Productivity improvements using Operations Management in Manufacturing industry

PRODUCTIVITY IMPROVEMENT OF GROVER

INDUSTRIES SUBMITTED BY :-

INDERPREET SINGH BEDIJAGMEET SINGH BAJAJ

JASHANDEEP SIINGH DHILLONKRITI SHARMA

PROBLEMS FACED AND PROJECT GOALS

Grover Industries is a small scale gear manufacturing company. The company has as an inefficient production system which leads to

bottlenecks, rework and scrap and hence leads to lower productivity.

Goal :- The project aims at increasing the productivity of the manufacturing process by using the various operational methodology and techniques.

OBJECTIVES

New effective production layout which would streamline the manufacturing process.

Reduce the Non-Value added activities.

MACHINERY AVAILABLE

Four CNC machines for turning and facing operations

Four Lathe machines for turning

Four Milling (Horizontal) machines for teeth cutting

Four Gear Hobbing machines for special teeth cutting (for cutting

splines and cutting sprockets )

GEAR MANUFACTURNG PROCESS

SHAFT CUTTIN

GTURNIN

GMILLIN

GGEAR

HOBBING

WELDINGHEAT

TREATMENT

FINISHINGPACKAGIN

G & SHIPPING

PRODUCT DESCRIPTIONThe company manufactures six types of products

PRODUCT CATEGORIZATIONThe products were categorized into 3 different part families

Product 1

Product 2

Product 4A

Product 3A

Product 5A

Product 4B

Product 3B

Product 6

Product 5B

OLD LAYOUT

PRODUCTIVITY IMPROVEMENT

LAYOUT DESIGN WORK REDISTRIBUTION THROUGH WORK METHOD AND TIME

STUDY BY DECREASING NON- VALUE ADDED ACTIVITIES BY APPLYING GENERAL OPERATIONAL MANAGEMENT TECHNIQUES

NEW LAYOUTBy using the principle of Group Technology and Cellular Manufacturing, the manufacturing process was streamlined and was divided into three cells for three part families.

CELL-1

CELL-2

CELL-3

NEW LAYOUT - DIFFERENTIATION

DIFFERENTIATING BETWEEN VALUE ADDED, SEMI-VALUE ADDED & NON-VALUE ADDED ACTIVITES

VALUE ADDED ACTIVITIES

SEMI-VALUE ADDED ACTIVITIES

NON-VALUE ADDED ACTIVITIES

TIME STUDY

LOAD CHART There were 17 stations before and the breakdown of the VA,SVA

and NVA is shown below :-

Lathe 1

Lathe

2

Lathe 3

Lathe 4

Shaft

cuttin

g 1

Shaft

cuttin

g 2

Shaft

cuttin

g 3

Gear Hob

bing 1

Gear Hob

bing 2

Gear Hob

bing 3

Gear Hob

bing 4

Miliing 1

Miliing 2

Miliing 3

Miliing 4

CNC 1

CNC 2

CNC 3

CNC 4

0102030405060708090

100

LOAD CHART _BEFORE

60%16%

24%

Va,sva,nva1 2 3

LOAD CHART

Shaft cutting 1

Lathe 1 Lathe 2 CNC 1 CNC 2 Miliing 1 Miliing 2 Gear Hobbing

1

Gear Hobbing

2

0102030405060708090

100

Cell 1

VA SVA NVA

Shaft cutting 2 Lathe 3 CNC 3 Miliing 3 Gear Hobbing 30

102030405060708090

100

Cell 2

VA SVA NVA

Shaft cutting 3

Lathe 4 CNC 4 Miliing 4 Gear Hobbing

4

0102030405060708090

100

Cell 3

VA SVA NVA

62%16%

22%

VA,SVA,NVA

VA SVA NVA

MATERIAL REQUIREMENT PLANNING

Sample MRP Sheet proposed for raw material purchasing

THANK YOU