INDUSTRIAL IN-PLANT TRAINING

UNDER THE GUIDANCE OF-Mr. M. MAGDUM (D.G.M. Mfg Engg.)Mr. A. HARISH (A. M. Mfg Engg.)

PROJECT

BY-AMEYA MARGAJPANKAJ KHAIRNARAISSMS COE, PUNE-1

ACTIVITIES JAN 2012

FEB 2012

MAR 2012

APRIL 2012

MAY 2012

JUNE 2012

FINALIZE PROJECT

GATHER DATA

ANALYSE DATA

SELECT SOLUTION

IMPLEMENT

CLOSURE

TIMELINE

STREAMLINING THE ZIG-ZAG FLOW AND LINE BALANCING

CONTENTS:1. Defined hourly outputs for all cells depending upon the

customer requirement (i.e. TAKT Time) and Preparation of Standardized Work Charts according to Line Balancing .

2. Streamlining the Zigzag Flow.3. Analysis of Downtimes in Peripheral Assembly.4. Improvement projects for reducing inventory (i.e. Reducing Cost).5. Stabilization of process by monitoring and analysis through process

capability (Cp) and process capability index (Cpk) for Critical Processes.

PROBLEMS :- Line Balancing

• More operator idle time.• Improving Human efficiency.• Less formation ratio.

DATA COLLECTION:- Line balanced according to the cycle times taken

LINK TO ALL C.T. LINK TO ONLINE PDI

1. DEFINE STANDARD CYCLE TIMES FOR SBC, ROD CELL, ASSEMBLY & PDI

1 2 30

2

4

6

8

10

12

1412

8 8

DIA 22 FR BEFORE

OPERATORS

TIM

E(SE

C)

1 20

2

4

6

8

10

12

14

16

18

12

16

DIA 22 FR AFTER

OPERATORS

TIM

E(SE

C)

LINE BALANCING FOR ONLINE PDI (STRUT LINE ASSY) Assembly C.T. = 16sec

LINE BALANCING FOR ONLINE PDI (STRUT LINE ASSY) Assembly C.T. = 23sec

LINE BALANCING FOR ONLINE PDI (NEW LINE ASSY) Assembly C.T. = 21 sec

Assembly C.T. = 32 sec

LINE BALANCING FOR ONLINE PDI (NEW LINE ASSY)

STREAMLINING THE ZIG-ZAG FLOW AND LINE BALANCING

CONTENTS:1. Defined hourly outputs for all cells depending upon the customer

requirement (i.e. TAKT Time) and Preparation of Standardized Work Charts according to Line Balancing .

2. Streamlining the Zigzag Flow.3. Analysis of Downtimes in Peripheral Assembly.4. Improvement projects for reducing inventory (i.e. Reducing Cost).5. Stabilization of process by monitoring and analysis through process

capability (Cp) and process capability index (Cpk) for Critical Processes.

2. STREAMLINING THE ZIG ZAG FLOW (IN ASSEMBLY CELL)

STRUT LINE: W201 FR (BEFORE)

T

I/T check& B/v

Pressing

Torquing & Stacking M/c Oil Filling

Rod Guide press

Damping Force

Checking

Spinning

Rod

I/T

O/T T T

Gas filling

Striker Cap

Pressing

Gas Load

Check

Rod Assy

Seal Deflection

M/c

CONVEYOR

PDI

Issues:-1.Distance 2. Output per shift 3. Quality

Distance : 10.5m

I/T

STRUT LINE: W201 FR (AFTER)

BENEFITS:-• Distance Reduced by 1.5m• Cycle time reduced by 6 sec.• Output per shift increased

by 100 NOS. • Improved Quality.

Sticker Cap

Pressing

I/T check& B/v

Pressing

Torquing & Stacking M/c

Oil FillingRod

Guide press

Damping Force

Checking

Spinning

Rod

O/T

T

T T

Gas fillingGas Load

Check

Rod Assy

Seal Deflection

M/c

CONVEYOR PDI

Distance : 9 m

T

STREAMLINING THE ZIG ZAG FLOW(IN STRUT BODY CELL)

KNUCKLE BKT

PRESSING-1 (PV)

ROBO WELDING

TWO TORCH

WELDING

LEAK TESTING

HYDRAULIC ROLL

MARKING O/T

END CAP

CRIMPING

PROOF LOAD

TESTING

ROBO WELD CELL ( PRESENT)

Distance : 9.44 m

SPRING SEAT & KNUCKLE

BKT PRESSING -2

Issues:-1.Distance 2. Output per shift

ROBO WELD CELL ( PROPOSED)

T

KNUCKLE BKT PRESSING-1 (PV)

ROBO WELDING

TWO TORCH

WELDING

LEAK TESTING

HYDRAULIC ROLL

MARKING O/T

END CAP

CRIMPING

PROOF LOAD

TESTING

Distance : 7.92 m

SPRING SEAT & KNUCKLE

BKT PRESSING -2

BENEFITS:-• Distance reduced by 1.5 m• Operator walking time reduced by 3 seconds• Output per shift will increase by 23 NOS.

