by which we can execute
are project without errors.
Planning: It involves defining the problem, collecting data, selecting theme,
defining targets and analysis.
Bottleneck time of Trimming line was very high(0.85). Due to this
insaturation and N.V.A activities in line were very high.
We thoroughly analyzed the Activity breakdown sheet and noted all the
activities performed on every station in line.
Do: Implementing things or changes finalized in planning section.
Distribution of some activities on other O.P Stations and elimination of
various N.V.A activities was done.
Check: After ‘Do’ operation, running experimentation, feedback is to be
taken to analyze and evaluate the thing implemented.
Act: It involves standardization, lesson learned and horizontal development.
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6. Project 1
SAFETY Improvement
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FIAT AUTO has decided to raise its standards to world class level, as reflected
in World Class Manufacturing (WCM) route map. Together with leading
European and Japanese experts, we have defined our production system that
embraces the entire organization of the factory, involving quality system,
maintenance system, cost management and logistic with in evolutionary
perspective.
FIAT is a World Class Manufacturer where SAFETY and its Awareness is an
essential value.
7. Personal Protective Equipments (PPE) required
for SAFETY:-
1. Hand Gloves
2. Safety Mask
3. Hand Sleeve
4. Safety Goggle
5. Ear plug
6. Helmet
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8. Example
While keeping the pallet for PWT unloading it could dash to the operator,
thus guards were provided to restrict the pallet position in order to
safeguard the operator.
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Fig. No 1
13. Example 1
In february,2013 there were 9 defects
related to Alternator bracket bolt loose.
To find its root cause we used the tool
TWTP (The Way to Teach People). On
using TWTP it was found that the root
cause was process weakness.
The root cause was eliminated by
changing the torquing sequence of the
Alternator Bracket and an OPL (One
Point Lesson) showing the torquing
sequence was displayed at O.P 70 were
the above operation is carried out.
(Alternator Bracket bolt loose)
ONE POINT LESSON(OPL) SHEET
Changed Torquing Sequence of Alternator Bracket.
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Fig. No 5
14. PROJECT 3
(NVAA Reduction in present Trimming Assembly Line, Bottleneck Time
Reduction & In saturation Reduction)
PRODUCTIVITY IMPROVEMENT
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20. BENIFITS
REDUCTION OF FORKLIFT – 1 NO
FORKLIFT CHARGES PER ANUM RS. 3,12,000/-
DRIVER SALARY PER ANUM RS. 1,49,760/-
• TOTAL BENEFIT RS.4,61,760/-
TOTAL COST INCURRED RS. 7,920/-
B/C = 58.30
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21. N.V.A.A REDUCTION BY MERGING PDI-
PRODUCTION WITH CARE AND PDI-QUALITY
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PDI PRODUCTION and PDI QUALITY, which were earlier done offline are now
being done online. After doing a thorough study of the inspection points of
CARE, PDI PRODUCTION and PDI QUALITY it was found that PDI
PRODUCTION had most of the inspection points common with CARE and PDI
QUALITY, therefore a proposal to eliminate PDI PRODUCTION has been made.
Eliminating PDI PRODUCTION will reduce Non-Value Added Activity (NVAA)
and In saturation present in main line.
24. ANALYSIS :-
STATION ACTIVITY CYCLE TIME (min) NVAA TIME (min)
OP-145 CARE 1 0.804 0.804
OP-280 CARE 2 0.810 0.810
OP-270 PDI-PRODUCTION 0.816 0.816
OP-300 PDI-QUALITY 1 0.818 0.818
OP-310 PDI-QUALITY 2 0.818 0.818
All 3 stations are inspection activities of Power train
STATION ACTIVITY NO.OF CHECK POINTS
OP-260 CARE 24
OP-270 PDI-PRODUCTION 9(D)/21(P)
OP-280 PDI-QUALITY 31(D)/23(P)
COUNTERMEASURE :-
DELETING THE PDI-PRODUCTION OPERATION BY COMPILING THE COMMON CHECK
POINTS WITH CARE AND PDI-QUALITY OPERATION AND LINE BALANCING
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Table No. 6
Table No. 7
28. Proposal for
Reduction in Bottleneck & In saturation time
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
op
10.1
op
10.2
op
20
op
40.1
op
40.2
op
40A
op
45
op
50
op
60
op
70
op
80
op
90
op
95
op
100
op
110
op
130
op
135
op
140
op
150
op
160
op
180
op
190
op
195
op
210
op
220
op
230
op
240
op
260
Actual line
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
op
10.1
op
10.2
op
20
op
40.1
op
40.2
op
40A
op
45
op
50
op
60
op
70
op
80
op
90
op
95
op
100
op
110
op
130
op
135
op
140
op
150
op
160
op
180
op
190
op
195
op
210
op
220
op
230
op
240
op
260
Prop. line
29. Operation
Stations Observations Action Taken Benefits
op 40.1 N.V.A was very high due to twice the rotation of
pallet.
