line efficiency
TRANSCRIPT
11
PROJECT ON LEAN
22
TEAM STRUCTURE
MR. KV KALRA
MANPREET SINGH
SHIVIT BANSAL
PRABHJOT SINGH
MUKESH KUMAR
ANKUR PRATAP SINGH
KIRANVIR SINGH
Our team consisted of 6 members.This project was done under guidance of Mr. KV Kalra (HOD, Paint Shop)
33
4
LINE EFFICIENCY (DISMOUNTING LINE)
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 6735 = 59.39% 270*42
• Low line efficiency in terms of manpower deployed in dismounting line (59.39%).
• Non-uniform work load distribution.
Problem/Present Status
5
DISMOUNTING ASSY
CURRENT STATUS TARGET(5.26%
IMPROVEMENT)
LINE EFFICIENCY 59.39% 64.65%
TOTAL MANPOWER 73 NO. TO REDUCE 6.5NO. MANPOWER
LEAD TIME 85 MINUTES(13TRCTR/HR)
15 TRCTRS/ HR(105 TRCTRS/SHIFT)
DISMOUNTING ASSEMBLY
CURRENT STATE OF DISMOUNTING ASSEMBLY LINE
NO. OF LHS STATION 16
NO.OF RHS STATION 15
NO. OF SUB ASSY STATION 4
TOTAL 35
6
STATION CYCLE TIME
NVA TIME NVA% MANPOWER REQUIRED
MANPOWER DEPLOYED
EFFICIENCY
TRACTOR GREASING
350 120 34.28% 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%
7 PIN SOCKET 200 20 10% 1 1 74%
REAR FRAME 150 30 20% 1 1 55.5%
SHEET METAL LHS 300 115 38.33% 2 3 37%
SHEET METAL RHS 300 120 40% 2 3 37%
FRONT SHEET METAL
130 40 30% 1 1 48.14%
TAKT TIME PER TRACTOR 270 SECONDS
TARGETED STATION FOR INCREASING EFFICIENCY
7
TR
AIL
ER H
OO
K
CLU
TCH
TIE
RO
D
RIG
HT
FEN
DER
TR
ACT
OR
GR
EASI
NG
RIG
HT
REA
R W
HEE
L
FEN
DER
SEA
T
OIL
DR
AIN
7-PI
N S
OCK
ET S
/A A
ND
FI
TM
ENT
FUEL
TA
NK
ST
RA
P
DA
SHB
OA
RD
PLA
TE
S/A
INST
RU
MEN
T P
LAT
E S/
A
ELEC
TR
ICA
L CO
NN
ECT
ION
S
DA
TA
PLA
TE
LHS
SHEE
T M
ETA
L
FRO
NT
GR
ILL
SILE
NCE
R
0
50
100
150
200
250
300
350
400
230 225
100
150
180200
350
200
230 230
120100
70
150
200180
120
350
280
180
315
240230
200 200
335
300 300
170
220
150
230
YAMAZUMI CHARTC
YCL
E T
IME
( in
s)
STAGES UNDER CONSIDERATION
TAKT TIME = 270s
8
OPERATION TIMEREAR FRAME S/A
35
PICKING PF MATERIAL AND MOVING TOWARDS LINE 25
BOLT TIOGHTENING OF FRONT FRAME 30
DRIVE CABLE FITMENT40
TAKING REAR FRAME TO LINE 10
