JUNIVERSITY OF MANAGEMENT AND TEHCNOLOGY

Visit Report
Visit to Sanpak Pvt. Ltd. Plant
Kumail Rizvi 091420-147 5/1/2011

Kumail Rizvi

Visit Report

091420147

Visit Report
On 14 April 20011, UMT-IIE Student Chapter arranged a visit to Sanpak Pvt. Ltd. The visit was for academic and learning opportunity. The visit was coupled with a tour of the facility along with a chance to work as an IE and perform Work Study and Method Engineering tools at some of the work stations. It was a great opportunity as an undergraduate student to get hands on exposure to the things that we are learning in our university. The leading person of the whole program was Prof. Salman Butt who is also the Co-Advisor of the student chapter. We were received at Sanpak by Mr. Atique Tipu who is the Operations Manager. We were seated in a nice meeting room. After a brief introduction of all the students and the Sanpak staff we were introduced to GM Technical Mr. Amir. After the introduction it was the presentation session which was quite interesting. The first presentation talked about how Sanpak Pvt. Ltd is a joint venture with Japanese Company Sanden and that they manufacture Automobile Cooling systems. With over 70 years of Sanden Corporation's technical, management and manufacturing know-how, Sanpak created confidence throughout the region as an OEM supplier capable of meeting stringent technical specifications of some the world's most prestigious automobile manufacturers. Their customer portfolio includes every Automobile Manufacturer in Pakistan such as Honda, Suzuki, Nissan, Toyota and Hyundai to name a few. Their line of products in this field is MFC (Multi-Flow Condensers), Aluminum Heat Exchangers, Compressors, Receiver Driers, HVAC, Coreless Pancake Motors. All Products and of Sanpak are certified by ISO: 9001, TUV CERT, ISO: 14001-2004. They use Nocoloc Heat Exchanger, Hose Crimping Machine, Automatic CNC Bending Machine and Automatic Paint Oven. After companys introduction we had Mr. Asif who is an industrial engineer their and is working for productivity and efficiency enhancement. He presented to us various methods that their team is applying their and how it is improving their productivity. His presentation was of the Process Engineering Department. The department follows 4M as their top priorities i.e. (Man, Machine, Method and Material). This basically comes in Ishikawa diagrams where causes of events are drawn on simple charts but they help get to the cause of events. In applying Six Sigma they are using DMAIC approach i.e. (Define, Measure, Analyze, Control and Implement). Using these techniques they are keen for productivity improvement. Using these techniques in the manufacturing of Alto and Mehran systems they have achieved 15% productivity enhancement. They also perform Method studies where they are doing process study, motion study and total research. They are also performing Work Measurements where they are calculating Working Hours of their works and dealing with them in Work, Time ratio. Using Kaizen and Lean Manufacturing thoughts they are improving their lines and their efficiencies. The visit was of an intense educational experience and I believe for any undergraduate student such visits and hands on experience is necessary. These things help student frame their mind to understand their responsibilities that they will be expected from in the future. Industries and 2

Kumail Rizvi

Visit Report

091420147

Universities should combine themselves together where Students should be taken to such places and perform Case Studies then in their classrooms students should be given tasks to solve problems. In this way understand of student can reach up to a new level where not only they are learning the techniques they are also at the same time applying them to real world problems.

Experiment no.1
Our group was allotted the Crimping workstation, in this process the worker would take a fitting and then press it together and then grab another fitting and then use the crimping machine to press it firmly together. 2 workers were working together on this workstation and there was also a little movement involved in it. We calculated the modapts and did time study of the whole process and then compared the modapts with the observed time. Time Study To conduct time study we first observed roughly the process of the worker and the machine and took readings roughly. Then we separated the process of the worker into different steps and then calculated the time for each step 3 times and calculated the average time for each step.

