case study setting time reduction

8/7/2019 CASE STUDY SETTING TIME REDUCTION

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2/12

CELL I - Set Up Time Reduction - ( Loss Number 2 )

Product : Wheel Cylinder Machining

Approach:

Cross functional team formed

VTR Study conducted

Activities Classified as Removal, Fixing

& adjustments

Counter Measures & Kaizens Identified

Target set - 2 Months

Operation : Fine Reaming & Rolling

Machines : REAMING 2

Brakes India LimitedBrakes India Limited, Padi, Padi

Theme : Set Up Time Reduction

Back Ground : -

12 Product Varieties are Handled in Reaming Machine -2.

Customers require weekly delivery schedule than monthly delivery.

Capacity constraint is there to accommodate all the varieties by weeklyFrom pareto, we found setting time increased due to high frequency

PARETO CHART ON LOSS HOURS IN REAMIING 2

8.2

1.8

0.24 0.2

78.54

95.7910098.08

0

2

4

6

8

10

SETTING TOOL CHANGE ADJUSTMENT

LOSS

BREAK DOWN

TIMEINHRS

0

10

20

30

40

50

60

70

80

90

100

PERCENTAG

5


3/12

Identify Machine

Set Theme


Conduct Time Study, Video Study

Categorize Activities Removal,Fixing & Adjustments.

Implement Kaizens for Tool Presetting

Fixture Presetting etc.,

Implement Kaizens for Conversion from

Internal to External activities

Implement Kaizens for

Internal & Adj. Activities

Sustain

Standardise

Horizontal Deployment Savings Evaluation

Identify

KAIZENS

Identify

KAIZENS

Observe Performance

SET UP TIME REDUCTION

METHODOLOGY


4/12


Exist ing Target

1 Removal of Acrylic Guard Spindle To Aviod Oil Spillage Required - 5 5

23 Nos Alen screw loosening from Top

locatorFixture For holding Top locator Required - 30 30

33 Nos Alen screw removal from Top

locatorFixture To change the Part No Eliminate

Elongated radial Slot to be Provideded in

Top locator65 0

4 Grub screw loosining from spindle Spindle For holding the spindle Required - 15 15

5 Reamer & Locator removal Fixture & Spindle To change the Part No Reduce PLC to be modified 35 15

6 Bottom locator removal Fixture To change the Part No Required - 10 10

7 Washing exsisting Locators Kerosine Tank To remove the burr Required - 10 10

8 Removing Rolling tool Rolling m/c To change the Part No Required 60 60

Fixing Activity

9 Washing new Locators Kerosine Tank To remove Forign materieal Required - 10 10

10 Fixing Bottom Locator Fixture For holding the Part Required - 25 25

11 Fixing Top Locator Fixture For holding the Part Reduce PLC to be modified 30 10

12 Fixing Reamer Spindle For cutting the bore Reduce PLC to be modified 35 10

13 Tightning Grub screw to spindle Spindle For holding the spindle Required - 12 12

14 3 Nos Alen screw fixing to Top locator Fixture For holding Top locator EliminateElongated radial Slot to be Provideded in

Top locator65 0

15 Tightning 3 nos alen screw to top locator Fixture For holding Top locator Required - 25 25

16 Fixing Acrylic Guard Spindle To Aviod Oil Spillage Required - 5 5

17 Fixing Rolling tool Rolling m/cTo meet the Specification of

the ProductRequired - 25 25

Adjustment Activity

18 Bottom Dog Loosining Limit Switch To change the Part No Required - 5 5

19 Bottom Dog Adjustment Limit Switch To change the Part No setting Reduce Setting Block to be introduced 15 5

20 Bottom Dog Tightning Limit Switch For holding the Dog Required - 5 5

21 Slide Postioning slide ways For travel of reamer Eliminate Setting Block to be introduced 60 0

22 Approch Dog Loosining Limit Switch To change the Part No Required - 5 5

23 Approch Dog Adjustment Limit Switch To change the Part No setting Reduce Setting Block to be introduced 15 524 Approch Dog Tightning Limit Switch For holding the Dog Required - 5 5

25 Slide Postioning slide ways For travel of reamer Reduce Setting Block to be introduced 25 10

26 Adjustment Rolling tool Rolling m/cTo meet the Specification of

the ProductEliminate Pre setting to be Introduced 240 0

Internal Activity

27Control Plan,Drawing,Locators,&

Reamer taken from StoreTool Store To change the Part No Eliminate

Before Setting all tools lying in near the

Machine300 0

28 Mercer Plug taken from store Tool Store To change the Part No EliminateBefore Setting all tools lying in near the

Machine150 0

29 Adjustment of Mercer Plug Setting Gauge Stand To meet Master Value Reduce Pre Setting to be Introduced 80 20

30Bore Concentricity checking at S urface

TableInspection Table To Meet Product Specification Reduce K ept in Near the Machine 90 30

31Bore Surface Finish checking at

Stds.RoomInspection Table To Meet Product Specification Reduce Kept in Near the Machine 120 60

32 First off Report Preparation Inspection Table o preparation of Product History Reduce Kept in Near the Machine 180 120

