A model case study of Improvement Activities

© torque Management Services Pvt. Ltd.

Case Study

of

A Chassis Manufacturer

© torque Management Services Pvt. Ltd. 2

Basic Challenges

Too Dirty….Inside Bins, Workstations, Components, Trolley’s, Machines & Equipment's, Ceiling & Roof Structures , Shop Floor, To create cleaning Culture. I make Dirty I clean. Broom Stand to every area, Cleaning Day. Too Much

WIP …Careless / doesn't know the importance of material, Material Get Dropped on Floor. Go For 01 Hrs. WIP on line…later on it will be 30 minutes. Too HeavyMaterial Handling Bins, trolleys etc. Weight ratio of 20 (Trolley Weight) : 80 (Components) Poor Visual control’s.Within one Minute Search Time.


Work Initial Level Target

To achieve Top Class 5S-level with maximum Audit Score

45 pt 100 pt

Reduction of Quality Defect (DMP Points) by 50%

191pt 100pt

Improvement in Productivity by Data Not Available

20-30%

Safer Work Environment avoiding any Accident

2 Acc/month Zero Acc/Month

Better Inventory Management, reduction of WIP by 50-60% Over 8-hours 2-hours

Objectives


Awareness Revolution & Training on Lean Tools

Formation of Teams

5S, 3-Fixed & Visual Control

Stores Reform, FIFO introduced

Deployment of Container Kanban & Water Spider

Lighter & Sleek Combination Trolleys introduced

Better line Balancing & Process Improvements

Key Steps Taken


ImprovementsIn

5S & Material HandlingAt

Shop Floor


Before After

Benefits:

• Fasteners keeping racks replaced with trolleys with small bins (96 big bins replaced with 46 smaller ones)

• 02 hours inventory for fasteners ensured

Optimization of space utilization


BeforeBenefits:

• Better looks with 02 hours inventory & free space

After

Optimization of space utilization


After Before

Damper damaged due to improper storage

A Frame trolley designed for Damper

Advantage – Damages eliminated

Material handling Improvement


Subject Engine Trolley Modification

Improvement

■ Before Improvement : ■ After Improvement :

1. No alignment.2. Difficulty in loading on fixture.3. Damaged & Strength less

1. Single piece flow.2. Ease of loading.3. Strengthened & Wheels replaced

Snap shots

Teflon & Strengthen

Kaizen Improvements


Subject Shop 02 Maintenance

Improvement

■ Before Improvement : ■ After Improvement : 1. No Cleaning2. Wanted + unwanted items3. No Systematic Arrangement

1. Cleaning2. Removal of unwanted3. Systematic Arrangement of wanted items

Snap shots

5S improvement


Trolley Marking

5S Improvements


Line Side all Trolleys Made, Sub Assembly & Rear Axle

Assembly Cover

Kaizen Improvements


StoresImprovements


Subject Store Small pallet FIFO system with Transparent & easy access to the stored materials

Improvement


1. No accessibility inside small pallets2. No FIFO system for the stored parts3. Condition of the parts not visible4. Loose material filled

1. Clear accessibility inside small pallets2. FIFO System for the stored parts3. Condition of the parts are visible 4. Sets of 100nos bundled

Snap shots

14

Stores Kaizen-2


Subject Air Piping Area

Improvement

■ Before Improvement : ■ After Improvement : 1. Air pipes lying in improper condition2. No segregation of air pipe variants3. Stored in high rise racks with non accessible

areas

1. Air pipes arranged in proper condition2. Segregation of different model pipes3. New racks with low rise partitions with easy

accessible areas

Snap shots

Stores Kaizen-3


Area Chassis Assy – Shop II Imp. Process Shop 02

Team VC Dwivedi, Amrish, RK Sharma, Sridhaar, Aidan, Vikas Loss / Waste Type 5S/Time / Movement/Inventory

Subject Mezzanine floor racks are flooded with Fasteners in Open condition, it gets dusty , no inventory norms

Improvement All Fasteners are packed in separate packing with minimum quantity, no dusty fasteners, pack of 100nos made


Snap shots

5.Control ■ Improvement Effect :- 1) 5s 2) EEI Improved

Stores Kaizen-4


Tool KeepingConcept


Another tool keeping arrangement with the similar concept

Many types of Tool Arrangement


Arrangement made for keeping different sizes of Torque wrenches, according to the usage.

Torque Wrenches Arrangement


Drop BoxConcept


DROP BOX-PLAN : A Revolutionary concept

SCALE FOR ACCUMULATION LEVEL

• Collect any tiny part dropped on floor

• Put it immediately in Drop box

• Analysis & clear the items once in week


Material Drop Trend -(4-Weeks)

22

Accounting leads to improvement----


Time Study &

Productivity Improvement


Time study (Stage 1 & 2)

TOTAL ASSOCIATES ON 2 STAGES (BEFORE): 11 Nos.

STAGE 1 STAGE 2

CONVEYOR DIRECTION

OP 1 LH OP 2 LH

OP 4 RHOP 3 RH OP 4 RH OP 3 RH OP 2 RH OP 1 RH

OP 5 LH OP 4 LH OP 7 LH


Time study (Stage 1 & 2)

TOTAL ASSOCIATES ON 2 STAGES (AFTER): 9 Nos. (Time study is going on for further stages)

STAGE 1 STAGE 2

CONVEYOR DIRECTION

OP 1 LH OP 2 LH

OP 4 RHOP 3 RH OP 9 RH OP 8 RH

OP 5 LH OP 6 LH OP 7 LHOP 2 LH

OP 4 RH


20 % Increase in productivity achieved at the first 2 stages. Same concept has been planned to be deployed gradually in all stages.


Shop Look – After Improvement

WIP Reduced (01 Hrs Norms)

Space Saved (Trolleys 130 to 60,BIN Size FPO 35 to 15, 26 Hardware Racks removed )

Housekeeping Improved Effort and Time Reduced Better Visual Better Ergonomics

Customer Speaks---


WorkInitial Level Target Achieved

To achieve Top Class 5S-level with maximum Audit Score 45 pt 100 pt 78 ptReduction of Quality Defect (DMP Points) by 50% 191pt 100pt 100pt

Improvement in Productivity by

To be assessed

20-30% 20%

Safer Work Environment avoiding any Accident 2

Acc/month

Zero Acc/Month Zero

Acc/MonthBetter Inventory Management, reduction of WIP by 50-60% Over 8-

hours2-hours 2-hours

Goals Achieved at the end of Project


Business

A model case study of Improvement Activities