VW Project Presentation

Page No : 1Projects & ME - MIS April 2015

Improvements in

Vehicle Despatch Warehouse


Objective

• To explain the current processes involved, their

time studies and difficulties.

• Improvements possible in process and equipment

to manage the increase in vehicle production

(from 800/day to 1200/day)


Current scenario

• Production in May’15 - 800 bikes per day

• These bikes are despatched in 3 shifts comfortably

• The average time taken to load one bike into the truck is 105 sec, using one scissor lift, the bottleneck for the total process

• For improving the efficiency of the process and find the bottleneck, following 3 major criterions to be considered

A. Hourly Backflush

B. Bike movement for packing

C. Scissor Lift operating Speed


A) Backflush

• The hourly backflush data taken over the month of

April and Mid-May shows that there is inconsistency

in number of vehicles being sent to the warehouse.

39

14 3

30

1 4 6 13 1422

16

34 33

46

83

29

37

46

3034

19

39

26

46

23

1

71

33

0 10 11 12 2

39

17

45

1

89

47

25

38

17

3227

23

7

35

53

0

22.5

45

67.5

90

112.5

12-1 am 1-2 am 2-3 am 3-4 am 4-5 am 5-6 am 6-7 am 7-8 am 8-9 am 9-10 am 10-11am

11-12pm

12-1 pm 1-2 pm 2-3 pm 3-4 pm 4-5 pm 5-6 pm 6-7 pm 7-8 pm 8-9 pm 9-10 pm 10-11pm

11-12am

April May

Hourly Backflush Data For April and May


A1) Improvement In Backflush

• An average of 60 vehicles to be delivered each hour from

the assembly area to the warehouse is suggested to make

the packing and despatch process non-cumbersome.


B) Bike Movement From Storage To Ready For Despatch Area

• It currently takes 50 sec to bring a packed bike to the

ready to despatch area.

• This process has 2 scopes of improvement. With time

studies conducted, the new process will deliver bikes

at a rate of one bike per 31 sec.

– Addition of 2-way opening VRC doors on 1st and 2nd floor

– Changing floor plan of warehouse on 1st and 2nd floor


B1) Improvement In Bike Movement

• The current floor plan does not provide an efficient system of

loading and unloading the VRCs and hence it is time consuming. It

takes 100 seconds to take up a bare bike and bring down one

packed bike per VRC.

• By implementing both sides opening in VRC (on 1st and 2nd floor),

the process flow becomes streamlined and the time for VRCs

reduces to 62 sec per bike per VRC.

• Another essential process to be improved is taking out and re-

stocking of bikes in VRCs, this process has to be done instantly to

reduce idle time, reduce empty cycles and to maximise utilisation.


C) Loading Of Bikes Into Trucks

• Currently it is measured that 105 sec are being taken

to load a bike using one scissor lift only.

• This is also one of the time consuming processes

• A suggested solution is to improve the scissor lift

speed from 1.8m/min to 3m/min


C1) Improvement In Loading Process

• 15 mins per truck can be saved by reducing idle time of trucks.

• By using 2 scissor lifts simultaneously 1200 bikes can be despactched per day.


Proposed Layouts For 1st & 2nd Floor

The following advantages can be

achieved with new floor plans:

• Capacity increase by 112

bikes(22%).

• Previous Capacity: 498

• New Capacity: 610

• More space for packing

provided

Requirements:

• Addition of doors for VRCs on

both floors

• New line marking to be done on

the floor


VRC Door Addition

• As marked, there is a requirement

of motorized doors to be added on

the 1st and 2nd floors of the VRC.

• This will reduce number of empty

cycles

• Make the process flow stream lined

• Require less space for operations


Gate Pass System

• A Gate Pass will be provided to the

truck driver upon entry, that needs to

be submitted to despatch office

• Only after all the required documents

are given to the driver, he be given

the Gate Pass with the seal

• No transport vehicle will leave

without depositing the Gate Pass at

the gate

• This will ensure proper

documentation


Manpower Requirement (For Running 2 Shifts, Domestic Only)

• For VRC Operation : 8

• Responsibility: Complete movement of bikes between floors,

despatch area, waiting area and temporary storage.

• For Packing : 6

• For Loading: 12 (6 on each Scissor Lift)

• For marking and verification : 1 (Maximum 2)

• Total Manpower required(for domestic): (8+6+8+2)= 28(per shift)


Processes Not Considered In Time Study

• Packing the bike is a time consuming process which

is carried out on the 1st and 2nd floor. But it can be

made faster by deploying more man power. This

process will not bottleneck the system as it is not

machine dependent

• Packed bikes storage time (holding time) is not

considered.


Actions

• Lift doors to be added at first priority on upper floors• Change layout of parking at upper floors• Idle time of trucks in the loading bay to be reduced• Introduction of a Gate Pass system is required to ensure the

truck is leaving with all required documents.• No need to increase speed of scissor lifts. 4.9% improvement in

time is not a substantial improvement and the investment is not justifiable.

• Backflushing process is required to be made more consistent• More manpower is required for 2 scissor lifts to be used

simultaneously• Parking space for 1200 bikes is required in total, proposed

space is the scrap area near the canteen


Conclusions

Current scenario:

Bike Production:800 in 2 shifts

Despatch per day: 800 in 3* shifts

Storage space of packed Bikes:

498 nos.

(1 & 2 floor)

Manpower Requirement: 18/shift

Rate of bike despatch: 105 sec per

bike by using 1 scissor lift (2nd lift is

not utilized fully)(Bottleneck due to loading)

Proposed:

Bike Production: 1200 in 3 shifts

Despatch per day: 1200 in 3 shifts

Storage space of packed Bikes : 610

nos.

(1 & 2 floor)

Manpower Requirement: 28/shift

Rate of bike despatch: 47 sec per bike

using 2 scissor lifts(By reducing truck idle time and adding VRC

doors)

By reducing idle time, 1 truck can be

loaded in 100 mins instead of 114, and by

using 2 scissor lifts simultaneously 1 truck

can be filled in 50 mins.

Hence time required for loading per bike

reduces to 47 sec per bike.

*3rd shift is mostly used for model matching

Documents

VW Project Presentation