stti presentation 19.07.2010. (1)

Stanzen Toyotetsu India Pvt., Ltd.

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Study Report in WELD LINE

MSRIT

Muzammil Shadab Minkul Tekwani Shreyas KN

Md.Mushtaque Ahmed

Guided by,Mr.Hiremath & Mr.Pradeep Kumar (PC Dept)


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Presentation Outline

Conveyance MinomiProblems facedCounter measuresAcknowledgementConclusion

Objective : Detailed analysis of Conveyance and Minomi routes of weld line.


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Conveyance

Conveyance is the transportation of stamped parts from the storage area to the welding line

In STTI –

A

ROUTE A B C D

MAN POWER 1 1 1 1

ROUTE LENGTH 45m 75m 45m 75m


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Problems Faced A B C DKanbans not used 40 45 41 38 16

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Standard Route not followed 8 12 5 10 35

Non Availability of parts 1 14 12 10 37

Wrong Storage of Stamped

parts

6 3 2 4 15

Traffic/Collision 7 5 12 5 29

Absenteeism 0 4 0 2 6

62 83 72 69Number of samples – 50/course


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From the Problem Vs. Conveyance Route Chart, • Course B is the most problematic & changes need to be made• Kanbans not being used is the most commonly observed

problems


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Minomi

Minomi is a concept wherein parts are transported and displayed at the assembly stations completely without packages.

ROUTE A B C

MAN POWER 1 1 1

ROUTE LENGH 75m 100m 75m

IN STTI:


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Problems Faced A B CKanbans not used 23 25 19 67

Standard Route not

followed

28 25 18 71

Non Availability of parts 15 13 5 33

Traffic/Collision 9 9 0 18

Absenteeism 2 0 4 6

Mixing of parts 14 6 18 38

9178 64

Number of samples – 30/course


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• Course A is the most problematic and changes need to made

• Most commonly found issue – Standard Routes are not being implemented whilst Minomi


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SWOT AnalysisStrengths•STTI has employed Heijunka ie levelled production and Just In Time (JIT)•Visualization with help Kanbans and Poka-Yoke•Efficient inventory Management is followed•Safe working environmentWeakness•Kanban System needs to be implemented perfectly•Stock checklist should be regularly updatedOpportunities•Cycle Time can be reduced to increase productivityThreats


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ACTIVITY DIAGRAM : COUNTER MEASURES

IMPLEMENT KANBAN USAGE TO TRY AND DISTINGUISH BETWEEN RH AND LH

ABSENCE OF KANBANS MIXING OF PARTS

CHECKLIST UPDATATION

ABSENTEEISM

ROUTES NOT IMPLEMENTED

NON AVAILABILITY OF PARTS

ENSURE IMPLEMENTATION OF KANBAN SYSTEM

WEEKLY UPDATING OF ALL AVAILABLE KANBANS AND PARTS

IN CASE OF ABSENTEEISM , ENSURE BACKUP MANPOWER IS PRESENT.EXTRA WORKFORCE CAN BE ASSIGNED OTHER TASKS.

RE-PRINTING OF ALL MISSING KANBANS

EDUCATE THE LABOURERS TO FOLLOW STANDARDIZED ROUTES.REGULAR MONITERING TO FOLLOW ROUTES.


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INTER-RELATIONSHIP DIAGRAPH

TRAFFIC/COLLISION

MIXING OF PARTS

ABSENCE OF KANBANS

CHECKSHEET NOT UPDATED

ROUTES NOT IMPLEMENTED

ABSENTEEISM

NON AVAILABILITY OF PARTS


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PARETO CHART FOR % DEFECTS

IT IS FOUND THAT THE MAXIMUM MAGNITUDE OF PROBLEM DECREASING THE CYCLE TIME IS MISSING KANBAN

% Defect


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AcknowledgementAcknowledgement

We would like to thank the Management of STTI for providing uswith the opportunity for taking up the Training at STTI Plant. Also would like to thank Mr Ravishankar,Mr Guruprasad and ourGuides, Mr Hiremath and Mr Pradeep Kumar of the PC Dept


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After a month of study we put into our assignment of studying the weld line we would like to conclude that ,though STTIhas tremendously succeeded in delivering excellent service to its customers ,there is still a lot of scope for improvement in reducing the cycle time which can result in increased productivityAnd also decreased man power .By doing so STTI cansubstantially cut down on its expenditure and also increase its profitto some extent .The Toyota Production System though in use hasto be implemented at every step and regular monitering has tobe done to keep it in place.

Conclusion


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stti presentation 19.07.2010. (1)

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