VISTEON MATERIAL OUTWARD STORE

Self Enhancement Activity of TVSLSL

Productivity Improvement & Improving material flow

OWNERSHIP TEAM:K.Imrankhan

SUPPORT TEAM :Mahendran .m

1

Imran khan& team

Vision OfficerMember

Developmentby Coaching of

Problem Solving

Imran khan

Project Team Co Operation

OWNERSHIP TEAM OF ACTIVITY

CUSTOMER

Sharing the Success StoryDevelop All team Members

2

Mahendran

Manpower Breakup

3

S.NO WORKING AREA Shift A Shift B Shift CNO OF

HEAD COUNTS

1 LINE FEEDING & FORD SEQUENCE 5 5 5 15

2 DISPATCH- HMI & REPACKING 3 3 3 9

3 DISPATCH- FORD 3 3 3 9

4 DISPATCH- MOBIS 2 2 2 6

5 PACKING - GMI,NISSAN,THAILAND,SPARE,EXPORT 7 3 1 11

6 BOX FEEDING 1 1 1 3

7 EMPTY RECEIVING 2 2 2 6

8 FORD CUSTOMER SUPPORT 2 2 2 6

9 TROLLEY WASHING 2 2 0 4

10 DOCUMENTATION 1 0 0 1

11 SUPERVISORS 1 1 1 3

12 HR 1 0 0 1

13 PLANT INCHARGE 1 0 0 1

TOTAL 31 24 20 75

Utilization Figures from Time Study (Line Feeding and Ford Sequence) Productivity Can be improved

Problem Solving : Step 1. Clarify the problem

Target Areas for Improvement

4

Sl. Operation Sub lineCurrent

Manpower/ShiftWork Distribution% Total Utilization %

1

BA HVAC

BA Hvac

1

43%

86% CLICK HERE2 LCI 10%

3 Bols 15%

4 PA 17%

5

B515 HVAC

HA Hvac

1

22%

71% CLICK HERE6 B515 Hvac 31%

7 B515 Cond 8%

8 Comp 11%

9

COOLING MODULE

B517

1

14%

76% CLICK HERE10 HA COOL MOD 18%

11 BA COOL MOD 25%

12 RBI 19%

13

A/C HOSE

BA P

1

17%

65% CLICK HERE

14 BA D 11%

15 B517 16%

16PA 10%

BIN 10%17

18 FORD SEQUENCE B517 Cooling module 1 50% 50% CLICK HERE

TOTAL AVG 70%

5

EXISTING LAYOUT

How did we arrive at the figures?

• Video Analysis to capture process and time required

• Determine the appropriate Unit of Measure (UOM)

• Collect data to calculate average volume / day of the UOMs

• Calculate total time required per activity

• Arrive at utilization rate by comparing time required total available hours at the activity

Problem Solving : Step 1. Clarify the problem

6

Sample Study Data of Waiting Time

Waiting time - 5 cycle for each line

Waiting Reason Wait Time % Total Time NVA = 2.24 hours(144

mins)Cumulative

Waiting for fork lift 38% 55 mins 38%

Quality Check delay 28% 40 mins 66%

Gangway Blocked 17% 24 mins 83%

Waiting for Air Cleaning area

17% 24 mins 100%

7

38%

28%

17% 17%

0%

5%

10%

15%

20%

25%

30%

35%

40%

Waiting for fork lift Quality Check delay Gangway Blocked Waiting for AirCleaning area

Reduce footfall by streamlining activities and improving process

Problem Solving : Step 3. Set target

Target of activity

Sl. Target Metric Current Initial Target

1. Labour utilization in numbers per shift 5 4

2. Labour Utilization % Average (Improvement Areas) 70% 87%

8

Root Cause Analysis – Quality check delay

Problem Solving step 4 : Analysis of the root cause

Quality check delay

4 sub lines parts checking in single quality checking points

Why? Why?