Rough Calculations
STEPS 1 2 3 4 5 6 7 8 9 10 11 TIME 0.63 0.53 0.76 0.72 2.1 0.72 25.2 0.82 1.30 0.75 0.71

Kumail Rizvi

Visit Report

091420147

MODAPTS (Modular Arrangements of Predetermined Time Standards

Sr. # 1. 2. 3. 4. 5. 6.

Activity Reaching in the box and grabbing the hose Transfer it to other hand
Reach to grab fitting Hold both together, press to join them Remove Cap Reach to grab another fitting (sometimes) wait for machine Reach crimping machine Place and wait for finish Crimping Take out and Place on the table by moving 3feet extra sometimes even wait for other person to move aside Reach back 5 feet from point of placement to start work again

Left Hand M4G1

Right Hand

Total MODs 5

Time (s) 0.645 0.387 0.645 0.645 1.548 0.645

M3 Issue 1 M4G1 G1X4 G4X4 M4G1 Wait because other worker is using the same machine M4 M3P5 X4

3 5 5 12 5

7. 8. 9.

4 8

0.516 1.032

10.

M4 Issue 2

0.516

11.

M4 Issue 3

0.516

Total MODAPTs Time = 7.095s

Kumail Rizvi

Visit Report

091420147

Time Study

El.

Element Description
T1

Observed Time
T2 0.68 0.31 1.52 2.5 2.5 0.68 19.39 1.50 1.95 T3 0.70 0.21 1.33 1.57 1.38 0.66 29.70 1.60 2.03 Av. T 0.69 0.32 1.46 2.52 1.99 0.67 24.57 1.58 2.31

1 2 3 4 5 6 7 8 9

Reaching in the box and grabbing the hose Transfer it to other hand
Reach to grab fitting Hold both together, press to join them Remove Cap Reach to grab another fitting (sometimes) wait for machine Reach crimping machine

0.70 0.45 1.52 3.5 2.1 0.67 24.62 1.65 2.94

Place and wait for finish Crimping

10

Take out and Place on the table by moving 3feet extra sometimes even wait for other person to move aside

1.73

1.83

1.79

1.78

1.39

1.65

1.80

1.61

11

Reach back 5 feet fropoint of placement to start work again

Total Observed Time = 39.43s Difference between modapt time and calculated time = 32.335s The main reason for this difference in time is the idle waiting time for the machine in step 7. 5

Kumail Rizvi

Visit Report

091420147

Process Flow Sheet

Date : 14 -April- 2011 Process Symbol Sr # 1 2 3 4 5 6 7 8 9 Item / Activity Cutting & Marking 1st Manual insertion Crimping 2nd Insertion Angle correction via jig Inspection 2nd crimping O-ring insertion with jig Tranportation

. Ideas

. . . . . . . . . . . . . . . . .

Remove loops and reduce cutting angle

Both insertions should be done together and crimped at one staion

.
Roller conveyor should be used to transport wip

10 Water dip leak check (1 min) 11 Tranportation 12 Drying by Blowing 13 Tranportation 14 Part No printing 15 Final Inspection 16 Safety caps 17 Bundling (5 pcs) 18 Storage 19 Placing in boxes 20 Storage 21 Sticker Identification 22 Inspection of packing 23 Storage in warehouse

. . . . .
it is time taking should be romoved it is time taking should be romoved
computerized identification

Kumail Rizvi

Visit Report

091420147

Improvement Ideas & Thoughts

2 Person Task is better because it can reduce queue length on both sides of the operating part. Basket should be added, baskets carrying fittings and hoses should be arranged according to the workers ability of arm usage. 1st station should complete the fixture job on both sides and pass on this will eliminate 2nd crimping rather utilize it for other purpose. The facility should have fresher look by increasing the amount of labels and quality in the colors and drawings of the assistance drawings etc. and these should be maintained. This will raise the energy levels of employs because of colorful fresh environment. Torn, dirty or old labels should be replaced as soon as possible because old and dirty labels add a low esteem to the worker mind.