TPES Project Engine SA

7/31/2019 TPES Project Engine SA

1/23

TPES project

Engine sub assembly (CV-CX

line1)


2/23

LAYOUTEngine Sub - assy.

E

N

G

I

N

E

SU

B

A

S

S

EM

B

L

Y

STATION

E-9ASTATION

E-9BSTATION

E-8STATION

E-7

STATIONE-6A

STATION

E-6BSTATION

E-5

STATIONE-3A

STATION

E-3BSTATION

E-2

FITMENT OF TURNING TUBEADJUSTMENT OF TURNING TUBEFITMENT OF SPEED SENSORFITMENT OF REVERSE LIGHT SWITCH ( CMVR ENGINE ONLY )FITMENT OF L BRACKET

INSPECTION OFENGINE

FITMENT OF CLUTCH BOOSTERFITMENT OF 6 DIA CLUTCH PLATEFITMENT OF CLUTCH HOUSING

UPPER INSPECTION COVER

FITMENT OF GEAR BOXTIGHTENING OF CLUTCH HOUSINGCHECKING OF TORQUE

GBS 600 & 750 4.5 MKG

GBS 50 13.5 MKG

FITMENT OF POWER STEERING PUMPFITMENT OF PIPETIGHTENING OF HARNESS WITH CABLE TIE

EARTHING CONNECTION IN ALL MODELFITMENT OF TURNING TUBEFITMENT OF AC HEAD SOCKETFITMENT OF AC HEAD PIPE ELBOW & 6 DIA PIPE

FITMENT OF ACC. PULL ROD

FITMENT OF BABY FILTER

FITMENT OF OIL PRESSURE SWITCH

HARNESS CONNECTION STARTER

EARTHING OIL PRESS SWITCH

FITMENT OF GEAR SHIFTING LEVER ENSURE TORQUE 6.9 MKGFITMENT OF EXHAUST FIRST PIECEFITMENT OF GEAR LEVER BKT. SILENCER HANGERBKT. & Z BKT ( ALL LPO )

FITMENT OF INTERCOOLER PIPE LH & RH WITH SOCKETFITMENT OF ALTERNATOR CONNECTION

FITMENT OF PRESSURE

PLATEFITMENT OF CLUTCH PLATE & CHECKING OF ORIENTATION

FITMENT OF HOUSING ( 330 DIA ONLY )

TORQUE CHECKING

HARNESS CONNECTION IN CNG CMVR


3/23

Engine Sub - assy.

Summary

No of fitment 40

No. of station - 9

Cycle time 5.93 minWork content 53.23 min

No. of operator - 21

Target

To reduce the work content and in turn cycle time of the engine sub

assembly line

To make the fitments ergonomically safe and easier for the operator


4/23

OPERATING MOTION LOSSES

VA NVA ANALYSIS

NVAE(min),

13.63, 26%

NVAN(min),

11.26, 21%

VA(min), 28.34,

53%

NVAN(mi

n)

NVAE(mi

n)

VA(min)

Most analysis

Fitment wise analysis


5/23

Avg. utilization = 47%

% Utilization Chart


6/23

Operator wise analysis


7/23


8/23

Initial analysis of all fitment

of Sub assy line

Ergonomic analysis


9/23

Ergonomic analysis

Ergonomics Status - Engine sub-assy.

Yellow, 19, 68%

Green, 7, 25%

Red, 2, 7%

Red

YellowGreen


10/23

Major problems in sub assy area

Frequent change in model

5S implementation improper

Runner (bend and pick) problem

Late delivery of engine (material shortage)

Improper synchronization between engine and chassis line

Material problem (sub assemblies)

Bending problem in few fitments

Blind and obstructed situation in few fitments

Conveyor line designed since 1992, no changes since then

Material specifications

Space problem, lot of congestion

Tools and equipment shortage

Line imbalanced

Hammer is also used in few fitments


11/23

Improper 5S implementation

Tools and parts are kept in the same kit Tool sharing by operators which are at

different stations

Manual kit movement

Runner (bend and pick problem)

In most of the fitments operator has

to bend and pick up the runner Runner is often shared accounting for

the waiting time


12/23

Bend, blind and obstructed situations

More than 50% of the fitments includeexcessive bending postures

Few fitments are even blind and obstructed

Few fitments for ex clutch housing

cover(lower) involves dangerous posture

Space problem

Gap between two stations is just 1 meter

Width of conveyor line is also 1 meter

Operations are done on both sides ofengine leading to congestion


13/23

Line imbalanced

Station 1&2 are overloaded, whereas

station 3,4,5 are under loaded and rest of

the line is balanced

Fitments do not take place according to

station-fitment list.