STREAMLINING THE ZIG-ZAG FLOW AND LINE BALANCING

CONTENTS:1. Defined hourly outputs for all cells depending upon the customer

requirement (i.e. TAKT Time) and Preparation of Standardized Work Charts according to Line Balancing

2. Streamlining the Zigzag Flow3. Analysis of Downtimes in Peripheral Assembly4. Improvement projects for reducing inventory (i.e. Reducing Cost)5. Stabilization of process by monitoring and analysis through process

capability (Cp) and process capability index (Cpk) for Critical Processes.

3. ANALYSIS OF DOWNTIMES IN PERIPHERAL ASSEMBLY

• PROBLEMS:-1. Material Shortage2. Trolley Shortage3. High Downtimes

• DATA COLLECTION:-1. Monitored line production for complete shift for 3 weeks.LINK TO DOWNTIME ANALYSIS SHEET.xls

• SOLUTIONS:-o Complete material necessary for one shift provided at once.o Separate bush fitting machine provided at online PDI.(W201 RR)

BENEFITS-1) Downtime due to material

shortage reduced.2) TLT reduced by 0.5 shift3) Material Travel distance

reduced by 25 m

STREAMLINING THE ZIG-ZAG FLOW AND LINE BALANCING

CONTENTS:1. Defined hourly outputs for all cells depending upon the customer

requirement (i.e. TAKT Time) and Preparation of Standardized Work Charts according to Line Balancing

2. Streamlining the Zigzag Flow3. Analysis of Downtimes in Peripheral Assembly4. Improvement projects for reducing inventory (i.e. Reducing

Cost)5. Stabilization of process by monitoring and analysis through process

capability (Cp) and process capability index (Cpk) for Critical Processes

4. DEFINITION OF WIP IN BETWEEN DIFFERENT PROCESSES

• PROBLEMS:-1. Undefined WIP in between rod welding and assembly,

piercing and assembly, autophoretic and assembly, assembly and PDI.

2. Frequent shortages due to undefined WIP.

• SOLUTION:-1. Developed an inventory model wherein WIP will be defined

with respect to the process bottleneck cycle time.2. WIP ALL MSW-ASSY.xlsx3. Defined area to keep this WIP.

STREAMLINING THE ZIG-ZAG FLOW AND LINE BALANCING

CONTENTS:1. Defined hourly outputs for all cells depending upon the customer

requirement (i.e. TAKT Time) and Preparation of Standardized Work Charts according to Line Balancing

2. Streamlining the Zigzag Flow3. Analysis of Downtimes in Peripheral Assembly4. Improvement projects for reducing inventory (i.e. Reducing Cost)5. Stabilization of process by monitoring and analysis through

process capability (Cp) and process capability index (Cpk) for Critical Processes

5. STABILIZATION OF OIL FILLING PROCESS

• What is Oil Filling Process ??

• PROBLEMS1. Variation in oil quantity.2. Frequent adjustment of Stopper length.3. Wastage of oil during set-up confirmation.

SR. NO. READING IN CC WEIGHT

1 225 192

2 226 193

3 226 193

4 226 193

5 228 196

6 228 196

7 228 196

8 228 296

9 230 197

10 205 177

11 205 177

12 230 197

13 230 197

14 230 197

15 230 197

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15190

195

200

205

210

215

220

225

230

235

VW RR(HBK) BEFORE

ANALYSIS:

SOLUTIONS:• Time delay program changed• Play in the piston cylinder arrangement completely eliminated• Provision of fixed stoppers instead of adjustable ones.

• Time Delay Program not adjusted properly• Presence of the play in piston cylinder arrangement• Use of adjustable stoppers as time delay program not

adjusted properly.

• PROCESS CAPABILITY

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15226

227

228

229

230

231

232

233

VW RR (HBK) AFTER

VW RR(HBK)

SR. NO. READINGS IN CC WEIGHT

1 230 197

2 230 197

3 230 197

4 228 196

5 230 197

6 230 197

7 230 197

8 230 197

9 230 197

10 230 197

11 232 198

12 232 198

13 230 197

14 230 197

15 230 197

BENEFITS:-

LINE BALANCING– Streamlined Process Flows.– Reduction in number of Operators by 2.– Human efficiency improvement for W201 FR from 43% to 60% – Increase in output per shift by 100 nos.

PROCESS CAPABILITY.– Quality improvement by process stabilization.

ANALYSIS OF DOWNTIMES– Material Shortage time reduced.

THANK YOU