IMPLEMENTATION OF LEAN IMPLEMENTATION OF LEAN MANUFACTURING IN CAB TRIM MANUFACTURING IN CAB TRIM
THROUGH V.S.M THROUGH V.S.M
M6234 - ADVANCED MANUFACTURING M6234 - ADVANCED MANUFACTURING SYSTEMSYSTEM
Submitted by
ARANGANATHAN SOUNDARARAJAN - G0900691ABHASKARAN RAGHUKARTHIK - G0900695L
NATARAJAN KARUPPAIH - G0900707CPRAVEEN KANTHARAJ BALASUBRAMANIAM - G0900718J
SANKARANARAYANAN TYAGGARAJAN - G0900725ESENJIVEL SENTHIL KUMARAN - G0900779E
ABSTRACTABSTRACT
The aim was to analyze its current manufacturing system and to propose a
more advanced system for its future migration.
From the derived current VSM, we identified the potentials for
improvement and implemented the same while mapping the future state
VSM. They can be listed as,
• Unequal distribution of work load – Waiting time
• High potential for sub assembly in main line
• Wasteful motion
Hence the objective is to increase the production by eliminating the
non-value adding activities.
CABIN MANUFACTURINGCABIN MANUFACTURING
CAB WELDING
CAB PAINTING
CAB TRIMMING
CHASIS ASSEMBLY
LINE
43 Assembly Station26 Sub Assembly Station 16 Stages
Cabin Manufacturing involves :
Cabin welding:
-The various panels get spot welded - cubed into a shell -
reinforced to gain strength
-Then they are MIG welded and then moved to Cab paint shop
through an automatic conveyor
Cab Painting:
-Here the shell is further degreased
-And primer coated by an Electro Deposition painting process
and top coated with required color
-The cabin is then moved to Waxing zone where the cabin body is
PVC coated.
Cab Trimming:
-The painted shells are trimmed in a conveyor line with 43
stations and 26 sub-assembly stations which are grouped into 16
stages.
-Here the cabin gets the real shape
-The fully trimmed cabin is picked up for fixing on to the chassis
through a automatic conveyor arrangement.
CLASSIFICATION OF MODEL CLASSIFICATION OF MODEL CABINSCABINS
Cargo day cabins Cargo sleeper cabins LHD- day cabins LHD- sleeper cabins Stallion LRV
The introduction of Cargo in ABC Ltd product range
paved the way to meet company's corporate goal of
"Global Standards-Global Markets".
PRODUCTS MANUFACTUREDPRODUCTS MANUFACTURED
The wide ranges of products manufactured by ABC Ltd are
listed below.
7 Ton GVW to 45 Ton GTW Vehicles
26 To 90 Seated Buses
Special Application Vehicles
Off highway vehicles
Defense support vehicles
Diesel Engines for Industrial & Marine Application
SYSTEM ARCHITECTURE IN CAB SYSTEM ARCHITECTURE IN CAB TRIMTRIM
Stage 1- Main loom routing, Wind chord fixing
Stage 2- Pedal box, Fuse box, P-B Valve
Stage 3-Head lamp, E2 Valve
Stage 4-Rear cab lock, under body Lamp.
Stage 5-Drop glasses, Regulator, Door glass, Door lock.
Stage 6- Wind screen Quarter vent glass, Rear glass, and Side glass.
Stage 7- Roof marker lamp, Hood seal.
Stage 8-Linings
Stage 9-Floormat, Door beading, Seat bracket
Stage 10-Wiper assembly
Stage 11- Berth seat, Belt, First aid box.
Stage 12-Mirror bracket, Driver seat
Stage 13-Hood, Steering, Windscreen Washer.
Stage 14-Sun visor, Clutch Bundy pipe, Door pad
Stage 15-E2 Valve, Instrument panel.
