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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