lean project-improvements -fiber patch cord

Cost Optimization - Fiber Patch Cord

Problem Statement : • High Product Cost

Project LeaderRahul Vazurkar

TeamRahul Vazurkar Sushant DesaiSaish PalKedar BorkarShivani PrabhuSiddhesh Dessai

SponsorRajkumar Timmarayan

Project Timing Start Date End Date

Goal statement :• Reduce Product Cost

Business Impact : • Product Std Cost Reduction by 20%

Risk Assessment :•Machine breakdowns leading to increased down times

Go to Gamba (Process walk through)

USEFUL TIME : 1932 DMHDESIGN TIME : 2407 DMHINDUSTRIAL EFFICIENCY : 35 %

Cord preparation Connectorizing Crimping PolishingVisual Inspection

Heat Shrinking Testing Winding

Define

PackingFiber Patch Cord

Man Material Useful/Design Time

Measure Fiber Patch Cord

Assembling Cost

High man power deployed for assembling

High Material Cost involved at testing & packing stage

High Useful time and Design time

Man-Power Measure

•Man-Power required for assembling of Fiber Patch Cord is 9•High DT•Capacity Per Hour is 30

MeasureRaw Material Cost

Blister For Patch Cord

Test Certificate Plastic Bag 3*4

Glaze Card

SC Connector LC Connector

SM Duplex

MeasureTime study

Fiber Patch Cord Line Analyze

•UT= 215 DMH•DT = 261 DMH•KD = 82 %•Involves Glaze Card Preparation

Testing Packing

•UT= 273 DMH•DT = 341 DMH•KD = 80%•Involves test report preparation

•UT= 322.5 DMH•DT = 417 DMH•KD = 77 %•Offline activity•High DT as the operator moves out of the main line

Polishing

ImprovePolishing -Offline Polishing –Inside the U-line

Results

•Offline Activity•Operator wastes time (20 dmh) for polishing activity

•Wash basin provided inside the line•Time saved thus improving KD

Test report

Printed label

Improve Test report eliminated and replaced with auto test report label machine

Results•Test report preparation eliminated after Auto-test- printing machine •Testing involved Test Report Preparation

Blister

Glaze Card

Poly bag

Improve

Winding Fixture

Results•Packing involved glaze card preparation and blister packing

•New Fixture Provided for winding •Blisters eliminated and replaced with poly bag

Fiber Patch Cord Packing- Blister replaced with poly bags

11SPS-0159EN V01 Kaizen Report Template

RESULTSTime study

12SPS-0159EN V01 Kaizen Report Template

RESULTSLine Architecture

13SPS-0159EN V01 Kaizen Report Template

Raw Material

RESULTS

Blister For Patch Cord Test Certificate Plastic Bag 3*4 Poly Bag