Sona Koyo Steering Systems Ltd Dharuhera Team

Welcomes

1/49

Organization & Products

*

DELHI

GURGAON

MUMBAI

Chennai PlantChennai Plant

CHENNAI

Dharuhera Plant

DHARUHERA

PRODUCTS DHR PLANTColumn Electric Power Steering Assy. (CEPS)

Pinion Valve Assy. (PV Assy.)

Upper Shaft

Dharuhera PlantFounded : Jul 20061st. SOP started : Jul 2007Annual Sales F-10 : 264Cr.

Hydraulic Power Steering Assy.(HPS)

Gurgaon PlantGurgaon Plant

SKSSL Group(Gurgaon, Dharuhera & Chennai)

Products & Customers

Column Electric Power Steering (CEPS) Hydraulic Power Steering

Customer: Maruti Suzuki India Ltd

Mo

de

ls

Assembly Assembly

Wagon R Alto

Zen Estilo

Customer: Mahindra & Mahindra

Mo

de

lsScorpio

Bolero

Productivity improvement on Valve Body Line

Project Selection

Valve Body

Pinion Valve Assembly

Theme Selection

Customer RequirementF13F14F15

182,023

206,340

236,340

0

50000

100000

150000

200000

250000

F13 F14 F15

Customer Requirement for HPS

CustomerRequirementN

os

For HPS Customer Requirement trend increasing

19695

12278

0

10000

20000

30000

Customer Requirement line Capacity

Capacity Vs Requirement per month

Gap : 7417 Nos

Problem Statement

Increase Line capacity by investing in

new machines

Increase Line capacity by

doing kaizens

Option chosen

HPS line capacity found 44 % less compared to customer requirement for F-15

Process Mapping : HPS Group

Understanding Situation

Receipt store RQA

HPS AssemblyDispatch

Input Shaft

PV Assembly

Valve Body

Pinion Shaft

Torsion Bar

HPS Assembly Block Diagram

21600 21207

12278

44862

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

50000

I.S P.S V.B T.B

Customer requirement Vs line capacity Customer Requirement

per month 19695Nos &Takt Time 56

Capacity

Requirement

Bottleneck Line :Gap of 7417 parts

Understanding Situation

IDGrinding

Gangway

Crack Detection

Pass Hole Deburring& pining

I DBuffing

Washing

Spline &SlitBroaching

Slit GrindingHoning

Sleev Pressing

I D Deburring

Pass Hole Drilling

ID & ODBuffing

Line Layout & Process flow

Gangway

A-83 A-91 A-74 A-62 B-85

A-88

Induction Hardening

A-70A-68A-84A-86

B-08For Assy.

Washing

B-10

A-76

Understanding Situation

Induction HardeningPasss Hole Deburining & piningSleev PressingI.D GrinidingSlit GrindingHoningI.D. & O.D Buffi ngCrack CheckWashing

46 4535 39 36

90

35 4052

3547

3645

35

0102030405060708090

100

M/c Cycle Time

Cycle Time

Cyc

le T

ime

( Se

c )

Understanding Situation

Target Cycle Time 55 Sec

HPS line capacity found 44 % less compared to customer requirement for F-15

Target Setting

90

50

5

0

20

40

60

80

100

Current Target

Sec

onds

Target cycle time for Induction Hardening Process Manual

Auto

We set target of achieving Induction Hardening process Cycle Time 55 sec (50 sec Auto +5 sec Manual) by 30th May-14 .

Action Plan

S.No Activities Feb-14-Jun-14

Feb March April May Jun July

1 Understanding Situation

2 Data Collection

3 Analysis

4 Countermeasure implementation

5 Effectiveness Monitoring of Countermeasures

6 Standardization

AnalysisOperation Sequence at

Induction Hardening M/c.

