VSM (Lean Manufacturing) Project PPT

FINAL YEAR PROJECT PRESENTATION

LEAD TIME REDUCTION OF

BAKING PLATE VIA

VALUE STREAM MAPPING

GROUP MEMBERS Fasih Iqbal (G.L) D-12-IND-305 Adnan Ali Khan D-12-IND-319 Abdullah Nisar D-12-IND-328 Mukaram Ahmed D-12-IND-323 Fahad Ali D-12-IND-317

PROJECT ADVISORINTERNAL ADVISOR EXTERNAL ADVISOR Prof. Shahab Afroz Mr.

Parvez Sadiq

PROJECT COORDINATORMr. Rano Khan

OVERVIEW

INTRODUCTION

DATA COLLECTION AND METHDOLOGY

RESULTS & DISCUSSIONS

CONCLUSION

OVERVIEW INTRODUCTIONDATA

COLLECTION & METHODOLOGY

RESULTS & DISCUSSIONS CONCLUSION

Company Profile:Alsons AutoParts (Pvt.) Ltd. Is an ISO 9001 and ISO-14001-2004 Certified company which was established in 1988, and has become a leading name in the Pakistan Automotive Industry.

Major Products:Alsons AutoParts Pvt. Ltd. consists of three main products in their manufacturing plant, which are given below;

Plastic Injection Moulding Products




Sheet Metal Products:

Automotive assembly products:




Existing Situation:




The existing situation of press shop is that they have a targeted schedule of the production of 1200 plates daily for Suzuki with a Takt time of 0.375 min/pcs which is difficult to achieve so in order to meet the customer demand they go for over time.

The company experiences the following issues in the manufacturing of backing plate at press shop. Lack of Traceability of product. Greater lead-time. Unnecessary stoppages Greater Takt time

Issues:

INTRODUCTION:

Industries are in the favor to get more capital and resources to improve theirproductivity.It is necessary to optimize their capital, time and working environment. Industriesneeded improvement tools to optimize its processes to attain more capable results.Many improvement techniques and tools were developed and adapted to work in thedifferent types of business.

Now day’s industries focused on more production with higher efficiency in less leadtime. The companies focused mainly on customer satisfaction. In an increasinglycompetitive environment, many manufacturing firms are looking for a winning cardover their competitor. Manufacturers have to understand that the conventionalproduction system has to connect with the lean tools and techniques.

Lean manufacturing system was developed by Toyota, Japan.




Project Background:

A shorter lead time results into better utilization of manufacturing resources, quick adaptation to customer’s demand, reduced cost and better products. Today companies are intensively indulging in activities to reduce their production lead times.

Our Team, keeping in mind, the importance of a short lead time, therefore we worked in Alsons AutoParts with the intention to reduce Production Lead time. Technique that the team adopted was Value Stream Mapping .

Value stream mapping is the technique of Lean Manufacturing.




VALUE STREAM MAPPING:

Value Stream Mapping (VSM) tool shows all the activities, from supply to final product through the different processing steps.In other words it is a sketch of a production line.

Value stream map is the technique that bring the all processing steps at one place. It shows the big picture of shop floor rather than individual processes and improving the each area at the production line. It is used to draw attention to different wastes and eliminating them in Future State Map.

It is necessary that every process as closely as possible produces only what its customers need. The existing processes have some types the waste in a production line which is the result of product design and machinery.




Lead Time:

• A lead time is the time interval between the initiation and execution of a process.

• In industry, lead time reduction is an important part of lean manufacturing




Critical inputs for the VSM:The following data are considered to be important in a value stream mapping project.

• Cycle time

• Number of operators

• Waiting time

• Process time per shift




Methodology:




1.Selection of the Product:The selection of the product is very important step in Value Stream Mapping.Baking plate is the critical product of the Alsons AutoParts due to itsrequirement and demand by the Suzuki Automobiles.

There is the lack of traceability, scheduling, greater lead time, unnecessarystoppages, etc. Due to these problems the completion of the customerdemand on time will be difficult.

After observing all these major issues which will directly effects the wholeproduction system .BAKING PLATE is our critical product for working forthe improvement




2.Collection of Relevant Data:




I. Product flow within press shop.

II. Cycle time of each process.

III. Identification of bottlenecks.

IV. Transportation of product within press shop.




I. Product Flow within Press Shop:

II. Cycle Time of each process:

Process Cycle timeShearing 13secBlanking 23secForming 12sec

Collar Bending 11secFlattening 8secPiercing 1 10secPiercing 2 10sec

Chamfering 11secCO2 Welding 20sec

Remering 10secSpot Welding 28sec

Debeurring 12sec




Flattening It has the capacity of 960 pieces per shift which is a bottleneck for press shop.

Reason: Lack of trollies at the workstation, which stops the production after 100 pieces which creates bottleneck for production system.

III. Identification of Bottlenecks:




Spot Welding: It has the capacity of 450pieces/shift by each machine. Press shop has 2 spot welding machines which produces 900 pieces per shift.




IV. Transportation Method: 1-With the help of trollies. 2-Fork lifter. 3-Manual lifter







3.Current State Map:

Description:

• The current state map shows that the backing plate has the production lead time of 12.6 hours.• It clearly shows the unwanted Waiting Time between each workstation .• It shows the big picture about the real time process & performance of the production process.




4.Identification the nature of wastes in the process:




Wastage of time:• Un necessary usage of lifter between the process shearing &

blanking which causes delays in production up to 1 hour due to un availability of lifter at the press shop.

• Lack of availability of trollies at each work station which causes the process to stop & wait for the raw material inventory .




5.Future State Map

Future Product Flow Layout:




Description:• Lead time reduced about 2.25 hours i.e. 20% reduction

which reduces the companies overtime cost.• Reduced the transportation between the processes.• Kaizen burst:

1)Machine Relocation2)Material handling equipments3)New machine.




6.Suggestion for Improvements:




Ergonomic trollies should be used

which provides effectivetransportation within press shop.

I. Material Handling Equipments

II.Machine Relocation:Relocation of blanking machine near to shearing machine so that the operation of lifter will be eliminate which reduces:

1- Transportation time.2- Transportation cost. 3- Process waiting due to un availability of lifter.




III. New Machine

Another Spot Welding Machine should be install to fulfill the requirements.

Cooling system must be maintained properly for effective working.Good quality electrodes will help to increase productivity & on time delivery of products.




Conclusion:The project was to reduce the production lead time, for this purpose the teamselected lean manufacturing tool Value Stream Mapping.In addition to reduction of lead time, following benefits were expected afterthe completion of the project.

Improved productivity Determination of Value stream Better understanding of Wastes and their causes A roadmap towards an efficient, lean production line




VSM (Lean Manufacturing) Project PPT

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