REAR FRAME FITMENT10
TOTAL TIME 1507 PIN SOCKET FITMENT
30
REFLECTOR PLATE FITMENT 30
TOTAL TIME 210
BASIS90 TPS
KAIZEN 1
Present Proposal
BALANCING OF OPERATIONS OF REAR FRAME AND 7 PIN SOCKET FITMENT
OPERATION TIMEREAR FRAME S/A
35
PICKING PF MATERIAL AND MOVING TOWARDS LINE 25
BOLT TIOGHTENING OF FRONT FRAME 30
DRIVE CABLE FITMENT40
TAKING REAR FRAME TO LINE10
REAR FRAME FITMENT10
9
TR
AIL
ER H
OO
K
DR
IVER
SEA
T
CLU
TCH
TIE
RO
D
HO
RN
, FA
N B
ELT
RIG
HT
FEN
DER
LEFT
FEN
DER
TR
ACT
OR
GR
EASI
NG
FRO
NT
WH
EELS
RIG
HT
REA
R W
HEE
L
LEFT
REA
R W
HEE
L
FEN
DER
SEA
T
WA
TER
SEP
AR
AT
OR
OIL
DR
AIN
REA
R F
RA
ME
AN
D 7
-PIN
SO
CKET
FIT
MEN
T
7-PI
N S
OCK
ET S
/A
FUEL
TA
NK
FUEL
TA
NK
ST
RA
P
RA
DIA
TO
R
DA
SHB
OA
RD
PLA
TE
S/A
DA
SHB
OA
RD
FIT
MEN
T
INST
RU
MEN
T P
LAT
E S/
A
INST
RU
MEN
T P
LAT
E FI
TM
ENT
ELEC
TR
ICA
L CO
NN
ECT
ION
S
STEE
RIN
G W
HEE
L
DA
TA
PLA
TE
BA
TT
ERY
LHS
SHEE
T M
ETA
L
RH
S SH
EET
MET
AL
FRO
NT
GR
ILL
AIR
CLE
AN
ER, M
IRR
OR
SILE
NCE
R
DIE
SEL,
DIF
FER
ENT
IAL
OIL
CO
OLA
NT
0
50
100
150
200
250
300
350
400
230 225
100
150180
200
350
200230 230
120100
70
210
140
180
120
350
280
180
315
240 230200 200
335300 300
170
220
150
230
YAMAZUMI CHART(AFTER KAIZEN 1)
CY
CLE
TIM
E (
in s
)STAGES UNDER KAIZEN
BETTER WORK DISTRIBUTION
TAKT TIME = 270s
10
EFFECT OF KAIZEN 1 ON LINE EFFICIENCY :-
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 6595 = 59.39% 270*41
PRESENT AFTER KAIZEN 1
55
56
57
58
59
60
61
59.39 59.57
LIN
E EF
FICI
ENCY
(%
)
K1
BETTER
11
KAIZEN 2
OPERATION TIME( seconds)
MANPOWER DEPLOYED
STICKER PASTING 40
7 NO. MANPOWER
BATTERY COVER FITMENT
30
BONNET LOCK S/A
40
PANEL LOCK FITMENT
45
RHS SHEET METAL FITMENT
180
BONNET FITMENT
55
LHS SHEET METAL FITMENT
235
FRONT GRILL FITMENT
130
TOTAL TIME 755
OPERATION TIME (s) MANPOWER DEPLOYED
STICKER PASTING 40 735FE & 843OSM panel sticker given to Contractor
BATTERY COVER FITMENT
30 Fitted at Paint shop
OPERATION TIME(s) MANPOWER DEPLOYED
FRONT GRILL, NO. PLATE FITMENT & BATTERY COVER TIGHTENING