Time taken reduced from
0.850 to 0.747. Earlier
this was use to be
Bottleneck.
op 40.2 N.V.A was very high due to twice the rotation of
pallet.
Pick up M12 nut -1 Nos and M12 bolt -1 Nos ,
shifted to OP 40A
Station cycle time and
insaturation decreased
op 40A Insaturation was very high at this operation 1)Pick up M12 nut -1 Nos and M12 bolt -1 Nos ,
Loose fitment of Counter weight shifted to
OP110. 2) Final tourqing of M12 no 1 shifted
here.
Insaturation decreased
op 45 Tourqing of M12 nut- 1 Nos Shifted to OP 40A Bottelneck Time
Reduced from .811 To
0.809
op 70 POKE YOKE present so marking of bolts not
required
Marking of bolts eliminated 1) BN time Reduced 2)
NVA reduced
op 90 ENR present so marking of bolts is not required
because POKE YOKE present
Marking of bolts eliminated BT time and NVA
reduced
op 110 Insaturation was very high at this operation Loose fitment of counter weight added in this
operation
Insaturation decreased
op 140 ENR present so marking of bolts is not required
because POKE YOKE present
Marking of bolts eliminated 1) BN time Reduced 2)
NVA reduced
op 220 ENR present marking of bolts not required Marking of bolts eliminated Insaturation decreased
op 240 Insaturation present is more Cleaning of the carrier side face and baricentrc
bracket face and apply gum can be shifted here.
Insaturation decreased
op 260 Cleaning of the carrier side face and barcentric
bracket face and apply gum can be shifted to OP
240
Cleaning of the carrier side face and baricentrc
bracket face and apply gum can be shifted to OP
240
Bottleneck time and NVA
reduced
Modifications:-
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30. Reduction In Bottleneck Time
Actual
Bottleneck Time
Prop. Bottleneck
Time
Series1 0.85 0.788
0.75
0.76
0.77
0.78
0.79
0.8
0.81
0.82
0.83
0.84
0.85
0.86
Bottleneck Time (min)
30
Reduction is
beneficial
Reduction in In saturation
Actual Insaturation Prop. Insaturation
Series1 4.038 2.765
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
In saturation (min)
Reduction is
beneficial
31. In saturation Reduction Benefits Converted into Money:-
Actual insaturation 4.038
Prop. Insaturation 2.765
Improvement/ cycle 1.273
Improvement/ day 612.31
Converted to hrs 10.205
Annual Improvement 3061.6
Monitory benefit Rs.1,83,694
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32. N.V.A.A Reduction
Actual Prop.
Time 6.339 5.969
5.7
5.8
5.9
6
6.1
6.2
6.3
6.4
N.V.A.A Reduction
Percentage N.V.A.A reduction = 5.8
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Reduction is
beneficial
N.V.A.A benefit converted into
Money:-
Actual NVAA 6.339
Prop. NVAA 5.969
Improvement/ cycle 0.37
Improvement/ day 178
Converted to hrs 2.966
Annual Imrovement 889.9
Monitory benefit Rs.53,391
33. Increase in Production
Actual production Prop. Production
Series1 481 519
460
470
480
490
500
510
520
530
NO.ofEngines/day
Increase in Production
Percentage increase in Productivity = 7.9
33
Increase is
beneficial
Increase in powertrain/day =38
Productivity Benefit:-
Manpower/Powertrain 0.071
Benefit of
Manpower/day 2.6861
Per annum 805.82
Monitory benefit 3,86,794
Total benefit = Rs 6,23,879.0788
34. NEW PRODUCT INTRODUCTION
(EURO-5 95 HP 1.3 SDE)
PROJECT 4
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OBJECTIVE:-
Assembly of 1.3 SDE TATA 95HP EURO 5 in existing Production Line (Trimming
Assembly Line) with Desired Quality, Safety and Minimum cost.
