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4.

1) WATER SPIDER OPTIMIZATION BY ELIMINATING


DUPLICATE ACTIVITIES

PROJECT GOAL
- Identification and elimination of non – value addition activities
- Redesigning of trim transportation trolley
PROJECT LEADER
- Mr. Abhinaw Raj (N.I.F.T. Chennai)
PROJECT MENTOR
- Mr. Kalyan Kanuri, Asst. Manager (H.O.D. – B.C.I.P)
PROJECT STAKEHOLDERS
- B.C.I.P.
- Lead team
- Production department
- R.M.W.H. department
- Finance department

4.1.1) INTRODUCTION
Water spider is a specific person on the production floor, whose main job is to make sure that
materials are supplied to where they are needed. It allows for transportation waste and
inefficiency to be isolated into one position; thereby allowing the rest of the personnel to devote
their full attention to tasks that add value to the process. The main reason to implement a water
spider is to decrease variation for everybody else, allowing them to improve their efficiency by
devoting their entire attention and effort on the value-addition task.

BAI – 1 had implemented the position of water spider back in 2015. They had 4 classes of
water spider based on the task allotted to them. These were:
 RM WATER SPIDER – Transportation of Fabric and CAD markers from RMWH
and CAD department respectively to the cutting section of each block.
 TRIM WATER SPIDER – Transportation of trims (packing and sewing) from
RMWH to the module.
 LABEL WATER SPIDER - Transportation of labels and price ticket from RMWH to
the module.
 BLOCK WATER SPIDER – Ensuring supply of raw material (cut panels, packing
trims, sewing trims) to each module of the block assigned to them.
 FG WATER SPIDER – Transportation of completed cartons from module to FGWH.
This project was a part of a long-term project to realign the water spiders by combining the
tasks of 2 or more water spiders. The project was aimed towards trim water spider optimization
and reducing its tasks so that it can be clubbed with another water spider.

4.1.2) METHODOLOGY
1. Current state analysis
2. Brainstorming session to identify probable areas of improvement
3. Data collection and analysis
4. Presentation of finding and implementation of result

4.1.2.1) CURRENT STATE ANALYSIS


The project began with a current state analysis to get an understanding of the position of water
spider, especially the trim water spider. Following results were gathered after 2 weeks of
observation:
Water spider head count
DESIGNATION COUNT PER SHIFT AREA OF RESPONSIBILITY
RM Water Spider 2 Entire Unit
Trim Water Spider 4 1 Section
Label Water Spider 4 1 Section
Block Water Spider 4 1 Block
FG Water Spider 16 1 Section

Time distribution of trim water spider


ACTIVITY TIME
Collection of trims 25 minutes
Travel time to section (average time taken) 8 minutes
Distribution of trims 10 minutes

Time distribution of trims water spider

23% Collection of trims


Travel time to section
58%
19% Distribution of trims
Process flow for trim issuing

Arrive at the trim issuing window of the particular section

Recieve job sheet and pick list from RM issuing person

recieve trims from RM issuing person

Verify given quantity against pick list quantity*

Sign the job sheet

Input details into trims recieved register.

Transport the trims to the module using trolley.

place the trims in the designated area at the start of the module

Return to trim issuing window of the particular section

* Manual counting (100%) is done for price ticket, label, thread, binding rolls, poly bags and
stickers. For lace and elastic box quantity mentioned on the label is added and matched
against job sheet quantity
4.1.2.2) BRAINSTORMING SESSION TO IDENTIFY PROBABLE AREAS OF
IMPROVEMENT
The findings were presented in a meeting with the lead team following which it was decided
to pursue reduction in collection of trims since it accounted for 58% of the total work and
hence even a small reduction could lead to significant savings.
Following data was gathered after a week of observing the activities performed by trim water
spider at the trim issuing window:

Time distribution of trim water spider at trim issuing window


ACTIVITY TIME
Receiving job sheet and pick list 0.5 minutes
Quantity verification 22 minutes
Data entry into trims issuing register 3 minutes

Time distribution of trims water spider


2%
12%
Receiving job sheet and
pick list
Quantity verification and
placing in trolley
Data entry into trims issuing
86%
regster

Based on this data it was decided to reduce time taken in counting of trims.

Several meetings were held with the R.M.W.H. H.O.D. and Section H.O.D. Based on the
discussion in those meetings following points were found:
 RMWH department
o Trim preparation process was working optimally.
o Trim preparation operators were responsible for ensuring right quantity is
prepared and issued.
 Production department
o Water spider were instructed to verify the quantity as a shortage in production
could lead to a line being idle resulting in reduced output.
o In case of shortage of trims due to any reason section H.O.D.s had to follow
the M.R.N. (Material request note) Protocol to get excess trims. M.R.N. takes
about 2 hours for trim to be issued.
Since shortage was the only reason for quantity verification it was decided to collect data to
analyze if the shortage due to incorrect quantity issue really occurred.
4.1.2.3) DATA COLLECTION AND ANALYSIS
Trim water spider and label water spider of each section were given the following formats to
fill respectively:

Date Module Style No. Schedule No. Cut No.


