THEME

PRODUCTIVITY IMPROVEMENT

AT
HEATER CONTROL ASSY. LINE
MODEL : YN - 4
 REASON FOR SELECTION

1. TO MEET INCREASED CUSTOMER DEMAND

PRODUCTION/SHIFT: 700 NOS/DAY

REQUIREMENT: FROM APR’10 - 850 NOS/DAY

2. IMBALANCED LINE (UNEVEN WORKLOAD)

3. TO ACHIEVE SINGLE PIECE FLOW

 ACTIVITY PLAN
S. PDCA Activity Plan Nov’ 09 Dec’09 Jan’10 Feb’10 Mar’10 Apr’10 Feb ’11
N. CYCLE ~May10

1 P Project identification
& data compilation,
Team formation
2 P Kick off session

3 P Brain storming
among the team for
counter measures
4 D Implementation of
counter measures

5 C Result monitoring
&
A Standardization
6 C Report making &
presentation

Plan
Actual
 TARGET - SETTING

PARAMETER BEFORE TARGET

PRODUCTION 700 Nos. 850 Nos.

MANPOWER 10 10

TIME 7.5 HOURS 7.5 HOURS

PRODUCTIVITY /
9.33 11.33
MAN / HOUR
PERCENTAGE
------ 21.44%
IMPROVEMENT
 PROCESS – FLOW : BEFORE
GREASING PINION FAN SW. PANEL &
PCB & LENS DIAL KNOB
IN GEAR & ASSY IN ASSY IN DUMMY
ASSY ASSY.
BASE BASE BASE PLUG ASSY.
27 sec 22 sec
30 sec 26 sec 12 sec 24 sec

1 2 3 4 5

VISUAL
MANUAL AUTO CABLE VISION ILLUMINATI
CHECK &
CHECKER CHECKER ASSY CAMERA ON CHECK
PACKING
20 sec 38 sec 21 sec 6 sec 24 sec
21 sec

10 9 8 7 6

TOTAL MANPOWER-10
TOTAL STATION-12
 TEAM MEMBERS
S.N. NAME DEPTT. ROLE

1 ASHISH SRIVASTVA ASSEMBLY TEAM LEADER

2 ANIL YADAV ASSEMBLY MEMBER

3 PAWAN KUMAR ASSEMBLY MEMBER

4 GAYATRI ASSEMBLY MEMBER

5 PANKAJ KAUSHIK PRODUCTION ENGG. MEMBER

 ELEMENTAL STUDY OF PINION ASSY & FAN SWITCH ASSY: BEFORE

S.N Activity Time taken Symbol

 
1 PICK PINION & ACTION SPRING FROM BIN 0:02:00

2 GREASING IN SPRING & ASSEMBLED IN PINION 0:02:00  

3 PICK STEEL BALL FROM BIN & PLACE PINON WITH STEEL BALL 0:03:00  

4 PICK PINION FROM BIN & ACTION SPRING . 0:02:00  

5 GREASING IN SPRING & SPRING ASSEMBLED IN PINION. 0:02:00  

6 PICK STEEL BALL FROM BIN & PLACE PINON WITH STEEL BALL 0:03:00  

7 PICK BASE ASSY & CHECK GREASE 0:03:00  

8 PLACE BASE ASSY IN M/C 0:02:00  

9 PRESS PUSH BUTTON 0:01:00  

10 PINION ASSY DONE BY M/C 0:03:00  

11 REMOVE BASE ASSY FROM M/C 0:01:00  

 
12 CHECK LOCKING OF PINION, STEEL BALL MISS 0:02:00

13 OPERATOR MOVES FROM PINION ASSY TO FAN SW. ASSY STATION 0:02:00

14 PICK & PLACE BASE ASSY IN FAN SW. ASSY FIXTURE 0:02:00

15 PICK FAN SW. FROM TRAY 0:01:00

16 CHECK OK MARK ON FAN SW. ASSY 0:01:00

17 FAN SW INSERTED IN BASE ASSY & PUSHED 0:03:00

18 BASE ASSY REMOVED FROM FIXTURE 0:01:00

19 CHECK LOCKING OF FAN SW. LOCKING IN BASE 0:02:00

TOTAL 38 SEC
PERCENTAGE DISTRIBUTION

S.N ACTIVITY SYMBOL TIME ( SEC ) PERCENTAGE

1 SALEABLE 13 34.21

2 NSBN 18 47.37

3 WASTE 7 18.42
 CALCULATION OF TAKT TIME
SHIFT TIME : 9:00AM – 5:30 PM

TOTAL TIME : 510 Mins

DOWN TIME : 30+15+15

AVAILABLE TIME : 450 Mins

TAKT TIME : (450*60)/700

: 38.57 Secs.

