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Lean Manufacturing - StoresSN Elements
1 Workstudy for Material Feeder person23 List of items data collection4 Space utilized measurement5 Makigama6
7
8 Distance travelled by feeder person
Current state data collection for Stores & PPC
Material/man movement path within factory3C/Triple C/ unpacking/2bin system action plan
Lean Manufacturing - StoresMethod for collecting data Target Date Dadra WadaVideo shoot & process studyGembaAs per actuals in systemAny distance measurement toolGembaSpaghetti Chart
Gemba
Pedometer
Lean Manufacturing - StoresHP2 HP1
Ahmedabad
BLUE STAR LIMITED Purpose: VSM and VSM Metrics cretion for stores.
CURRENT STATE MAPING OF STORES
Sr.No. Parameter UnitStores
Value Rs.1 Inventory
1.1 Raw Material1.2 Finished Goods
22.1 Raw Material Sq Meter 5539 2.2 Finished Goods Sq Meter 1867
3 No of material handlers in a day Assembly line 13.1 Feeders 23.2 Feeder Supporters 1
4 Work content in a day
4.1 Feeder Minutes 3504.2 Feeder Supporters Minutes 300
5
5.1 Feeder Nos. 155.2 Feeder Supporters Nos. 3
6 Distance travelled in a day
6.1 Feeder Kms6.2 Feeder Supporters Kms
7 Nos. 25
8 No of non standard location %
9Constant container nos 25%
Floor space used ( foot print - not verticle )
Operator 1(Name)
No.of parts handled in a day ( Variety of parts handled in the entire day min & Max )
Operator 1(Name)
Operator 1(Name)
Different variety of bins in which material is fed to assly lines
50% standard / 50% non standard locations
How many parts delivered without 3C
Constant qty nos
Costant locaiton nos 40%
9 Part code RCSL-BPV1706D-00
Value 22.74 Lacs.No of days 4 Yrs
11 Nos
12 Nos 2
No part delivered with constant qty
What is the oldest material locked & how long
How many parts are ready to use condition without unpack in stores
No parts are ready to use condition in
stores
No. of parts fed to Assly duly un-packed
BLUE STAR LIMITED Purpose: VSM and VSM Metrics cretion for stores.
CURRENT STATE MAPING OF STORESStores
Inv. Turn.
21
310 420400 400
No.of days Inv.
Assembly line 2
Operator 2(Name)
Operator 3(Name)
Operator 2(Name)
Operator 3(Name)
Operator 2(Name)
Operator 3(Name)
RCSL-BPV1706D-00
Purpose: To measure the work content of individual material handler, Measure the Value added and Non Value added Time, Type of waste and analysis. Kindly draw the Spagatti Diagram (Material handler Loop Diagram)
SN
Material Feeder Name: No of variety of components handled :
OPERATOR
Activity Time Start Time End
123456789
101112131415161718192021222324252627282930313233343536
373839
Purpose: To measure the work content of individual material handler, Measure the Value added and Non Value added Time, Type of waste and analysis. Kindly draw the Spagatti Diagram (Material handler Loop Diagram)Products: DSA661 IDU
Assembly line : OPERATOR
Load Unload Transport
Purpose: To measure the work content of individual material handler, Measure the Value added and Non Value added Time, Type of waste and analysis. Kindly draw the Spagatti Diagram (Material handler Loop Diagram)
OPERATOR
Search Rework Downtime
Purpose: To measure the work content of individual material handler, Measure the Value added and Non Value added Time, Type of waste and analysis. Kindly draw the Spagatti Diagram (Material handler Loop Diagram)Observer Name :
Date : OPERATOR
Ideal
Notes(observations/improvement
ideas during proces study/Wastes identified)
Distance travlled in meters (if
applicable)
Purpose : To understand the operator irritations/Unspoken issues which cause Quality/working speed/Safety issues.
Part
Yes No.
Fan Motor No No
Stage No
max. 2 Hour inventory on
line
Two bin System
Unpacked/ready to use material
Base Panel
Loading
Compressor
Yes.2 pallet on
Assembly line
Fan motor
assembly
NO.
NO NO No
Fan blade Yes
Control box
assembly
Control box
Fan blade
assembly
2 trolleys available 1 on assembly
line & 1 trolley in stores
OthersOverall actions required
Purpose : To understand the operator irritations/Unspoken issues which cause Quality/working speed/Safety issues.3C Triple C
Yes No Yes
No No No Yes
Constant Container
Constant Quantity
Constant Location
Count free
Yes. Compressor supplied on
pallet as received from
supplier.
No No No
Yes No No No
Marking to be done
Purpose : To understand the operator irritations/Unspoken issues which cause Quality/working speed/Safety issues.Triple C Ergonomics
No Yes
No Yes
Contact Free
Contaminant free
Distance from operator
position (No of Steps or Meter) use
any one unit of measure
Weight of the component
No No
Yes Yes
Purpose : To understand the operator irritations/Unspoken issues which cause Quality/working speed/Safety issues.Ergonomics
9-Apr-16
N M Rao 30-Apr-16
N M Rao 8-Apr-16
N M Rao 8-Apr-16
N M Rao 22-Apr-16
Operator Bend/Arise Required?