Heat seal

Trims Issue (Section 4) Shift -A


Sticker

Tag Pins

PolyBag

Thread

Elastic

Lace

Binding

Required
Actual
W.S
R.M

Instructions to fill:
 Input date of issue, module, schedule no. and cut no.
 Put a tick against the trim being verified.
 Input required quantity under required column (quantity mentioned in job sheet)
 Input received quantity under actual column
 If quantity under required column = quantity under actual column water spider to sign
under W.S. column
 If quantity under required column ≠ quantity under actual column RM issuing person
to sign under R.M. column
 Handover completely filled sheet to the R.M. issuing person to get new sheet.
Trims Issue (Section 1) SHIFT- A
Schedule PRICE TICKET LABEL Remarks
Date Module Style No. No. Cut No. Required Actual Required Actual W.S RM

Instructions to fill:
 Input date of issue, module, schedule no. and cut no.
 Input required quantity under required column of price ticket and label respectively
(quantity mentioned in job sheet)
 Input received quantity under actual column of price ticket and label respectively
 If quantity under required column = quantity under actual column water spider to sign
under W.S. column
 If quantity under required column ≠ quantity under actual column RM issuing person
to sign under R.M. column
 Handover completely filled sheet to the R.M. issuing person to get new sheet.
These sheets were given out for a period of 1 week and the data gathered was input into excel
for analysis and following results were received:
Trim Total cases Cases with deviation Percentage of cases with deviation
Heat seal 16 0 0.000%
Sticker 3 0 0.000%
Thread 103 1 0.009%
Elastic 126 5 0.039%
Lace 93 2 0.021%
Binding 10 0 0.000%
Price ticket 132 3 0.022%
Label 205 1 0.004%

Total cases 688


Cases with deviation 13
Cases with positive deviation 8
Cases with negative deviation 5

Based on this data its evident that the cases of deviation was very less and even in cases of
deviation the cases of positive deviation i.e. excess issue were predominant.

4.1.2.4) PRESENTATION OF FINDING AND IMPLEMENTATION OF RESULT


In a joint meeting with the lead team as well as RMWH H.O.D. and Section H.O.D.s the
above data was presented and a proposal to eliminate counting was floated which was
approved.
This was followed by a meeting with the trim and label water spider where they were told
about the project, data and the analysis in presence of the section H.O.D.s. After presentation,
they were instructed to stop the verification of quantity for a week during which the section
H.O.D. would observe if the production was affected by the same.

4.1.3) RESULT
Before the project After the project
Collection of trims 25 minutes 6 minutes
Travel time to section 8 minutes 8 minutes
Distribution of trims 10 minutes 10 minutes
Total 43 minutes 24 minutes
 44% - time reduction
 19 minutes per round
 152 minutes per shift (average 8 rounds per shift)
4.1.4) TROLLEY REDESIGNING
BAI – 1 used trolley for transport of trims from the R.M.W.H. to the Block. It was a basic
trolley and wasn’t designed specifically for the trim transportation. As part of the project it was
decided to redesign the trolley considering factors like ergonomics and utility.

Before

After
Improvements

S.NO. BEFORE AFTER


1 Labels and price tickets put into plastic Bin holders (circular ring at the
bags and transported by hand resulting beginning of trolley) are given to place
in accidental slippage as well as the plastic bags containing label and
difficulty in operating the trolley price ticket
2 Binding rolls hang from the trolley Binding spokes attached at the front of
(length of binding rolls > length of trolley for upright transportation of
trolley) resulting in bumping into other binding rolls
operators while transportation
3 Trims slipping from the side of trolley Placing covering on the sides of trolley
and falling down while transportation to prevent trims from slipping and
falling to the floor
4 No partition n trolley resulting in no Different sections in trolley made
systematic way for keeping different specifically for transport of different
trims trims
- Bins (labels, price tickets and
miscellaneous small trims))
- Spokes (binding and laces)
- Section 1 between handle and
spokes (sewing threads)
- Section 2 adjoining spokes
(elastic and lace boxes)

4.1.5) FUTURE PROGRESS


Similar project will be undertaken with other water spider, on completion of which the activity
of 2 water spider would be combined.
Possible combinations are: -
 Trim and RM water spider (most optimal combination)
 Trim and FG water spider (most feasible combination)
 RM and FG water spider
After combination of the water spider a new trolley would be used that would work on a screw
coupler.

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