ACTIVITY PLAN:-
• Comparison of Euro-4 and Euro-5 operations.
• Prepare the list of tooling, jig, fixtures and equipment required.
• Identify the modification of existing processes.
• Implement the changes required in existing processes.
• Identify the sources for procurement.
• Conduct Trial Assembly of EURO-5 Engine on Existing line.
• Prepare the list of exclusive operations.
• Record the observations.
• Reaction plan to deviations / Observations.
• Correction of Process .
• Trial run.
• PPAP
• Delivery
35. Comparison of EURO-4 & EURO -5 operations:-
On comparing the History Sheet of EURO-4 AND EURO-5 engine we
observed the following additional parts need to assemble EURO 5 Engine
:-
• Oil rubber cap
• Post Card sensor connector bracket
• Bracket for throttle body
• Adaptor with O Ring
• Lambda sensor clips
• Gasket TC outlet to assembly pipe
• Reverse indicator W/H connection
• Temperature sensor
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36. PROCESS MODIFICATION:-
Process No-1 :- Assembling and Disassembling of A Mount bracket.
As per TML, first batch of imported 96 engines will come with FIAT Imported Engines
Mounting bracket (A Mount) which needs to be replaced at FIAL also an additional bracket
for Temp. sensor is to be assembled along with engine mounting bkt (A mount). We cannot
perform this activity on Mainline due to its cycle time and non-availability of tool required. So
this activity to be performed on Pilot Line itself.
Tools Required:- ENR with 60Nm Torque, Reaction arm to resist Torque.
Problem Description:-Disassembly and Assembly of ‘A’ mount bracket activity will result
heavy thrust on the arm of operator.
Proposal:-
1. Engine will transfer to Engine assembly to dismantle and assemble of ‘A’ mount bracket
and again transfer to Trim Plant.
2. Facility to be provided in Trim–Pilot line for dismantle and assemble of ‘A’ mount
bracket .
Proposal Validation 1:-
1. Engine will transfer to Engine assembly to dismantle and assemble of ‘A’ mount bracket
and again transfer to Trim Plant.
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37. Disadvantage :-
• Transport arrangement to be made for engine transfer from Trim Plant to engine
assembly and Vice –Versa
• Pallet to be made for storage of engine
• Chances of damage of engine while multiple handling
• Time consuming activity
• Additional man power required for transport activity
Proposal Validation 2:-
2. Facility to be provided in Trim – Pilot line for dismantle and assemble of ‘A’
mount bracket
Available Source:-
Nut runner of 60 Nm torque
Feasibility Study:-
1. Dismantling and assembling of ‘A’ mount bracket is possible in pilot line and transferred
to main line for further assembly by minimum movement.
2. But no arrangement to resist the reaction force developed by nut runner while
performing activity (60 Nm)
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38. Idea:-
Provision of reaction arm for 60 Nm torque nut runner
Cost of Development of Reaction Arm :-
1. Out source
2. In-house
Out source:-
Development cost of Reaction arm is
Rs 348242/-
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39. In-House:-
Reaction arm can be made in house with minimum cost than out source
Execution :-
Materials for manufacturing the reaction arm are used from scrap
Solution :-
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41. Process No-2 :- Clutch kit assembly
Imported engines will come without clutch kit; Clutch kit assembly is carryover from
existing Tata BS4 SDE90. This activity can’t be performed on Main Line due to cycle
time and unavailability of tools required on the line as earlier this operation is
performed in Engine Plant itself. So this activity also to be performed on Pilot Line.
Tools Required:-
• Clutch Plate Pressing Tool
• Jig Fixture
Action Taken:-
Station was created by availing the tools required on Pilot Line. For
clutch kit, first preference to be given to M/s. Luk & incase not available
M/s. Valeo to be used.
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