160 1
RHS SHEET METAL FITMENT 180 1
BONNET AND HEADLIGHT FITMENT
105 1
LHS SHEET METAL FITMENT 185 1
TOTAL TIME AND TOTAL MANPOWER
610 4
LINE BALANCING AT SHEET METAL FITMENT
Present Proposal
BONNET LOCK S/A 40 1No. Contractor Manpower
PANEL LOCK FITMENT 45
Already implemented
Proposed actions
MANPOWER REQUIRED AFTER ABOVE IMPLEMENTATIONS
12
TR
AIL
ER H
OO
K
DR
IVER
SEA
T
CLU
TCH
TIE
RO
D
HO
RN
, FA
N B
ELT
RIG
HT
FEN
DER
LEFT
FEN
DER
TR
ACT
OR
GR
EASI
NG
FRO
NT
WH
EELS
RIG
HT
REA
R W
HEE
L
LEFT
REA
R W
HEE
L
FEN
DER
SEA
T
WA
TER
SEP
AR
AT
OR
OIL
DR
AIN
REA
R F
RA
ME
AN
D 7
-PIN
SO
CKET
FIT
MEN
T
7-PI
N S
OCK
ET S
/A
FUEL
TA
NK
FUEL
TA
NK
ST
RA
P
RA
DIA
TO
R
DA
SHB
OA
RD
PLA
TE
S/A
DA
SHB
OA
RD
FIT
MEN
T
INST
RU
MEN
T P
LAT
E S/
A
INST
RU
MEN
T P
LAT
E FI
TM
ENT
ELEC
TR
ICA
L CO
NN
ECT
ION
S
STEE
RIN
G W
HEE
L
DA
TA
PLA
TE
BA
TT
ERY
LHS
SHEE
T M
ETA
L
RH
S SH
EET
MET
AL
FRO
NT
GR
ILL
HEA
DLI
GH
T C
OV
ER A
ND
BO
NN
ET
AIR
CLE
AN
ER, M
IRR
OR
SILE
NCE
R
DIE
SEL,
DIF
FER
ENT
IAL
OIL
CO
OLA
NT
0
50
100
150
200
250
300
350
400
230 225
100
150180
200 205 200230 230
120100
70
210
140
180
120
350
280
180
315
240 230200 200
335
185 180160
105
220
150
230
YAMAZUMI CHART(AFTER KAIZEN 2)
CYCL
E T
IME
( in
s)
STAGES UNDER KAIZEN
3 NO. MAN-POWER RE-
DUCED
TAKT TIME = 270s
13
EFFECT OF KAIZEN 2 ON LINE EFFICIENCY :-
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 6590 = 62.58% 270* 39
AFTER KAIZEN 1
AFTER KAIZEN 2
55
56
57
58
59
60
61
62
63
59.39
62.58
LIN
E EF
FICI
ENCY
(%
)
K2
BETTER
14
KAIZEN 3
OPERATION TIME( seconds)
MANPOWER DEPLOYED
REMOVING OF OLD CAPS 60
2 NO. MANPOWER
PICK GUN MOVE TO TRACTOR 5
GREASING ALL 19 POINTS 125
CLEANING EXTRA GREASE 40
PLACING THE GUN BACK 5
MOVE TO PICK NEW CAPS 5
PLACING CAP ON GRESE POINTS 105
MOVE BACK TO STAGE 5
TOTAL 350
OPERATION TIME SAVING (s)
METHOD REQUIRED
GREASING OF TIE RODS, LEVELLING ROD, TOP LINK (TOTAL 7 POINTS)
45 To be offloaded
IMPLEMENTATION OF FLIP TYPE CAP REMOVAL & GREASING IN ONE GO
60
NO. OF REDUCED GREASE POINT CAP(7 NO.)