Positioning

Tempering

Unloading

Loading

Cooling

Positioning

I.D Heating

Quenching

PositionIng

Slit Heating

Quenching

Sketch Diagram of Induction Hardening M/c

Loading I.D. Hardening Slit Hardening Tempering Un-Loading

Three operation (ID Hardening, Slit Hardening & Tempering) performed for each component

37%

63%

Effective Process Time

Non Effective ProcessTime (Transfer Time)

Analysis cont..

Non-effective operation Time for Induction Hardening process

S.No operation Time(sec.)

1 Positioning for I.D Hardening 102 Positioning for Slit Hardening 273 Positioning for Tempering 104 Component Unloading 10

Total Non Effective Time 57

Hence brain storming done to reduce None

Effective Process time

Effective operation Time for Induction Hardening process

S.No operation Time(sec.)

1 Heating at ID hardening station 82 Quenching at I.D hardening station 103 Heating at slit Hardening station 34 Quenching at slit Hardening 55 Heating at Tempering station 36 Cooling at tempering station 6

Total Effective Time 33

Cycle Time study done and found only 37 % time is Effective for Process but 63 % time is not effective for hardening Process to achieve product parameter

Analysis cont..Break-up of non effective time

Hardening machine

S.No Non Effective Time Time(sec.)

1 Positioning for I.D Hardening 102 Positioning for Slit Hardening 273 Positioning for Tempering 104 Unloading 10

Total Non Effective Time 57

1 Loader Reverse 22 Gripper Loading Station Clamp 13 Loader Up 14 Loader Forward 25 Loader Down 16 Gripper Loading Station Declamp 17 Job lift Up Id Hardening Station 28 Job Lift Down I.D hardening Station 19 Loader Reverse 210 Gripper I.D Station Clamp 111 Loader Up 112 Loader Forward 213 Loader Down 114 Gripper I.D Station Declamp 115 Job lift Up Slit Hardening Station 216 Rotate for Slit Detection 1117 Job Lift Down Slit Hardening Station 118 Ratate for Heating Position 219 Job lift Up Slit Hardening Station 220 Job lift Down Slit Hardening Station 121 Loader Reverse 222 Gripper Clamp Slit Hardening Station 123 Loader Up 124 Loader Forward 225 Loader Down 126 Gripper Declamp Slit Hardening Station 127 Job lift Up Tempering Station 228 Job lift Down Tempering Station 129 Loader Reverse 230 Gripper Clamp Tempering Station 131 Loader Up 132 Loader Forward 233 Loader Down 134 Gripper Declamp Tempering Station 1

S.No. Operation Time

Po

siti

on

ing

for

I.D

H

ard

en

ing

Po

siti

on

ing

for

Slit

Har

de

nin

gP

osi

tio

nin

g fo

r Te

mpe

rin

gC

om

po

nrn

t U

nlo

adin

g

Analysis cont..Is this Step Is necessary ?

Can We Eliminate ?

Can we reduce ?

Can we overlap with other activities ?

Conclusion (Should We Change it)

