A. STREAMLINING PROGRAM MANAGEMENT TRACKING SYSTEM FOR ORIGINAL EQUIPMENT MANUFACTURERS

B. TIME STUDY OF THE MUFFLER END SPINNING MACHINE

Term Project

By,Samhita K. PrajapatiB.E. Production60012115020

Project Details

Objective: Streamlining Program

Management Tracking System for OEMs

Method: Creating a Dashboard Program

using MS Excel

Aim: To form a centralised Database

containing data of multiple projects.

Problem Statement

The Program Management Department has to manage a large number of projects simultaneously.

Monitoring of various projects becomes time consuming.

A centralised database which would be reviewed and updated monthly was desired.

Method

Dashboard is a single sheet displaying all the compiled data dynamically.

Visual Basic for Applications (VBA) language for MS Excel was used to create codes for dynamic programming of the various sheets.

Sheets

The Sheets designed for the “Project Health Report” are: Manager Input Pilot Paynter Customer Tooling and ED&T TAVA Status Customer Milestones Dashboard

Manager Input Sheet

Pilot Sheet

Paynter Sheet

Customer Tooling Sheet

Customer ED&T Sheet

TAVA Sheet

Status Sheet

Customer Milestones Sheet

Dashboard

Conclusion

The Project Health Report is a handy management tool.

It is user-friendly and can be used by anyone with minimal knowledge of MS Excel.

It is colour coded for quick analysis with financial data represented in the form of tables and charts.

Project Details

Objective: To conduct a time study of the Muffler

End Spinning Machine

Method: Video Time Study

Aim: To compute production target for each shift

of a working day

Introduction

A Time Study is conducted with the aim of boosting productivity rates.

Time study duration varies according to the product being manufactured.

Method study and Time study are usually conducted together.

It is initiated when: Desired productivity rate is not achieved An improvement is desired There is a change in layout/machinery A periodic review is to be conducted

The Process Layout

StorageEmbossin

gSpot

WeldingNotchin

g

Lock-Seaming

Flanging &

Stuffing

Welding (if

required)

End Cap Fitting

(if required)

EndSpinnin

g

Leakage Test

(if required)

FG Trolley

Method

Time and Method study was conducted in the following manner:

1. A video study of each of the individual operations in the defaulting manufacturing cell was conducted

2. The station with operating time much greater than machine cycle time was considered to be the bottleneck operation.

3. A thorough Method and Time Study is then carried out on the bottleneck operation to determine the cause of delay

Note: Always conduct a the study with a highly skilled operator manning the machine

Bottleneck

The Spinning Machine was found to have a much greater operating time.

It was selected for further study.

Machine Cycle Time = 22 seconds

General Operating Time = 39.4

seconds (avg)

Next Step

The End Spinning Machine was further studied.

The actions of the operator were divided into the following elements:- Walk, take muffler and load

on M/C. Take unloaded job and place

on table Press cycle start and observe

1 rotation Walk to LT & right LT value Unload job and put on table,

load new job, initiate test Check unloaded job and put

in FG trolley

The Table of Readings

Microsoft Office Excel Worksheet

Allowances

An operator will not perform his operation with 100% consistency.

The ISO Handbook has specified guidelines regarding allowances for the worker’s safety and welfare.

These allowances are calculated into the machining time.

Calculating Allowance

Microsoft Excel Worksheet

Cycle Time

Load 42Process 81 On Table & FixtureUnload 9Idle Time 0Allowance in seconds 29

Tea time Allowance in seconds 0

If all allowance is considered in Idle time, then only tea time allowance is applicable

Total cycle time in seconds 132Applicable cycle time 161.04

Actual Hourly Output (5% allowance) 57 min hour 21Shift Output 162

Cycle Time

Available Working Time

Time Calculation MinsA Total Shift Time 510Less Lunch Time 30B Available time for work 480

C Personal Need Allowance 5% 24

D Available time for work 456LessE Shift Start, PM, Inspection 10F Shift end Cleaning & Last off 10

GNet Working Time (for calculation of Output) 436

Shift I (7am – 3:30pm)

Time Available Time

Net Time including 5% personal need allowance

Net time (Tea time distributed)

Hourly Output

7-8 am 60 47 48 188-9 am 60 57 58 229-10 am 60 57 58 2210-11 am 60 57 58 2211-12 am 30 28.5 29 1112-1 pm 60 57 58 221-2 pm 60 47 48 182-3 pm 60 57 58 223-3:30 pm 30 18.5 19 7Shift I 480 426 436 162

Shift II (3:30pm – Midnight)

Time Available Time

Net Time including 5% personal need allowance

Net time (Tea time distributed)

Hourly Output

3:30-4 pm 30 18.5 19 74-5 pm 60 57 59 225-6 pm 60 42 43 226-7 pm 60 57 59 227-8 pm 60 57 59 118-9 pm 30 28.5 30 229-10 pm 60 57 59 1810-11 pm 60 57 59 2211-12 am 60 47 49 7Shift II 480 421 436 162

Shift III (Midnight – 7am)

Time Available Time

Net Time including 5% personal need allowance

Net time (Tea time distributed)

Hourly Output

12-1 am 60 47 47 181-2 am 60 57 57 212-3 am 60 57 57 213-4 am 30 28.5 29 114-5 am 30 57 57 215-6 am 60 57 57 216-7 am 60 47 47 18Shift I 390 350.5 350.5 131

Conclusion

A video study of the Muffler End Spinning Machine was conducted. Ideal machining time is 32 seconds

The Cycle Time for the entire Muffler Assembly Cell for Product X was calculated to be 161.04 seconds.

Hourly Output Rate for each shift are: 162 products in Shift I 162 products in Shift II 131 products in Shift III

Thank You