NH Circle - 2016.ppt
- 2. Introduction to the team TEAM MEMBERS B V Mahesh Vinay A.M. Suresh T V G Reddy Vasanth 36 40 55 3 Trainee 40 27 29 52 20 20 7 11 30 2 QC QC QA PD QC TEAM Advisor: T V G Reddy TEAM Leader : Ravi Rao Plant : Suma Spring Deptt. : Production Sect. : Winding Circle Name : Improvement of Productivity Theme : Productivity Improve with Operator fatigue Reduce Member 1 Member 2 Member 3 Member 4 Member 5 Observer Observer Name ECode Age Exp Cycle : Winter / Summer Date of Registration : 14.05.2016. Section
- 3. Activity Plan START OF NH ACTIVITIES : Jan- 2016 Month COMPLETION OF NH ACTIVITIES : June-2016 Month PLAN ACTUAL SR. NO. ACTIVITIES PDCA RESP. Jan-16 Feb-16 Mar-16 Apr-16 May-16 1. Selection of Theme A N 2. Study of current situation TVG R 3 Goal / Objective setting A M S 4 Identification of Causes Team 5 Planning of C.Measures & assigning responsibilities Team 6 Implementation of Counter Measures Team 7 Countermeasure effectiveness check Ravi Rao 8 Prevention and Standardization Ravi Rao 9 Presentation Preparation Suresh P P P D D D C C A
- 4. Reason for Selection Avoid Operator Fatigue • Doing manual operation will create more pain on operator hand will cause to frequent Leaves from them. Improve productivity • Produced Quantity Less and rejection Quantity more with current Manual process. Reduce Manpower • With Manual unable to balance with the machine produced quantity which is causing to extra manpower.
- 5. Flow Diagram- Before Improvement Received Raw material from Supplier Inspection of Raw material Winding Rolling Bending (Manual) Heat treatment Identification mark Final Inspection Surface treatment / oiling Packing Despatch
- 6. Analysis Before bending After bending M/c Run Rate = 11 Pcs/Min Operator Run Rate = 6 Pcs/Min with operator Fatigue
- 7. Manual Vs. Pneumatic Manual Tool for Hook Bending Pneumatic Tool for Hook Bending Pneumatic Run Rate = 22 Pcs/Min Operator Run Rate = 6 Pcs/Min with operator Fatigue / 2 operators
- 8. Manual Tool for Hook Bending Pneumatic Tool for Hook Bending Pneumatic Run Rate = 22 Pcs/Min Operator Run Rate = 6 Pcs/Min per operator with Fatigue Manual Vs. Pneumatic Before Improvement After Improvement
- 9. Benefits / Learning FI.NO Before Improvement After Improvement 1 More difficult to operate with manual which will create Hand elbow & shoulder pain Pneumatic piston with gear operating tool 2 2 Manpower to balance the M/c quantity for the Hook bending operation. Machine operator itself handling the hook bending process in Pneumatic 3 12 Pcs /Min with 2 operator 22 Pcs /Min with Single Machine Operator. 4 Unable to meet the customer schedule with all HMSI Units Able to meet more then scheduled quantity with all HMSI Units. 5 Difficult to Handle & setup the tool every time. Easy to handle & attached with the Machine.
- 10. Received Raw material from Supplier Inspection of Raw material Winding Rolling Bending (Pneumatic) Heat treatment Identification mark Final Inspection Surface treatment / oiling Packing Despatch Flow Diagram- After Improvement