1. Project : Robotic Cell Utilization By Shifting S106 CCB Assy
Welding Fixture To P405/09 CCB Assy Line.
Plan Actual
Start Date 01.12.2022 25.02.2023
Completion Date 20.03.2023
Track Components LTD (Unit – IV)
Gate No. 390, Vill. – Nighoje,
Tal. – Khed, Dist. – Pune,
Maharashtra – 410501
Production Department
Current Status : Standardization
Team Name Department
Mentor Girish Bhendegave Plant Head
Leader Girish Yadav Production
Member
Sangeet Raman E & D
Prince Verma Production
Rahul Agnihotri E & D
Yogesh Kadam Production
Deepak Darekar Production
2. GEMBA OBSERVATION OF S106 (CURRENT PROCESS)
CYCLE TIME STUDY-S106-CCB
Cell No. Station No. Discription Cycle Time Remarks Actual Calculated
Total Cell
Time (Sec.) Production Per Shift
(85% Efficiency)
OP-20 & OP-30
Robo
cell-1
OP-10
LOADING TIME 280
loading and unloading time
is ZERO
135
277
59
UNLODING TIME 15
WELD TIME 135
OP-20
LOADING TIME 105
65
UNLODING TIME 15
WELD TIME 65
OP-30
LOADING TIME 95
77
UNLODING TIME 15
WELD TIME 77
OP-40 & OP-50
Robo
cell-2
OP-40
LOADING TIME 88
loading and unloading time
is ZERO
150
363
UNLODING TIME 15
WELD TIME 150
OP-50
LOADING TIME 90
109
UNLODING TIME 15
WELD TIME 109
OP-60
LOADING TIME 62
104
UNLODING TIME 15
WELD TIME 104
3. S106 CURRENT PRODUCTION STATUS
S106 CURRENT PRODUCTION :-
Production Per Shift (A Or B)= (25200/363)*0.85 *** Actual Production Time – 420 Min Out
= 59 No's Of 510 Min
Production Per Shift (C)= (21600/363)*0.85 *** Actual Production Time – 360 Min Out
= 50 No's Of 420 Min
Total Production per Day= (A+B+C)
= 59+59+50
= 168 No's
S106 CCB Total Production Per Day = 168 No's
Remark :- No Production Plan From Last 6 Months As Per Customer Schedule
We Used S106 CCB
Assy Line Only 0.15%
In This FY’22-23.
4. GEMBA OBSERVATION P405 (CURRENT PROCESS)
CYCLE TIME STUDY-P405-CCB
cell no.
station
no.
Discription cycle time remarks Actual calculated Total cell time
Total production /
shift(85% eff)
Robo cell-
1
OP-20 and OP-30
OP-20
LOADING TIME 28
loading unloading is
zero because of one
robot is working in two
fixtures
93
194
110
UNLODING TIME 10
WELD TIME 93
OP-30
LOADING TIME 25
101
UNLODING TIME 10
WELD TIME 101
Robo cell-
2
OP-40 and OP-50
OP-40
LOADING TIME 25
loading unloading is
zero because of one
robot is working in two
fixtures
89
189
UNLODING TIME 10
WELD TIME 89
OP-50
LOADING TIME 35
100
UNLODING TIME 10
WELD TIME 100
5. P405 CURRENT PRODUCTION STATUS
P405/09 CURRENT PRODUCTION :-
Production Per Shift (A Or B)= (25200/194)*0.85 *** Actual Production Time – 420 Min Out
= 110 No's Of 510 Min
Production Per Shift (C)= (21600/194)*0.85 *** Actual Production Time – 360 Min Out
= 94 No's Of 420 Min
Total Production per Day= (A+B+C)
= 110+110+94
= 314 No's
P405/09 Total Production Per Day = 314 No's
Remark :- Very Less Production Plan (40 No’s/Day Only) From Last 3 Months As
Per Customer Schedule
We Used P405/09 CCB
Assy Line Only 19% In
This FY’22-23.