FUTURE TAKT TIME : (450*60)/850

: 31.76
 TIME STUDY CHART : BEFORE
38 38

30
27 24 24 27

22 21
20

TAKT TIME CURRENT: 38.57Sec

TAKTTIME REQUIRED: 31.76Sec

 LIST OF KAIZENS IMPLEMENTED

SR. NO. BEFORE KAIZEN AFTER KAIZEN REMARKS

PCB & FAN SW. ASSY DONE ON

SAME FIXTURE FOR PCB ASSY & FAN TIME SAVED FOR FAN SW. INSERTION
1 DIFFERENT STATIONS ON
SW. ASSY IN BASE. IN BASE.
DIFFERENT FIXTURES.

ONE OPERATOR WAS DOING AT NOW OPERATOR IS DOING ONLY

CYCLE TIME REDUCED FROM 38 SEC
2 TWO STATIONS ( PINION ASSY. & PINION ASSY ( FAN SW. ASSY
TO 26 SEC.
FAN SW. ASSY IN BASE ). SHIFTED TO OTHER OPERATOR ).

AUTOCHECKER CYCLE TIME IS 38 AFTER IMPROVEMENT CYCLE TIME IS AUTOCHECKER CYCLE TIME REDUCED
3
SECONDS 30 SECONDS TO 30 SECONDS

MOVEMENT OF OPERATOR FOR SUB

MOVEMENT FOR SUB ASSY. IS SUB ASSY STATION SHIFTED NEAR
4 ASSY REDUCED BY SHIFTING SUB
MORE THE MAIN ASSY. LINE
ASSY NEAR TO THE MAIN LINE
 KAIZEN – 1.
KAIZEN
Company : Jay – Ushin Ltd. Deptt. : HVAC Assy. Result : Month of Report
(Manpower, Quality, Cost savings , April’10
Safety improvements etc)
Subject : Improvement Process: Fan Sw. Assy. HVAC YN4
1. Manpower, Manhour Saving
Before Improvement After Improvement
(Photo Explanation Drawing) (Photo Explanation Drawing)
2. Physical Distribution(Transporting
distance)

3. Space Saving

4. Commanisation Unification

5.Weight reduction

6. Energy saving

7. Yield

8. Quality Im provement

9. 5S

10.Cost Reduction

11.Safety

12. Horizontal Application

13. Others

Cost Saving / Year Is

Fan Switch & PCB A new fixture made which is ----
assembled at separate work used for fan switch & PCB Date of Implementation
stations, leading to more assy., leading to less cycle 10.04.10

cycle time. time. Suggested By

Pawan Kumar
BENEFITS Approved By
1. Equal work distribution Ashish Shrivastva

Company : Jay – Ushin Ltd.
Subject : Improvement
Before Improvement
(Photo or Explanation Drawing)
38
KAIZEN – 2.
KAIZEN
Deptt. : HVAC Assy. Result : Month of Report
(Manpower, Quality, Cost savings , April’10
Safety improvements etc)
Process: Fan Sw. Assy. HVAC YN4
1. Manpower, Manhour Saving
After Improvement
(Photo or Explanation Drawing)
30
2. Physical Distribution(Transporting

26
distance)

27 3. Space Saving

4. Commanisation Unification

5.Weight reduction

6. Energy saving

7. Yield

8. Quality Im provement

9. 5S

10.Cost Reduction

11.Safety

12. Horizontal Application

13. Others

First operator doing pinion assembly & fan First operator doing pinion assembly. Cycle time Cost Saving / Year Is
sw. assy. Cycle time is 38 seconds. Second is 26 seconds. Second operator doing fan sw., -----
operator doing pcb & lense assy. Cycle time pcb & lense assy. Cycle time is 30 seconds. First
Date of Implementation
is 27 seconds. Second operator waiting time operator waiting time is 04 seconds.
10.04.10
is 11 seconds.
Suggested By
Pawan Kumar