40
TOTAL 145
OPERATION TIME(s) MANPOWER DEPLOYED
PICK GUN MOVE TO TRACTOR 5
1 NO. MANPOWER
GREASING 12 POINTS 80
CLEANING EXTRA GREASE 40
PLACING THE GUN BACK 5PLACING CAP ON GREASE
POINTS 70MOVE BACK TO STAGE 5
TOTAL 205
LINE BALANCING AT TRACTOR GREASING STATION
Present Proposal
MANPOWER REQUIRED AFTER ABOVE IMPLEMENTATIONS
15
TR
AIL
ER H
OO
K
DR
IVER
SEA
T
CLU
TCH
TIE
RO
D
HO
RN
, FA
N B
ELT
RIG
HT
FEN
DER
LEFT
FEN
DER
TR
ACT
OR
GR
EASI
NG
FRO
NT
WH
EELS
RIG
HT
REA
R W
HEE
L
LEFT
REA
R W
HEE
L
FEN
DER
SEA
T
WA
TER
SEP
AR
AT
OR
OIL
DR
AIN
REA
R F
RA
ME
AN
D 7
-PIN
SO
CKET
FIT
MEN
T
7-PI
N S
OCK
ET S
/A
FUEL
TA
NK
FUEL
TA
NK
ST
RA
P
RA
DIA
TO
R
DA
SHB
OA
RD
PLA
TE
S/A
DA
SHB
OA
RD
FIT
MEN
T
INST
RU
MEN
T P
LAT
E S/
A
INST
RU
MEN
T P
LAT
E FI
TM
ENT
ELEC
TR
ICA
L CO
NN
ECT
ION
S
STEE
RIN
G W
HEE
L
DA
TA
PLA
TE
BA
TT
ERY
LHS
SHEE
T M
ETA
L
RH
S SH
EET
MET
AL
FRO
NT
GR
ILL
HEA
DLI
GH
T C
OV
ER A
ND
BO
NN
ET
AIR
CLE
AN
ER, M
IRR
OR
SILE
NCE
R
DIE
SEL,
DIF
FER
ENT
IAL
OIL
CO
OLA
NT
0
50
100
150
200
250
300
350
400
230 225
100
150180
200 205 200230 230
120100
70
210
140
180
120
350
280
180
315
240 230200 200
335
185 180160
105
220
150
230
YAMAZUMI CHART(AFTER KAIZEN 3)
CY
CLE
TIM
E (
in s
)STAGES UNDER KAIZEN
1NO. MAN-POWER RE-
DUCED
TAKT TIME = 270s
16
EFFECT OF KAIZEN 3 ON LINE EFFICIENCY :-
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 6445 = 62.82% 270* 38
BETTER
AFTER KAIZEN 2
AFTER KAIZEN 3
55
60
65
70
62.58 62.82
LIN
E E
FFIC
IEN
CY
( %
)
K3
17
OPERATION TIME (S) MANPOWER DEPLOYED
TOTAL CYCLE TIME FOR WATER SEPARATOR FITMENT
100
1FENDER STICKER PASTING 40
TOTAL 140
KAIZEN 4LINE BALANCING AT FENDER SEAT & WATER SEPARATOR FITMENT
OPERATION TIME (S)MANPOWER DEPLOYED
TOTAL CYCLE TIME FOR FENDER SEAT FITMENT
125 1
TOTAL CYCLE TIME FOR WATER SEPARATOR FITMENT
100 1
TOTAL 225 2
Present Proposal
OPERATION TIME (S) MANPOWER DEPLOYED
TOTAL CYCLE TIME FOR FENDER SEAT FITMENT
125
1CHASIS STICKER PASTING 20
TOTAL 145
BASIS90 TPS
