lean manufacturin and six segma

8/3/2019 lean manufacturin and six segma

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{D-08-IN-314, D-08-IN-331, D-08-IN-337, D-08-IN-338, D-08-IN-339}

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TEAM MEMBERS:TEAM MEMBERS:TEAM MEMBERS:TEAM MEMBERS:

Muhammad Ehsan (G.L) D-08-IND-314

Fiaz Ahmad D-08-IND-331

Shahid Ali D-08-IND-337

Muhammad Idrees D-08-IND-338

Rahmat Ali D-08-IND-339


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6.1 Ist Brainstorming Session:

Team first meeting was conducted on 31 October 2011.

An awareness session conducted on Lean Manufacturing & Six Sigma

6.2 2nd Brainstorming Session:

In this session, a deep study of the whole plant was conducted by all the teammembers, and also meetings with the concerns of the different departments havebeen made. Also efforts were being made to find out some specific problem,which they are facing, not much has been told to us regarding the problems.

In this session we also selected some sections of the plant (due to limited time,which we have) to implement and improve the techniques and tools of LeanManufacturing and Six Sigma.Areas selected are:

Main Assembly LineWarehouse

First we go through each and every stage of these areas, to find out whetherthese areas are working with their full capacity or not.

6.3 3rd Brainstorming Session:

From this session, we practically start our work.

DEFINE:DEFINE:DEFINE:DEFINE:

First to find out whether Main Assembly Line is working properly or not, we startto perform time and motion study. Almost every step was monitored and broughtunder study to find out whether there is any time loses or not?

MEASURE:MEASURE:MEASURE:MEASURE:

After performing and drawing an image of the Main Assembly Line, andcomparing all the data with the standard data.


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All these reading are average values of the various observations being made.

4th Brainstorming Session:

After gathering all the data, then all the team members set around and madediscussions and also compare data with standard data to get a clear picture ofthe wastages in assembly line.

ANALYZEANALYZEANALYZEANALYZE::::Here we look to the rout causes of the problems that why there is a high amountof time loses.

Figure: Different causes investigated which result in loses of time

First the huge delays which the workers usually experience are mainly due to


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improper materials being supplied by the vendors. Secondly the workers workingon the main assembly line are also mostly semi-skilled workers and a very few ofthe workers are skilled and experienced.

But the main reasons are the improper tools and materials, which causeinterruption in the work and are also, become the reason of huge delays.

From all the data, which we gathered, give us a clear picture of the otherproblems as well. Therefore to understand it easily, we classify these in thefollowing broad headings:

1) Improper Work Place Design2) Materials Quality Issues (Local Parts)

In the next phase, we will cover each of these separately.

1) Improper Work Place Design:

First we want to give a few example, which will show that why we are saying thisthat is problems in the work place.

Main Assembly Line


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All these pictures shows that the work place design is improper and various tools

used are also out-dated. There are certain things which can easily updated and

even with-out much more or high investments.

Like the nut and bolt tightening gun are mostly used in the assembly line, but the

pipe which is attached to these gun are a straight pipe, this can be replace with


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the new spiral pipe, which has the tendency to contract after use, thus the pipeattached to the gun will not effect the movement of the worker, after he use the

tightening gun.

Similarly the jigs or trolley which are used to hold materials or product for the use

on the main assembly line, are also not placed properly, this also effect the

movement of the workers. This problem can be tackle down by placing the rail on

the floor, which will help in aligning these trolleys and will also provide and proper

way for workers for their easy movements without causing any fatigue to the

workers, which will reduce the efficiency of the workers.

2) Materials Quality Issues (Local Parts):

Materials are most important element of the assembly process; the occurrence of

any issue in the required materials will slow down whole process. Therefore

much emphasis should be given to the materials.

Sample No. of Defects per VehicleNo. Defect in

Process

1 4 18

2 5 363 17 47

4 9 24

5 6 37

6 9 8

7 4 18

8 1 37

9 13 53

10 3 15

Total 71 --

These are problems, which occur in the vehicles, these are mainly due to the use

of defective sub-assembly parts. Also some are due to the workers negligence

but problem under negligence is quite lower as compare to the parts.

Also we develop a three sigma control for the above data, to find whether the

process is under control or not. So, that to take further decision as required.


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Here we will use the control chart which the number of defects per unit, thereforehere we use C- Control Chart for attributes.

Total number of units inspected or observations = 10

Total number of defects = 71

The Average number of defects per unit is = 71/10 = 7.1, Therefore = 7.1

Now as we know;

7.1 + 3 7.1 + 7.99 = 15.09 15.10

7.1 + 3 7.1 7.99 = 0.89 0

The green line represent the problems under control, whereas the red color show

the out of control problems, as the defects in that specific observation shows too


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much defects and therefore proper remedial actions should be taken to controlthese kind of situations.

Even though in the above case the 3rd observation shows defects on higher side

due to the use of defective parts. Therefore these kinds of special cases should

be removed to achieve the production with-in the control limits.

These are defects find out on the main assembly line, some other defects

associated with the vendors supplies are the shown in the following table. These

are investigated in the warehouse, when new lots of materials were received in

the warehouse and inspection has been done by the quality control concerns.The data is shown in the following table:

S.R # Part Name Qty Vendor Remarks

1 Brkt Fuel Filter 12 Micro Engg. Hole position out

2 Reinforcement 48 Micro Engg. Hole position out (CKD)

3 Reinforcement 48 Micro Engg. Hole position out

4 Brkt Air Cleaner 12 Micro Engg. Not as per drawing

5 Brkt Engine Mtg 24 Micro Engg. Fixture not available

6 Member Cross 2nd 30 A. R. Engg. Holes missing

7 Cover Side 06 Javed Engg. Poor paint quality

8 Brkt Radiator 12 Javed Engg. Height not as per drawing

9 Hanger Assembly 06 Mehboob Ind. Center Hole distance out

The above data shows that problems arise on main assembly line are mainly due

to the supplies of defective parts from the vendors side.

6.4 4th Brainstorming Session:

At this point after having a good know how of the Main Assembly Line and it

problems, now it is the time to take the required remedial actions to remove or

minimize these issues/problems to get smooth work flow, so that to achieve high

productivity with out surrendering key resources.


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CONTROLCONTROLCONTROLCONTROL::::

Here for controlling all the above mention issues hard and timely decisions

should be made, in order to improve the production capability and also to enable

smooth production efficiently and effectively.

In order to achieve all this following decisions should be taken:

First the work of the quality control department should be made more systematic

in order to achieve minimum defects. As we find out that most problems arise

due to the unavailability of defect free parts on line, this also effect the smooth

production flow, therefore the inspection of the received goods should be made

more strictly and more focused. For quality control personnel they should make it

possible to not depending on the sample size much, and for complex materials

they should go on to perform inspection of the whole lot if possible.

Secondly, some automation is also required in the main assembly line, if

possible, like more sophisticated tools should be used so that to minimize more

workers labor, this will help them in less fatigue and more efficient and effective

work performance.

The above example can help worker to do his work efficiently and with less

fatigue and labor.

Third, The Attitude Mater A Lot therefore the workers and even though the

management should also have to change their attitude, and do their work on time

and also take part in continuous improvement activities or processes, in order to

achieve organizational excellence and prosperity.

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lean manufacturin and six segma