Action Reqd on points with non
compliance
Responsibility
Target Date
Today
Status
Compressor storage area marking to be done on assembly line
Avinash J/N M Rao
Compressors need to come unpacked from storesFan motor trolley #02 (32nos)1 on assembly line & 1 trolley in stores
Trolley parking location to be defined when not in use
Unpacking to be done before it is supplied to assembly line
* Extra lug cutting & new lug crimping activity to be studied
N M Rao 13-Apr-16
N M Rao 22-Apr-16
N M Rao 22-Apr-16
8-Apr-16
8-Apr-16
8-Apr-16
8-Apr-16
N M Rao 22-Apr-16
N M Rao 22-Apr-16
Unpacking location to be defined
Unpacking responsibility to be defined
Area for packing waste storage to be defined
marking for fan motor trolley storage area on assembly line to be done
Avinash J/N M RaoControl box PPH
bins with partition from supplier (36#)
Nilesh Patel/ N M Rao/ Avinash J
Implemented
marking for control box storage on assembly line to be done
Avinash J/N M Rao
Process of returning empty boxes to be defined
Nilesh Patel/ N M Rao
Trolley storage location to be defined on assembly line
Avinash J/N M Rao
Unpacking location to be defined
Unpacking responsibility to be defined
N M Rao 22-Apr-16
13-Apr-16
13-Apr-16
Area for packing waste storage to be defined. Proposal to be prepared for managementTraining to operators for 2hrs inventory/ 3c & triple C to be given
Wasif Sayed/N M Rao
Training to PPC/Stores for VSM to be given
Wasif Sayed
skilled manpower required for better planning of material feeding on assembly line
To be decided
Frequent change in production plans to be prevented, to smoothen material supply on assembly line
To be decided
Purpose: Backup for Before after comparison and Work Balancing
Name Height Date
1 Alok jha 177 inch 12.04.2016 5175 3.912 Krupesh Patel 168 inch 13.04.2016 9015 5.95
3 Krupesh Patel 168 inch 14.04.2016 10559 7.025
4 Vijay Varali 15.04.2016 13103 9.67
Sr no.
No. of steps
Distance (km)
Purpose: Backup for Before after comparison and Work Balancing
Model Assly line
G -0DPAP661R1-O G -3 11DSW361R2-O G -3DSW 361R1-OA G -3DSW 661 R2-OA G -3DSW 661 R1-O G -3DSW 1052 R1- G -3DSW 1322 R1- G -3DSW 1322 R2-O G -3DSA661R1-OA G-2DSA661-K G-2DSA361R1-IA G-2DSA361R2-I G-2RUAHOP0614 G-2RUAHOP1014 G-2RUAHOP1514 G-2RUAHOS2014 G-2
No of variety of
component
04/22/2016 34/40 hcl263/c/Lean Manufacturing/315441112.xls
VALUE STREAM MAPPING : (PART Name: )PRESENT PROCESS MAPPING PROPOSED PROCESS MAPPING
Activity NVA (waste) Where Who Remark 1 WIP Activity NVA (waste) Where Who Qty. Remark 1 WIP Remarks
Total 0 0 0 0 Total 0 0 0 0Total mins. 0 Total mins. 0 1.6 KM
Total hrs. 0 Total hrs. 0
VA NVA but necessary
Qty./ Batch size
TIME FOR ACTIVITY
(sec.)
DISTANCE TRAVELLED
IN MTRS.
NO.OF M/CS /
EQUIPMENTS / BW
VA NVA but necessary
TIME FOR ACTIVITY
(sec.)
DISTANCE TRAVELLED
IN MTRS.
NO.OF M/CS /
EQUIPMENTS /
BW
Deleted Process change
Location change Aiming for deletion Value addedProcess change
SN Item Code Category
1 MOAC-F001014-002 Motor 764 899992
Purpose: To understand the curreent inventory condition ,How we can reduce,where to start and identify the low hanging fruits Level 1 exercise: Start with A & B Class Parts. (ABC & Runner/Repeater/Stranger Classification and Clearity is required before collecting data)
Description
Inventory in nos
Total value
MOTOR GE
DC403T
Vendor MOQ
1278 80
Purpose: To understand the curreent inventory condition ,How we can reduce,where to start and identify the low hanging fruits Level 1 exercise: Start with A & B Class Parts. (ABC & Runner/Repeater/Stranger Classification and Clearity is required before collecting data)
Lead Time without Forecast
% of Supply Adherence
against leadtime
Vendor Distance
from factory (km)
Supplier standard packagin
g
Marathon electric India
pvt ltd, Faridabad
Purpose: To understand the curreent inventory condition ,How we can reduce,where to start and identify the low hanging fruits Level 1 exercise: Start with A & B Class Parts. (ABC & Runner/Repeater/Stranger Classification and Clearity is required before collecting data)
For how Many runner models this part (item code) is applicable
Min Required quantity per model
Min Required quantity per model
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