Total in Seconds 1757.00 537

Total in Minutes 29.28 8.95

Time Taken (Secs)

Removing Activities

Machine : Reaming 2

Activities Split Up

Action Plan ( How )Counter

MeasureWhyWhereSl.No Activities


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Gantt Chart

AFTER - 8.95 MintsBEFORE 29.28

1 2 3 4 5 6 7 8

10 11 12 13 14 15 16 17 18 1

20 21 22 23 24 25 26 27 28 2

30

REMOVING

21

1

1

1

2

1

1

0.3

11

ADJUSTMENT

2

1

2

3

Internal

5

2

1

0.2

2

0.3

2

1 3

2

3 Remove Rolling Tool

1 Remove Locators

2 Remove Reamer

Fixing Rolling tool

5 Fixing Locators

6 Fixing Reamer

14

Control

Plan,Drawing,Locators,&

Reamer taken from Store

15 Mercer Plug taken fromstore

16Adjustment of Mercer

Plug Setting

17

Bore Concentricity

checking at Surface

Table

18Bore Surface Finish

checking at Stds.Room

1 First off Report

Preparation

Activities

13

Time In MINS

FIXING

Adjustment Rolling tool

11 Approch Dog Adjustment

Bottom Dog Adjustment

7

Elongated Slot

Introduced

PLC panel

Setting

Block

Introduced

Pre Setting

Introduced

Before Setting all tools

lying in near the Machine

Kept in Near the Machine



6/12

Major ImprovementsAfterBefore

PLC Control has been changed in Electrical Panel

Elongated Slot has been changed in Top locator


7/12

Setting Block has been Introduced

Major ImprovementsBefore After


8/12

GROUP A GROUP B GROUP C GROUP - D


Machine : Reaming - 2

Part No Over all Length Reamer No Reamer length

2966 3388 / 89 58.2 / 57.8 22RS2099 170

2966 6449 58.2 / 57.8 22RS2098 170

2966 6136 / 37 58.2 / 57.8 22RS2101 170

2966 5877 59.0 / 58.5 22RS2052 160

2966 5073 59.0 / 58.5 22RS2065 170

2966 5084 59.8 / 60.3 22RS2052 160

2966 5089 59.8 / 60.3 22RS2065 170

2966 4765 63.7 / 63.2 22RS2033 170

2966 2540 52.0 / 51.6 22RS2100 150

2966 5632 55.3 / 54.8 22RS2081 150

2966 5744 55.3 / 54.8 22RS2099 170

Group C 2966 2800 90.9 / 90.4 22RS2058 190

6467 5317 79.1 / 79.7 22RS2033 170

2966 5518 79.1 / 79.7 22RS2057 190Group D

Group A

Group B

Grouping Details For Setting Block


9/12

Results


A C T IV I T IE S S P IL T U P IN S E T T IN G - R E A M IN G 2

7 . 5

2 . 42

0 . 7

3 . 8 63 . 8 3

0

1 0

R E M O V I N G F I X I N G A D J U S T M E N T

NUM

BER

O

F

AC

G O O D

ACTIVITIES IN SETTING - REAMING 2

18

36

0

10

20

30

40

Bef ore A f ter

NU

MBER

II

IE

BEFORE AFTER

GOOD

EX T E R N AL AC T I IT IES

6

00

2

4

6

8

INTERA NA L EXTERNA L

N

UM

BERO

FA

CTI

I

BEFO RE A FT ER

G O O D


10/12


Results

INVENTORY REDUCED

2300

7000

0

2000

4000

6000

8000

BEFORE AFTER

QTY.

BEFORE AFTER

GOOD

FREQUENCY INCREASED

BEFORE AFTER

Nos

BEFORE AFTER

GOOD


11/12

Results

Benefits : Set Up Time Per Set Up Reduced from 30 to 9 Mins.


I I

9

30

0

5

10

15

20

25

30

35

May '05 June '05 July '05 Aug '05 Sep '05 Oct '05

I

I

I

Before

After


12/12

PERFORMANCE TREND CHART

0

20

40

60

80

100

PERFORMANCE

PE

FO

MANCE 81.2 96.6 92.9 92.8 90.3 87.3 89.8 88.9 91

200 200 200 Apr- Ma Jun-Jul- Au Se

QUALITY RATE TREND

99.7

99.75

99.8

99.85

99.9

99.95

100

QUALITY

RATE

QUALITY 99.8 99.95 99.91 99.96 99.92 99.91 99.92 99.98 99.98

2002 2003 2004 Apr- M ay- Jun- Jul- Aug- Sep-

AVAILABIL I

74

76

78

80

82

84

86

88

AVAILABILI

%

AVAIL. 80.63 84.81 78.25 82.02 82.3 82.85 83.1 85 85.9

2002 2003 2004 Apr- May- Jun- Jul- Aug- Sep-


55

60

65

70

75

80

OEE

OEE 65. 49 70. 3 72. 61 74. 3 74. 6 72. 21 7 4. 56 76 78

2002 2003 2004 A

May

J

J

l

05 A

Se

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