9

Location Not Available

Root Cause Analysis – Waiting for forklift

Problem Solving step 4 : Analysis of the root cause

Waiting for forklift Trolley not available on floor

Why? Why?

10

Forklift operator does not know the next picking trolley

Introducing Kanban

11

Gang way block

too many parts waiting at gangway for noise check

No separate space allocated for unchecked parts

Root Cause Analysis – Gangway block

Problem Solving step 4 : Analysis of the root cause

Why? Why?

Root Cause Analysis- waiting at air cleaning area

Problem Solving step 4 : Analysis of the root cause

12

Waiting at air cleaning area

Too many trolleys handle in single air cleaning area

Route and work balance not fixed

Why?Why?

Problem Solving step 5 : Develop countermeasure

13

SL.NO PROBLEM STATEMENT ROOT CAUSE COUNTER MEASURE

1 QUALITY CHECK DELAY LOCATION ALLOCATION NOT DONE ALLOCATE SEPARATE LOCATION FOR NOISE PARTS

2 WAITING FOR FORKLIFT IMPROPER PLANNING BY LINE FEEDER & OPEARTOR DESTACKED TROLLEY HAVE TO BE KEPT AS PER KANBAN click here

3 GANGWAY BLOCKED NO SEPARATE LOCATION ALLOCATED FOR UN CHECKED PARTS ALLOCATE SEPARATE LOCATION FOR UN CHECKED PARTS

4 WAITING FOR AIR CLEANING AREAROUTE and WORK BALANCE NOT FIXED(4 LINE FEEDER USING 3 AIR

CLEANING HOSES)(PROFILE CLUBBING) 4 LINE FEEDER REDUCE INTO 3

Kanban Process

Feed the empty trolley to empty line with kanban card

Go to empty location point

Forklift operator picking the kanban card and destack the trolley

Line feeder pick the trolley FIFO wise (Card triggering basis)

Filled trolley pick from line side

- Returnable flow- Material Flow- Document flow - Information Flow

Place the kanban card to kanban board

Move to FG location & taking the kanban card from the trolley

Single trolley position at allotted Area with kanban card

ALLOCATED SEPARATE LOCATION FOR NOISE PARTS

15

Before After

DESTACKED TROLLEY HAVE TO BE KEPT AS PER KANBAN

16

Before After

EXISTING & PROPOSED EFFIECENCY

17

EXISTING EFFIECENCY PROPOSED EFFIECENCY

BA Hvac

3

43%

86%

BA Hvac

3

43%

87%LCI 10% BA P 17%

Bolster 15% BA D 11%

PA 17% B517 16%

HA Hvac

3

22%

71%

HA Hvac

3

22%

82%

B515 Hvac 31% B515 Hvac 31%

B515 Cond 8% B515 Cond 8%

Comp 11% PA 10%

B517

3

14%

76%

Comp 11%

HA COOL MOD 18% B517

3

14%

86%

BA COOL MOD 25% HA COOL MOD 18%

RBI 19% BA COOL MOD 25%

BA P

3

17%

65%

BIN 10%

BA D 11% RBI 19%

B517 16% B517 Cooling module

3

50%

92%PA 10% Bolster 15%

BIN 10% PA 17%

B517 Cooling module 3 50% 50% LCI 10%

TOTAL AVG 70% TOTAL AVG 87%

NEXT IMPROVEMENT TARGET AREA

(HYUNDAI DESPATCH AND REPACKING AREA)

18

Utilization Figures from Time Study (HMI DISPATCH & REPACKING): Productivity Can be improved