18
TR
AIL
ER H
OO
K
DR
IVER
SEA
T
CLU
TCH
TIE
RO
D
HO
RN
, FA
N B
ELT
RIG
HT
FEN
DER
LEFT
FEN
DER
TR
ACT
OR
GR
EASI
NG
FRO
NT
WH
EELS
RIG
HT
REA
R W
HEE
L
LEFT
REA
R W
HEE
L
FEN
DER
SEA
T
WA
TER
SEP
AR
AT
OR
OIL
DR
AIN
REA
R F
RA
ME
AN
D 7
-PIN
SO
CKET
FIT
MEN
T
7-PI
N S
OCK
ET S
/A
FUEL
TA
NK
FUEL
TA
NK
ST
RA
P
RA
DIA
TO
R
DA
SHB
OA
RD
PLA
TE
S/A
DA
SHB
OA
RD
FIT
MEN
T
INST
RU
MEN
T P
LAT
E S/
A
INST
RU
MEN
T P
LAT
E FI
TM
ENT
ELEC
TR
ICA
L CO
NN
ECT
ION
S
STEE
RIN
G W
HEE
L
DA
TA
PLA
TE
BA
TT
ERY
LHS
SHEE
T M
ETA
L
RH
S SH
EET
MET
AL
FRO
NT
GR
ILL
HEA
DLI
GH
T C
OV
ER A
ND
BO
NN
ET
AIR
CLE
AN
ER, M
IRR
OR
SILE
NCE
R
DIE
SEL,
DIF
FER
ENT
IAL
OIL
CO
OLA
NT
0
50
100
150
200
250
300
350
400
230 225
100
150180
200 205 200230 230
145 140
70
210
140
180
120
350
280
180
315
240 230200 200
335
185 180160
105
220
150
230
YAMAZUMI CHART(AFTER KAIZEN 4)
CY
CLE
TIM
E (
in s
)STAGES UNDER KAIZEN
BETTER WORK DISTRIBUTION
TAKT TIME = 270s
19
EFFECT OF KAIZEN 4 ON LINE EFFICIENCY :-
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 6505 = 63.40% 270* 38
BETTER
AFTER KAIZEN 3
AFTER KAIZEN 4
55
60
65
70
62.82 63.4
LIN
E E
FFIC
IEN
CY
( %
)
K4
20
KAIZEN 5
OPERATIONTIME (sec)
MANPOWER DEPLOYED /SHIFT
EFFECTIVENESS
INSTRUMNET PLATE S/A
315 2UNDERUTILIZATION
OF 0.5 NO. MANPOWER
COVER PLATE S/A
280 2
UNDERUTILIZATION OF 0.7 NO.
MANPOWER
7 PIN SOCKET S/A
150 1
UNDERUTILIZATION OF 0.30 NO. MANPOWER
TOTAL 745 5 1.5 NO. MANPOWER UNDERUTILIZED
OPERATIONTIME(s) MANPOWER
REQUIRED
INSTRUMNET PLATE S/A
630 3
COVER PLATE S/A 5604
7 PIN SOCKET S/A 300
TOTAL 1490 7
LINE BALANCING AT INSTRUMENT PLATE , COVER PLATE , 7 PIN SOCKET S/A
Present Proposal
Proposed actions:IF WE PERFORM ALL THESE OPERATIONS IN ONE SINGLE SHIFT (GENERAL SHIFT) FOR BOTH THE SHIFTS WE CAN SAVE 3 NO. MANPOWER
MANPOWER REQUIRED AFTER ABOVE IMPLEMENTATIONS
•MANPOWER REQUIRED IN ONE SHIFT = 5•THEREFORE MANPOWER REQUIRED IN BOTH THE SHIFTS = 5X2 = 10
TOTAL REDUCTION IN MANPOWER = 3 NO.