1 Loader Reverse 2 P P Yes

2 Gripper Loading Station Clamp 1 P No

3 Loader Up 1 P P Yes

4 Loader Forward 2 P P Yes

5 Loader Down 1 P P Yes

6 Gripper Loading Station Declamp 1 P No

7 Job lift Up Id Hardening Station 2 P No

8 Job Lift Down I.D hardening Station 1 P No

9 Loader Reverse 2 P P Yes

10 Gripper I.D Station Clamp 1 P No

11 Loader Up 1 P P Yes

12 Loader Forward 2 P P Yes

13 Loader Down 1 P P Yes

14 Gripper I.D Station Declamp 1 P No

15 Job lift Up Slit Hardening Station 2 P No

16 Rotate for Slit Detection 11 P P Yes

17 Job Lift Down Slit Hardening Station 1 P No

18 Ratate for Heating Position 2 P No

19 Job lift Up Slit Hardening Station 2 P No

20 Job lift Down Slit Hardening Station 1 P No

21 Loader Reverse 2 P P Yes

22 Gripper Clamp Slit Hardening Station 1 P No

23 Loader Up 1 P P Yes

24 Loader Forward 2 P P Yes

25 Loader Down 1 P P Yes

26 Gripper Declamp Slit Hardening Station 1 P No

27 Job lift Up Tempering Station 2 P No

28 Job lift Down Tempering Station 1 P No

29 Loader Reverse 2 P P Yes

30 Gripper Clamp Tempering Station 1 P No

31 Loader Up 1 P P Yes

32 Loader Forward 2 P P Yes

33 Loader Down 1 P P Yes

34 Gripper Declamp Tempering Station 1 P No

Fo

r T

em

pe

rin

gF

or C

om

po

nrn

t U

nlo

ad

ing

S.No. Time

Questionnaire

OperationF

or I

.D H

ard

en

ing

Fo

r S

lit H

ard

en

ing

Analysis cont..

ProblemNon Effective time is more at Valve body Induction Hardening M/c

Why-1 Why Non effective (non-Operation) time is more ?

Answer Component Transfer time for different operating is more

Why-2 Why Component Transfer time for different operating is more ?

Answer At a time only single component transfer for different operation.

Why-3 Why single component transfer for different operation?

Answer Process was not optimize for Three component transfer at a time.

Root-causeAt a time only single component transfer for different operation

Counter measureAt a three component should be transfer for different operation.

Implementation of CountermeasureKaizen-1: Cycle time reduction Induction Hardening machine

O0004(NC PROG) BEFOREG98M47(LOADER REVERSE)M48 (GRIPPER 1 CLAMP)M44 (LOADER UP)M46(LOADER FORWARD)M45 (LOADER DOWN)M49 (GRIPPER 1 UNCLAMP)M40G04P1000 M08G04P1000 M3S80M12G04P1400 M10M13G04P10000M11M09G04P500M41M47(LOADER REVERSE)M50(GRIPPER 2 CLAMP) M44 (LOADER UP)M46(LOADER FORWARD)M45 (LOADER DOWN)M51(GRIPPER 2 UNCLAMP) G90G01F2000C0.0G04P500G90G01G31F2000C359.0 M69G04P500G01F2500C-90.0

G04P500M68B7500M70G04P3000 M19M71G04P6000 M20M69M47(LOADER REVERSE)M52(GRIPPER 3 CLAMP)M44 (LOADER UP)M46(LOADER FORWARD)M45 (LOADER DOWN)M53(GRIPPER 3 UNCLAMP)M42M17T4500M60G04P2000 M61G04P3000 M18M43M47(LOADER REVERSE)M66(GRIPPER 4 CLAMP)M44 (LOADER UP)M46(LOADER FORWARD)M45 (LOADER DOWN)M67(GRIPPER 4 UNCLAMP)G04P3000 /M99 M30

N6000M40 M38M36M08M3S27M12G04P5700(HARDENING TIME-3) M10M36M13M39M83IF[#1000EQ1]GOTO100M68N220IF[#1005EQ1]GOTO350G90G01F5000C0.0G90G01F5000C359.9IF[#1004NE1]GOTO220M42M11M69M74T1600(TEMP. POWER) M17M70G04P1800(TEMP TIME)M71M75G90G00F2500C-88.5M68IF[#1000EQ1]GOTO100M11M37M17M64B5650M60G04P1600M72M19P1000 M61M65

M41M09M20M75M43M14M20M69G04P1000 M15M18IF[#1000EQ1]GOTO100M73M20M47(LOADER REVERSE)M66 (GRIPPER 4 CLAMP) M52(GRIPPER 3 CLAMP) M50(GRIPPER 2 CLAMP)M48 (GRIPPER 1 CLAMP)M44 (LOADER UP)M46(LOADER FORWARD)M45 (LOADER DOWN)M67(GRIPPER 4 CLAMP) M53(GRIPPER 3 CLAMP) M51(GRIPPER 2 CLAMP)M49 (GRIPPER 1 UNCLAMP)M85G04P600IF[#1006EQ1]GOTO500M01IF[#1001EQ1]GOTO200GOTO6000 M47M30(PRG END)N100M80N200M81N300M82N350M98P9025 M99M30N500M98P2580 M30

