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