BENEFITS Approved By
1. Bottleneck process c/t reduced 38 to 30 seconds. Ashish Shrivastva
2. Equal work distribution

Company : Jay – Ushin Ltd.
Subject : Improvement
Before Improvement
(Photo Explanation Drawing)
38
KAIZEN – 3.
KAIZEN
Deptt. : HVAC Assy. Result : Month of Report
(Manpower, Quality, Cost savings , April’10
Safety improvements etc)
Process: Auto checker HVAC YN4
1. Manpower, Manhour Saving
After Improvement
(Photo Explanation Drawing)
30
2. Physical Distribution(Transporting
distance)

3. Space Saving

4. Commanisation Unification

5.Weight reduction

6. Energy saving

7. Yield

8. Quality Im provement

9. 5S

10.Cost Reduction

11.Safety

12. Horizontal Application

13. Others

Auto checker cycle time is 38 seconds Auto checker cycle time reduced to 30 Cost Saving / Year Is
------
(Bottleneck process). Auto checker seconds. Auto checker checking
checking capacity is 710 nos. / shift. capacity increased to 900 nos. / shift. Date of Implementation
15.04.10
(Improvement done in PLC program
of auto checker) Suggested By
Pawan Kumar

BENEFITS Approved By
1. Auto checker checking capacity increased 190 nos. / shift Ashish Shrivastva
 KAIZEN – 4.
KAIZEN
Company : Jay – Ushin Ltd. Deptt. : HVAC Assy. Result : Month of Report
(Manpower, Quality, Cost savings , April’10
Safety improvements etc)
Subject : Improvement Process: Panel sub assy HVAC YN4
1. Manpower, Manhour Saving
Before Improvement After Improvement
(Photo Explanation Drawing) (Photo Explanation Drawing)
2. Physical Distribution(Transporting
OPERATOR MOVEMENT 65 distance)
SECONDS/HOUR OPERATOR MOVEMENT ELEMINATED
3. Space Saving

4. Commanisation Unification

DISTANCE 12 MTR SUB ASSY. 1 MTR 5.Weight reduction

HVAC YN-4 6. Energy saving

HVAC YN-4 7. Yield

HVAC YC-5 8. Quality Im provement

HVAC YC-5 9. 5S

HVAC YL-6 10.Cost Reduction

HVAC YL-6 11.Safety
HVAC YG-4 12. Horizontal Application
HVAC YG-4 13. Others
SUB ASSY.

Panel sub assy. 12 meter far from Panel sub assy. shifted to near the Cost Saving / Year Is
---
main assy. Line. Operator takes 65 main line . Now operator movement
seconds/ hr to pick the sub assy. eliminated ( feeding done by sub assy. Date of Implementation
17.04.10
operator)
Suggested By
Pawan Kumar

BENEFITS Approved By
1.Operator movement eliminated. Ashish Shrivastva
2. 5 ‘s’ improved.
 ELEMENTAL STUDY OF PCB & FAN SW. ASSY : AFTER
S.N Activity Time taken Symbol
1 PICK FAN SW. ASSY FROM TRAY 0:01:00
2 CHECK OK MARK 0:01:00
3 PLACE FAN SW. ASSY IN FIXTURE 0:01:00
4 PICK & PLACE BASE ASSY IN FIXTURE 0:02:00
5 PICK PCB ASSY FROM BIN 0:01:00
6 PLACE PCB ASSY IN BASE 0:02:00
7 PICK PUSH SW. CHECKING GAUGE 0:01:00
8 CHECK PUSH SW. BY GAUGE 0:02:00
9 PLACE PUSH SW. GAUGE ON TABLE 0:01:00
10 PICK BIG LENS FROM BIN 0:01:00
11 PLACE BIG LENS IN BASE 0:01:00
12 FOLD THE COVER & PRESS 0:02:00
13 PICK SCREW 1 0:01:00
14 SCREW 1 ASSEMBLED IN PCB 0:02:00
15 PICK SCREW 2 0:01:00
16 SCREW 2 ASSEMBLED IN PCB 0:02:00
17 PICK SCREW 3 0:01:00
18 SCREW 3 ASSEMBLED IN PCB 0:02:00
19 PICK SCREW 4 0:01:00
20 SCREW 4 ASSEMBLED IN PCB 0:02:00
21 FOLD UP COVER 0:01:00
22 REMOVE BASE ASSY FROM FIXTURE 0:01:00
Total: 30 Sec
S.N ACTIVITY SYMBOL TIME ( SEC ) PERCENTAGE
1 SALEABLE 14 46.67
2 NSBN 13 43.33
3 WASTE 3 10.00
CALCULATION OF TAKT: AFTER