21
TR
AIL
ER H
OO
K
DR
IVER
SEA
T
CLU
TCH
TIE
RO
D
HO
RN
, FA
N B
ELT
RIG
HT
FEN
DER
LEFT
FEN
DER
TR
ACT
OR
GR
EASI
NG
FRO
NT
WH
EELS
RIG
HT
REA
R W
HEE
L
LEFT
REA
R W
HEE
L
FEN
DER
SEA
T
WA
TER
SEP
AR
AT
OR
OIL
DR
AIN
REA
R F
RA
ME
AN
D 7
-PIN
SO
CKET
FIT
MEN
T
7-PI
N S
OCK
ET S
/A
FUEL
TA
NK
FUEL
TA
NK
ST
RA
P
RA
DIA
TO
R
DA
SHB
OA
RD
PLA
TE
S/A
DA
SHB
OA
RD
FIT
MEN
T
INST
RU
MEN
T P
LAT
E S/
A
INST
RU
MEN
T P
LAT
E FI
TM
ENT
ELEC
TR
ICA
L CO
NN
ECT
ION
S
STEE
RIN
G W
HEE
L
DA
TA
PLA
TE
BA
TT
ERY
LHS
SHEE
T M
ETA
L
RH
S SH
EET
MET
AL
FRO
NT
GR
ILL
HEA
DLI
GH
T C
OV
ER A
ND
BO
NN
ET
AIR
CLE
AN
ER, M
IRR
OR
SILE
NCE
R
DIE
SEL,
DIF
FER
ENT
IAL
OIL
CO
OLA
NT
0
50
100
150
200
250
300
350
400
230 225
100
150
180200 205 200
230 230
145 140
70
210
0
180
120
350
0
180
0
240 230
200 200
335
185 180160
105
220
150
230
YAMAZUMI CHART(AFTER KAIZEN 5)
CY
CLE
TIM
E (
in s
)
SUB ASSEMBLIES ELIMI-NATED FROM MAIN LINE & SEPARATE CELL IS SETUP
TAKT TIME = 270s
22
EFFECT OF KAIZEN 5 ON LINE EFFICIENCY :-
LINE EFFICIENCY: = Sum of all stations CYCLE TIME Takt Time* NO. OF MANPOWER
= 5760 = 64.65% 270* 33
BETTER
AFTER KAIZEN 4
AFTER KAIZEN 5
55
60
65
70
63.4 64.65
LIN
E E
FFIC
IEN
CY
( %
)
K5
2323
Sheet metal Rear frame Water seperator/fender
seat
Greasing Electricals Total line efficiency improvement
0
10
20
30
40
50
60
70
80
90
40
55.5
41.6
64
5559.3956.5
77.7
52.7
7578
64.65
INCREASE IN EFFICIENCIES AFTER THE IMPLEMENTATION
Before After
5.26%
increase in
line efficiency
24
TO IMPLEMENT THESE PROPOSAL WE NEED SYNERGY OF FOLLOWING DEPARTMENT
STAGE DEPARTMENT NATURE OF WORK
SHEET METAL
HR WITHDRAWL OF 3 NO. MANPOWER/SHIFT
TECHNOLOGYDEFINING AREA FOR PANEL AND BONNET LOCK SUB ASSY AT ONE POINTALLOCATING WORK TO CONTRACTOR
STORE CHANGING FEEDING LOCATION OF MATERIALS
MANUFACTURING PROPER IMPLEMENTATION IN BOTH SHIFT
STAGE DEPARTMENT NATURE OF WORK
TRACTOR GREASING
TECHNOLOGY
WITHDRAWL OF 1 NO. MANPOWER/SHIFT
STORE CHANGING FEEDING LOCATION OF MATERIALS
MANUFACTURING PROPER IMPLEMENTATION IN BOTH SHIFT
25
STAGE DEPARTMENT NATURE OF WORK
WATER SEPARATOR / REAR FRAME
TECHNOLOGY ALLOCATING STICKER PASTING TO CONTRACTOR
STORE CHANGING LOCATION OF STICKER PASTING
MANUFACTURINGPROPER IMPLEMENTATION IN BOTH SHIFT
STAGE DEPARTMENT NATURE OF WORK
REAR FRAME
TECHNOLOGYPROVIDING A NEW SOP FOR WORK AT REAR
FRAME STATION
STORE CHANGING FEEDING LOCATION OF MATERIALS
MANUFACTURING PROPER IMPLEMENTATION IN BOTH SHIFT
STAGE DEPARTMENT NATURE OF WORK
ELECTRICALS
TECHNOLOGY
WITHDRAWL OF 1.5 NO. MANPOWER/SHIFT
PPC PROVIDE PRODUCTION DETAIL IN ADVANCE
STORE CHANGING FEEDING LOCATION OF MATERIALS
MANUFACTURINGPROPER IMPLEMENTATION IN BOTH SHIFT