4component transfer at a time

Only one Component transfer at time

Effectiveness of Countermeasure

50

90

72

0

20

40

60

80

100

Target cycle time Before After

Sec

Induction Hardening machine cycle time

Result after kaizen -1

Still Gap is 22 Sec

Countermeasure-2Video captured and analysis was done for operation on Induction Hardening M/c

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

1 Positioning

2 Heating

3 Quenching

4 PositionIng

5 Heating

6 Quenching

7 Positioning

8 Heating

9 Cooling

10

Cycle Time after action ( Total Cycle Time 72 sec.)

Time (Sec.)

Tempering

Unloading

S.No. Operation

ID Hardening

Slit hardening

Some Operation should be

simultaneously

Operation time is more

Countermeasure-2 cont..

After Kaizen Cycle Time 50 sec.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

1Positioning

2Heating

3Quenching

4PositionIng

5Heating

6Quenching

7Positioning

8Heating

9Cooling

10

Tempering

Unloading

Cycle Time After Condition ( Total Cycle Time 50 sec.)

S.No. OperationTime (Sec.)

ID Hardening

Slit hardening

Loading I.D. Hardening Slit Hardening TemperingUn-Loading

Countermeasure-3

Loading I.D. Hardening Slit Hardening TemperingUn-Loading

Before Condition Cycle Time 50 sec

After Condition Cycle Time 48 sec

Component Loading

Component Loading

Transfer Time 2 sec reduced

Check Result

50

72

48

0

20

40

60

80

Target cycle time Before After

Sec

Induction Hardening machine cycle time

StandardizationDATE(Ori gi n) 1/7/2007 CHECKED By PREPARED BY

Rev. No : 0

Rev da te : -

NEEDED UNITS PER

SHIFTA.K Si ngh Yoges h kuma r

STANDARD IN

PROCESS STOCK

QUALITY CHECK

SAFETY

Sona

Sta nda rd i n proces s

s tock 5

Productionper hour

40

STANDARDIZED WORK CHART

Pa rt No. D040-5911

Proces s Va lve Body Ma chi ni ng

Ta kt Ti me

Cycle Time90 min

1 2 3

DATE(Ori gi n) 1/7/2007 CHECKED By PREPARED BY

Rev. No : 0

Rev da te : -

NEEDED UNITS PER

SHIFTA.K Si ngh Yoges h kuma r

STANDARD IN

PROCESS STOCK

QUALITY CHECK

SAFETY

Sona

Sta nda rd i n proces s

s tock 5

Productionper hour

67.9

STANDARDIZED WORK CHART

Pa rt No. D040-5911

Proces s Va lve Body Ma chi ni ng

Ta kt Ti me

Cycle Time53 min

1 2 3

SWC Before SWC AFTER

Tangible Benefits

40

67.9

0

10

20

30

40

50

60

70

80

Before After

No

s

Productionper Hour

36

0 0

5

10

15

20

25

30

35

40

Before After

Are

a(M

eter

2) Space Saving

9

11.8

0

2

4

6

8

10

12

14

Before After

Nos

Production perMan Hour

90

0 0

102030405060708090

100

Before After

Ru

pe

s(La

c)

CapitalInvestmentSaving

Intangible benefits

1.Customer requirement fulfilled .

2.Capital investment can be deferred .

3.Highly motivated team

4.Motivated workmen force

5.Encouragement to other Teams

26/49

1. 2.

Future Plans

27/49

Thanks for Kind Attention