SHIFT TIME : 9:00AM – 5:30 PM

TOTAL TIME : 510 Mins.

DOWN TIME : 30+15+15

AVAILABLE TIME : 450 Mins.

TAKT TIME : (450*60)/900

: 30 Secs.
 TIME STUDY COMPARISION
TIME STUDY CHART : BEFORE
38 TAKT TIME : 38.57Sec 38
30
27 24 27
24 22 20 21

TIME STUDY CHART : AFTER

TAKT TIME : 31.76Sec
30 26 30 30
24 24 27
22 21
20
 PROCESS – FLOW : AFTER
GREASING PINION FAN SW., PANEL &
DIAL KNOB ILLUMINATI
IN GEAR & ASSY IN PCB & LENS DUMMY
ASSY. ON CHECK
BASE BASE ASSY PLUG ASSY.
22 sec 24 sec
30 sec 26 sec 30 sec 24 sec

1 2 3 4 5 6

VISUAL
MANUAL AUTO CABLE VISION
CHECK &
CHECKER CHECKER ASSY CAMERA
PACKING
20 sec 30 sec 21 sec 6 sec
21 sec

10 9 8 7

TOTAL MANPOWER-10
TOTAL STATION-11
 TARGET Vs- ACHIEVEMENT

PARAMETER BEFORE TARGET AFTER

PRODUCTION 700 Nos. 850 Nos. 900 Nos.

MANPOWER 10 10 10

TIME (Hrs.) 7.5 Hrs 7.5 Hrs 7.5 Hrs

PRODUCTIVITY /
09.33 11.33 12.00
MAN – HOUR

PERCENTAGE
------ 21.44 % 28.62 %
IMPROVEMENT
WORK DISTRIBUTION COMPARISION
 BENIFITS OF RETAINMENT

HVAC YN-4 & L ASSEMBLY PRODUCTIVITY FOR THE YEAR 2010

HVAC YN-4 & L ASSEMBLY PRODUCTIVITY FOR THE YEAR 2010-11
 

 
 
 
 
 
 
 
TARGET
 
 
MPS EFFECTIVENESS MAN \ HOUR \ 11.33
  STARTS FROM
 
APRIL'10
 
 
 
 
 
 
 
 
 
 
 
 
 
2010 JAN FEB MARCH APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN 11 FEB 11

ACTUAL 9.33 10.23 11.00 11.50 11.52 11.58 11.62 11.75 11.88 11.98 12.01 12.08 12.09 12.09

TARGET 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33 11.33
 STANDARDIZATION

1. STANDARD WORKSHEET UPDATED.

2. PROCESS CHECKSHEET UPDATED.
3. CONTROL PLAN UPDATED.
 HORIZANTAL DEPLOYMENT

1. SAME FAN SW. & PCB ASSY FIXTURE ALSO

PROVIDED IN HVAC YG-4 & HVAC YM-1 LINES.
 SUMMARY OF BENEFITS

1. PRODUCTIVITY IMPROVED BY 28.62 %

2. 5 S IMPROVED.
3. LINE BALANCING THROUGH LOAD BALANCING.
4. TEAM MORAL BOOSTED.
5. SINGLE PIECE FLOW IN LINE.
 NEXT THEME

PRODUCTIVITY IMPROVEMENT

AT
HEATER CONTROL ASSY. LINE
MODEL : YG - 4