Stage 16-Door trim, Weather strip
STAGE 1STAGE 1
STAGE 2STAGE 2
STAGE 3STAGE 3
STAGE 4STAGE 4
STAGE 5STAGE 5
STAGE 6STAGE 6
STAGE 8STAGE 8STAGE 7STAGE 7
STAGE 16STAGE 16
STAGE 15STAGE 15
STAGE 14STAGE 14
STAGE 13STAGE 13
STAGE 12STAGE 12
STAGE 11STAGE 11
STAGE 10STAGE 10
STAGE 9STAGE 9
Main loom routing, Wind chord fixingMain loom routing, Wind chord fixing
Pedal box, Fuse box, P-B ValvePedal box, Fuse box, P-B Valve
LiningsLiningsRoof marker lamp, Hood sealRoof marker lamp, Hood seal
Wind screen Quarter vent glass, Rear glass, and Side glass
Wind screen Quarter vent glass, Rear glass, and Side glass
Drop glasses, Regulator, Door glass, Door lockDrop glasses, Regulator, Door glass, Door lock
Rear cab lock, under body LampRear cab lock, under body Lamp
Head lamp, E2 ValveHead lamp, E2 Valve
Door trim, Weather stripDoor trim, Weather strip
E2 Valve, Instrument panelE2 Valve, Instrument panel
Sun visor, Clutch Bundy pipe, Door padSun visor, Clutch Bundy pipe, Door pad
Hood, Steering, Windscreen WasherHood, Steering, Windscreen Washer
Mirror bracket, Driver seatMirror bracket, Driver seat
Berth seat, Belt, First aid boxBerth seat, Belt, First aid box
Wiper assemblyWiper assembly
Floor mat, Door beading, Seat bracketFloor mat, Door beading, Seat bracket
OBJECTIVE OF THE PROJECTOBJECTIVE OF THE PROJECT
Implementing Lean manufacturing tool, VSM to identify the
Non value adding activities
To handle various models with varying work content
To finish the cabin in the line itself
To enable the line to produce fully built quality cabins
To improve the overall efficiency of the line
To distribute the work load equally to all stages
METHODOLOGYMETHODOLOGY
Study the current flow of material and information available in the
shop by value stream mapping.
Identify the losses due to unwanted/Non value adding activities.
Plan actions to reduce unwanted activities by Lean manufacturing
technique.
Balance the line to improve productivity.
Suggest recommendations to reach the target by using various
Lean tools to lean the line.
WHAT IS VSM ???WHAT IS VSM ??? Value Stream Mapping, a powerful tool used to map out both
the material and information flow.
The flow of the product from start to finish is the value stream
including all value added and non value added actions.
This includes action to process information from the customer
and actions to transform the products on its way to customer.
It is also known as Material Information Flow Analysis.
It is a simple diagram in a single page - a product path from
order to delivery.
VSM begins its journey with the current state MIFA . And it
ends with the future state MIFA.
Using VSM we can stream line work processes - cutting lead
time and operating costs.
A future state MIFA shows the opportunity for improvement
- to achieve a higher level of performance.
BENEFITS OF VSMBENEFITS OF VSM
Identify the flow of value stream and identify the waste.
All products are viewed from an overall system
perspective.
Draw both material and information flow of the value
stream.
Draw a blue print for lean transformation.
Prioritize the activities needed to achieve the future state.
SYMBOLS IN VSMSYMBOLS IN VSM
Movement of goods
Outside Source Lorry Movement from supplier to customer
Manufacturing Pull Arrow Push Arrow
Process
Company Name
1 per week 250 per box
Assembl
Inventory controlled by location, quantity and replenishment method
3000
First in First out Uncontrolled
sequence Shop stock inventory
Electronic Information flow
Data box
FIFO
C/T =
SHIFTS =
C/O
PROCEDURE FOR VSMPROCEDURE FOR VSM
The steps to map Value Stream are :
• Define Customer Requirement
• Draw Process step
• Gather Process Data
• Explains the external Material Flow
• Explains the internal Material and Information Flow
• Lead Time Hints
CURRENT STATE OF THE CURRENT STATE OF THE CABTRIMCABTRIM
Line Efficiency:
The task time is calculated as 129.11minute and the number of
stages is 16 with 12.02minutes as cycle time.
EFFICIENCY OF THE LINE = TASK TIME
(NUMBER OF STAGES) X (CYCLE TIME)
= 0.671 *100
= 67.1%
20
Current state V.S.M.Current state V.S.M.
Roof lamp
3.54
Rear glass Door inner W/S
4.6 2.16
Side glass Glove box lid
4.6 2.97
QV glass Inst panel
4.6 21
S/A Name E2 valve Door lock Wind screen
Speedo meter
Cycle Time 8 2.6 7 2.7
S/A Name Pedal Box Drop glass
ChannelRear lining
Acc Pedal Hood Console plate
Cycle Time 16.2 2.4 7 2.06 1.24 13 5.5
S/A Name Main loomPB valve S/A
Head lamp
Top glassHead lining
Acc X shaftStg column
Consloe cover
Cycle Time 18 4.4 12 7.6 3.07 2.94 9 4.8
Stall Work
Stall Work Stall work
Man power 2 12 2
STAGE1STAGE2&
3STAGE4
&5STAGE6&7
STAGE8&9
STAGE 10&11
STAGE 12& 13
STAGE 14& 15
STAGE16
1 2 3 4 5 6 7 8 9
No of activities
18 27 29 22 19 23 19 22 8
Activity Time L/R
11.20/4.7615.86/ 15.89
17.41 / 17.84
21.05 / 21.64
16.02 / 12.92
15.4 / 17.7915.43 / 14.8
14.31 / 17.37
2.44 / 2.44
No. Of Men 4 4 4 4 4 4 4 4 4
CAB WELD EXTL SUPPLIERS
LT-1.5 daysLT-25 days
CAB PAINT
STORES
Suppliers
LT 1.5 days
LT-1 day
MPS CELL Customers
Cust Demand Model ColourDay Chassis 20 2 4Sleeper Chassis 1 2 4
Stallion VFJ 44 1 1Exports Chassis - 2 1Total reqmt/day Both 65 7 6
PPC/ MPL H2
PURCHASE
Cycle Time = 12.02 Minutes
NON-VALUE ADDING ELEMENTSNON-VALUE ADDING ELEMENTS
Waiting Time – Worker being idle / overloaded – Line
Balancing
Wasteful motion reduction – Motion and Transport
Potential for sub assembly – Series Vs Parallel – Time
advantage
WAITING TIMEWAITING TIME
The work in these stages is needed to be distributed to avoid
unnecessary waiting of some workers and over loading of
some other workers.