6. FY’22-23 Monthly Dispatch Summary Sheet Of S106 & P405/09
Cross Car Beam Assy (0112AAZ06360N)
FY'22-23 Monthly Summary
1-Apr-22 to 15-Feb-23
Serial Number Month Dispatch Qty. (No's)
Max. Dispatch Qty.
(No's)
1 APRIL'22 1
2 MAY'22 0
3 JUNE'22 45 45 No's
4 JULY'22 9
5 AUGUST'22 0
6 SEPTEMBER'22 0
7 OCTOBER'22 0
8 NOVEMBER'22 0
9 DECEMBER'22 0
10 JANUARY'23 0
11 FEBRUARY'23 5
12 MARCH'23
GRAND TOTAL 60
Average Production Of S106 CCB Assy :- 6 No’s Per Month.
Remarks :- We Used S106 CCB Assy Line Only 0.15% In FY’22-23.
Cross Car Beam Assy (0112AAR01660N / 3210N/ 0420N)
FY'22-23 Monthly Summary
1-Apr-22 to 15-Feb-23
Serial
Number
Month
Dispatch Quantity (No's)
1660N 3210N 0420N
Total Supro CCB
(1660/3210N/0420N)
1 APRIL'22 378 42 0 420
2 MAY'22 1700 104 80 1884
3 JUNE'22 1426 109 125 1660
4 JULY'22 1366 23 83 1472
5 AUGUST'22 2078 303 105 2486
6 SEPTEMBER'22 2205 175 126 2506
7 OCTOBER'22 1659 189 0 1848
8 NOVEMBER'22 1218 105 84 1407
9 DECEMBER'22 612 68 63 743
10 JANUARY'23 733 134 63 930
11 FEBRUARY'23 461 21 21 503
12 MARCH'23
GRAND TOTAL 13836 1273 750 15859
Average Production Of P405/09 CCB Assy :- 1510 No’s Per Month.
Remarks :- We Used P405/09 CCB Assy Line Only 19% In FY’22-23.
7. INNOVATIVE IDEAS
Innovative Ideas For Robotic Cell Utilization Of S106 CCB
1. 2760N LHD Supro Part Deleted So, Fixture Eliminated From P405/09
CCB Assy Line.
2. S106 Fixture OP20 Shifted To Robotic Cell 2 In S106 Line & Both
Fixture (OP20 & 60) Used As Docable Fixture As Per Requirement.
3. S106 Fixture OP10 Shifted To Robotic Cell 2 In P405/09 Line.
4. S106 Fixture OP30 Shifted To Robotic Cell 1 In P405/09 Line.
8. P405/09 & S106 CCB ASSY CURRENT LAYOUT
S106 CURRENT
LAYOUT
P405/09
CURRENT LAYOUT
9. P405/09 & S106 CCB ASSY PROPOSED LAYOUT
S106
PROPOSED
LAYOUT
P405/09
PROPOSED
LAYOUT
ROBOTIC CELL 2
ROBOTIC CELL 1
ROBOTIC CELL 1
ROBOTIC CELL 2
Fix. OP 20 & 60
Are Docable Or
Movable
Robotic Cell 1,
Robot Released
For Upcoming
Dev. Projects
10. Tangible & Intangible Benefits :
Tangible Benefits:
1. Proper Robotic Cell Utilization By Shifting Welding Fixture From S106 To P405/09 CCB Line.
2. One Robot Can Be Released For New Upcoming Development Project Which Can Save Up To 15 Lacs.
3. One Welding Fixture Can Be Released After Elimination From P405/09 For Maintenance Use.
4. P405/09 & S106 CCB Assy Line Are Slow Moving Projects & It’s Customer Requirement Is Very Less From Last
Six Months
Intangible Benefits:
1. Customer Satisfaction.
2. Moral Improvement.
3. Space Utilization On Shop Floor.
3. One Robotic Cost Saving.
RESULTS