Problem Solving : Step 1. Clarify the problem

Target Areas for Improvement

19

EXISTING EFFICIENCY

Sl. Operation Sub activityCurrent

Manpower

Work distribution

%Labour Utilization %

1

HMI REPACKING

KIT READINESS FOR HA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

1

11%

38%2KIT READINESS FOR PA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

10%

3 STOCK TAKING & BIN READINESS 12%

4 KIT READINESS FOR BA - HOSE,TANK & COMP BOLT REPACKING 5%

5

HMI FLT OPERATOR

DESTACKING

1

6%

70%6 DUNNAGE AUDIT BEFORE LOADING 10%

7 TRUCK AUDIT BEFORE LOADING 9%

8 LOADING THE PARTS TO TRUCKS AS PER INVOICE 44%

9

HMI VANNING PERSON

PLAN RECEIVE FROM POINT CHAMPION

1

5%

72%

10 STOCK TAKING 4%

11 AS PER PLAN PARTS PICK FROM FG LOCATION 30%

12 DUNNAGE AUDIT BEFORE VANNING 10%

13 VANNING ARRANGEMENTS AS PER PLAN 14%

14 PHYSICAL vs INVOICE VERFICATION 8%

TOTAL AVG 60% click here

Reduce footfall by streamlining activities and improving process

Problem Solving : Step 3. Set target

Target of activity

20

Sl. Target Metric Current Initial Target

1. Labour utilization in numbers per shift 3 2

2. Labour Utilization % Average (Improvement Areas) 60% 90%

EXISTING & PROPOSED EFFICIENCY – WITH WORK RE-ALLOCATION

21

EXISTING EFFICIENCY

Sl. Operation Sub activityCurrent Manpo

wer

Work distribuition %

Labour Utilizatio

n %

1

HMI REPACKIN

G

KIT READINESS FOR HA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

3

11%

38%2

KIT READINESS FOR PA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

10%

3 STOCK TAKING & BIN READINESS 12%

4KIT READINESS FOR BA - HOSE,TANK & COMP BOLT REPACKING

5%

5

HMI FLT OPERATO

R

DESTACKING

3

6%

70%6 DUNNAGE AUDIT BEFORE LOADING 10%

7 TRUCK AUDIT BEFORE LOADING 9%

8LOADING THE PARTS TO TRUCKS AS PER INVOICE

44%

9

HMI VANNING PERSON

PLAN RECEIVE FROM POINT CHAMPION

3

5%

72%

10 STOCK TAKING 4%

11 AS PER PLAN PARTS PICK FROM FG LOCATION 30%

12 DUNNAGE AUDIT BEFORE VANNING 10%

13 VANNING ARRANGEMENTS AS PER PLAN 14%

14 PHYSICAL vs INVOICE VERFICATION 8%

TOTAL AVG 60%

PROPOSEDEFFICIENCY

Sl. Operation Sub activityCurrent Manpo

wer

Work distribuiti

on %

Labour Utilizati

on %

1

HMI FLT OPERATO

R

DESTACKING

3

6%

87%

2 DUNNAGE AUDIT BEFORE LOADING 10%

3 TRUCK AUDIT BEFORE LOADING 9%

4 LOADING THE PARTS TO TRUCKS AS PER INVOICE 44%

5 STOCK TAKING & BIN READINESS 12%

6KIT READINESS FOR BA - HOSE,TANK & COMP BOLT REPACKING

5%

7

HMI VANNING PERSON

PLAN RECEIVE FROM POINT CHAMPION

3

5%

93%

8 STOCK TAKING 4%

9 AS PER PLAN PARTS PICK FROM FG LOCATION 30%

10 DUNNAGE AUDIT BEFORE VANNING 10%

11 VANNING ARRANGEMENTS AS PER PLAN 14%

12 PHYSICAL vs INVOICE VERFICATION 8%

13KIT READINESS FOR HA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

11%

14KIT READINESS FOR PA - HOSE,BRACKET,TANK & COMP BOLT REPACKING

10%

TOTAL .AVG 90%

22

PROPOSED LAYOUT

BENEFITS

Tangible

Reduced 6 man heads out of 75

Direct cost saving of Rs.8.69 lakhs per annum (rs.12077*6*12)

Intangible

Work efficiency is improved from 70% to 87% at Line Feeding and Ford Sequence

Work efficiency is improved from 60% to 90% at Hyundai Dispatch and repacking

Customer delighted and opportunity for encirclement

23

Thank You

24