To avoid this we should concentrate on Line balancing.
Loom inserting and routing
Capacitor fitment
Fuse box guard fitment
Door beading fitment
Line Balancing:
• It stands for balancing the production line or an assembly line.
• Aims at grouping the facilities and workers in an efficient pattern
- to obtain an optimum or most promising balance of the
capacities and flow of the production or assembly processes.
• Tasks are grouped so that their total time is preferably equal to or
little lesser than the time available at each workstation – this
reduces the idle time.
• There are two basic concepts of assigning works to the stations.
They are,
Permeability of Tasks
Lateral transferability of tasks
STAGE RH IED LH IED CYCLE STAGE RH IED LH IED CYCLE
STAGE 1 11.20 4.76 12.02 STAGE 1 6.92 7.50 8.82
STAGE 2 11.19 9.48 12.02 STAGE 2 7.45 7.99 8.82
STAGE 3 4.67 6.41 12.02 STAGE 3 7.14 7.94 8.82
STAGE 4 7.42 7.85 12.02 STAGE 4 7.42 7.85 8.82
STAGE 5 9.99 9.99 12.02 STAGE 5 8.03 8.03 8.82
STAGE 6 12.02 12.02 12.02 STAGE 6 8.63 8.63 8.82
STAGE 7 9.03 9.62 12.02 STAGE 7 7.13 7.14 8.82
STAGE 8 9.90 6.16 12.02 STAGE 8 7.36 6.51 8.82
STAGE 9 6.12 6.76 12.02 STAGE 9 7.96 8.58 8.82
STAGE 10 6.62 7.89 12.02 STAGE 10 8.82 7.41 8.82
STAGE 11 8.78 9.90 12.02 STAGE 11 8.78 7.94 8.82
STAGE 12 8.47 7.60 12.02 STAGE 12 8.47 7.60 8.82
STAGE 13 6.96 7.20 12.02 STAGE 13 6.96 7.20 8.82
STAGE14 8.02 8.20 12.02 STAGE14 8.02 8.20 8.82
STAGE15 6.29 9.17 12.02 STAGE15 8.24 8.50 8.82
STAGE16 2.44 2.44 12.02 STAGE16 7.56 8.23 8.82
TOTAL 129.11 125.44 TOTAL 124.89 125.24
WTD AVG 7.9548 WTD AVG 7.8166
BEFORE BALANCING BALANCED LINE
WASTEFUL MOTION REDUCTIONWASTEFUL MOTION REDUCTION
In the 16 stages the cabin assembly takes a lot of wasteful
motion and transport which are identified by observing the
activities, distance between the parts and line observed by the
time and motion study. Some of the activities having wasteful
motions are :
• Removal of hood and placed in trolley
• Control rod fitment
• Dummy plug and cage nut fitment
• Windshield fitment
• Berth seat and back rest fitment
Removal of hood and placed in trolley:
-Hood is a part in front side of the cabin.
-It is removed in the first stage for doing other operations and to
replace it the worker has to walk for some 4 meter which takes
15 seconds.
-Distance can be reduced to 1 meter so that the time reduces by 5
seconds.
Control rod fitment:
-Control rod fits on the backside of the cabin.
-It is 5 meter away from the line which consumes up to 30
seconds to walk.
-So in order to eliminate the wastage of time, it is recommended
to place at a distance of 1 meter in a feasible way that consumes
only 5 seconds.
Dummy plug and cage nut fitment:
-These activities are carried out in more than 3 stages.
-For the fitment of dummy plug and cage nut, workers need to
move some distance which may vary in each case.
-These movements can be avoided by providing a kit that is
having those small parts, in the line itself with the cabin.
Windshield fitment:
-Windshield is the front glass fitted in the cabin which has to be
handled with care.
-Most of the scraping in windshield occurs while handling only
-This can be eliminated by providing a pneumatic device for
holding the glass.