Material specification problem

Material provided should be as per the

requirement of operation L bracket attached with baby filter has to

be tilted manually as shown alongside.

This involves excessive push force.


14/23

Effects

Lesser productivity

Increased chances of mishap

Improper utilization of workforce

Engine sub assembly has become a potential bottleneck as takt time is 5.5

min and cycle time is 5.93 min.

Inspection and quality assurance at stake at times of higher production rate


15/23

Improvements

Type ofimprovement

Costeffective

Timeconsuming

root causeeliminated

Resultseffectiveness

Process Yes No May be, maybe not

Not so effective

Engineering No Yes For sure Very effective


16/23

Engineering improvements

Changing conveyor design. At least 20 m length, 2 m width, pegs height 3ft above

ground level for same number of stations. This will reduce bending as well as space

problem

Changing palette design such that fitments which are difficult to be practiced on

conveyor line can be done on palette

Overhanging runners or runners kept at suitable height will reduce bending effort


17/23

Process improvements

Proper implementation of 5S principle.

Presence of tools and material within reach of worker to reduce walking.

Few fitments that involves excessive bending and blind obstructed positions should be

done before at pegs that are not on conveyor line.

Few difficult fitments should be done by vendor like acc. Control cable plate etc.

Following the station-fitment list.


18/23

5S implementation

Workers tool kit and inventory should bewell organized

Parts in the kitting trolley should be at their

fixed position.

Workspace should be neat, clean,

organized and spatial

Tools and parts within reach

To reduce unnecessary movement, tool

kit should be provided to each worker on

line.

Parts and other accessories should be in

the reach of worker


19/23

Zero sub station

Few fitments such as rear engine mtg.

brackets, oil pressure switch, butterfly

etc which involves bending and

obstructed postures should be done at

zero station where pegs are at suitable

height

Purchase specifications

Acc. Cable control plate fitment is a minor

activity but it takes sometimes more than 3

minutes to fit it due to its obstructed nature andsmall parts. Such fitments should be mentioned

in the purchase specifications to be done by

vendor.


20/23

Conveyor design change

Changing conveyor design. At least 20 mlength, 2 m width, pegs height 3ft aboveground level for same no. of stations. Thiswill reduce bending as well as spaceproblem

Alongside is the fitment of clutch housingcover, such blind and difficult to reach typefitments can easily be done on conveyorafter design change

Palette design change

Height at which engines are placed in palette

can be raised by changing the palette design in

such a way that difficult fitments on both sides of

engine could be done on palette itself

Purpose of the above change is at the times of

higher production rate when there isnt enough

time to keep engine at 0 sub station


21/23

Runner placement

Presently runner is generally placed onconveyor line due to which there is lot of

bending

Alongside is the pic. Depicting how this

bending effort can be reduced by providing

a stand for the runner at some height

These runner stands can be provided at

the sides of conveyor line

Overhanging runners can also be provided

to reduce bending.

This will reduce bending as well as space

problem


22/23


23/23

Improvement %age chart

Project outcomesTotal work content saved- 12.67minutes.

Total %age of work content saved-

23%.

Ergonomics improvements- status

of most of the fitments turned

.green, no red status left.

Productivity increased.

Efficient utilization of workforce.

Note:- Other improvements mentioned, will reduce the waiting and idle time ofoperator

12%

8%

20%

12%6%

42%

providing tool kit and

kitting trolley

providing raisedplatform

use of 0 sub station,

asking vendor

palette design change,

conveyor designchangeproper specifications

mentioned in purchase

listconveyor design

Documents

TPES Project Engine SA