POTENTIAL FOR SUB ASSEMBLYPOTENTIAL FOR SUB ASSEMBLY
Some activities that carried out on the Cab trim line can be done as
the sub assembly because it can stand as the constraint for the
productivity improvement. Some of such activities are
Air horn fitment
Hatch door lock, pad, and magnet fitment
Fuse box guard fitment
Door
Air Horn Fitment:
-In the air horn assembling, it needs to be assembling with a hose, and a clamp for the fitment.
-These two fitments itself takes more than 45 seconds.
-If we transfer it to the sub assembly or buy it as the assembled part, we can reduce this time and work load.
Hatch door lock, pad, and magnet fitment:
- Hatch door is in the top of the vehicle provided for stallion vehicles.
-It is provided in such a way that can be opened from inside it.
- lock pad and a magnet.
- Fitment of these three parts consumes more than 400 seconds.
- If we move it to sub assembly we can save such a significant amount of time. Hence the productivity will increase.
Fuse Box guard fitment:
-The fuse box guard is assembled with a valve and fitted on the high level II. This valve is for providing coolant supply to the demister.
-Assembling of this valve in the line itself consumes some 120 seconds.
-This can be done in the sub assembly or can buy it as the valve fixed fuse box guard from the supplier.
Door :
-The 2 doors of the cabin have works in two stages. Glass
assembly and Door trim.
In Glass assembly it needs to assemble,
Drop glass
Door top glass
Quarter vent glass
Door lock fitment
Regulator fitment
Channel fitment
Door glass beading fitment
In Door trim it needs to do,
Grease application
Remote lock fitment
Control rod fitment
Tape sticking and door seal sticking
Door pad fitment
Door handle fitment
Regulator handle fitment
Door belt inner weather strip fitment
These activities consumes totally 360 seconds for each door in
each stage. Hence if we move all these activities to sub
assembly, we can save 720 seconds on each side, by this we
can eliminate two or at least one stage.
A thorough study was done throughout the line stage by stage to
understand the various factors that contribute for productivity.
Due to large idle time, the cycle time was as high as 12.02
minutes.
The Line efficiency was only 67.1%.
We identified lots of improvement potentials. Mainly the
unbalanced line, wasteful motions, high potential for sub
assembly were the constraints identified.
By eliminating or modifying the non value adding elements, we
arrived the future state VSM.
36
Future state V.S.M.Future state V.S.M.
Roof lamp
3.54
Rear glass
Door inner W/S4.6 2.16
Side glass
Glove box lid
4.6 2.97
QV glass Inst panel
4.6 21
S/A NameDoor Fitment
E2 valveDoor lock
Wind screen
Fuse box
Speedo meter
Cycle Time 720 8 2.6 7 120 2.7
S/A Namehatch door
Pedal Box Drop glass
ChannelRear lining
Air horn fittment
HoodConsole plate
Cycle Time 400 16.2 2.4 7 2.06 Acc Pedal 13 5.5
S/A NameMain loom
PB valve S/A
Head lamp
Top glass
Head lining
Acc X shaft
Stg column
Consloe cover
Cycle Time 18 4.4 12 7.6 3.07 2.94 9 4.8
Stal Work
Stal WorkStall work
Man power 2 12 2
STAGE1 STAGE2&3STAGE
4&5STAGE
6&7STAGE
8&9STAGE 10&11
STAGE 12& 13
STAGE 14&15
STAGE 16
1 2 3 4 5 6 7 8 9
No of activities 15 25 24 12 19 21 15 20 7
Activity Time R/L
6.92/7.5 14.59/15.9315.45 / 15.88
15.76 / 15.77
15.32/ 15.09
17.6/15.3515.43/14
.816.26/16.
77.56/8.23
No. Of Men 4 4 4 4 4 4 4 4 4
CAB WELD EXTL SUPPLIERS
LT-1.5 daysLT-25 days
CAB PAINT
STORES
Suppliers
LT 1.5 days
LT-1 day
MPS CELL Customers
Cust Demand Model ColourDay Chassis 20 2 4Sleeper Chassis 1 2 4Stallion VFJ 44 1 1Exports Chassis - 2 1Total reqmt/day Both 65 7 6
PPC/ MPL H2
PURCHASE
Cycle time = 8.82 seconds
Estimated efficiency of the Future Estimated efficiency of the Future StateState
Efficiency of the line = Task time / (Cycle time * Number of stages)
Task time = 125.24
Cycle time = 8.82
Number of stages = 16
Efficiency of the line = 125.24/(8.82*16)
= 88.74%
CONCLUSIONCONCLUSIONCurrent VSM has been mapped
Non value added activities such as
Waiting, wasteful motion, potential for sub assembly
were identified
Line balancing has been suggested in order to reduce the
waiting time
In turn the efficiency of the line has increased to 88.74%
Thank You