Advance Cluster

ACT Cluster programs – a progression through skill

and competence development

Advance Cluster
• Create a Vibrant Workplace – Ready to Change.
• To Develop Lean Thinking and Competencies in organization.
• Promote Lean practices.
• Enhance excellence in Manufacturing Practices.
• Focus on Operating Cost Management.
• Promote Innovation

Helping companies move up the value chain

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 Advance Cluster
Advance Cluster - History
12 Version 13th & 14th
Successfully Cluster of 8 15th Advance
Completed 95 Companies In- Cluster –
Plants progress. enrolment ON

Overall
Payback
Feedback Total Savings
Period of Less
than 70 days Ratings = of Rs. 176 Cr
96%

Helping companies move up the value chain

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 Advance Cluster
Advance Cluster - History
Cluser-wise QCC Data

ADV CLUSTER - 12 78

ADV CLUSTER - 11 55

ADV CLUSTER - 10 48

0 10 20 30 40 50 60 70 80 90

285
Total QCC
Total 181
Kaizen
Completed
Completed

Helping companies move up the value chain

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 Advance Cluster
Advance Cluster - History

Helping companies move up the value chain

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 Advance Cluster
Four Pillars of Advance Cluster
Base Pillar Process Result Build sustainable culture

1. Total employee Involvement

Pillar 1 Lean Introduction
Competent People

2. Creating Lean Process

Lean Organisation
Pillar 2 Advance 5S
3. Lean Thinking and Lean culture

4. Value adding Management

Pillar 3 Material Handling Management
5. Develop Zero Defect Culture
Pillar 4 Cellular Manufacturing
6. Execute Zero Defect Quality

3 Material Handling Cellular manufacturing

1 Lean Introduction 2 Advance 5S
Management 4

• Employee Involvement • Addressing weak areas • Single Piece Flow • Indian production system
of 6M • Flow Manufacturing • PQCDSM
• Lean Culture
• Performance • FIFO • Enhance Competitive advantage
Improvement
•
Helping companies move up the value chain
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 Advance Cluster

Communication & Reward

Recent Clusters

186 QCC
761 Kaizens
36 Improvements per person
per annum

Helping companies move up the value chain

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 Advance Cluster

Employee Involvement

Employee
Involvement is Key to
success …. Cluster
Journey enhances TEI

Helping companies move up the value chain

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 Advance Cluster
Employee Involvement

Helping companies move up the value chain

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 Advance Cluster

Value Stream Mapping

Current State Map Future State Map

No. of Manpower 24 No. of Manpoer

20
Line Length 26 m Line Length 21 m
Total no. of Stations 26 Total no. of Stations 21
Total Lead Time 422 sec Total Lead Time 315 sec
Productivity/hr/op 95
Productivity/hr/op
120
VAR 0.8
VAR 56.80

Helping companies move up the value chain

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 Advance Cluster

Value Stream Mapping

Raw Material
Supplier
Purchase Raw Material

Current
BeforeState Map State Map
Monthly Customer Firm Order Given +
Dept. Next Three Days Customer Requirement Supplier
Marketing
STORE Child Part PPC Dept. Dept. STORE Purchase Monthly Customer Firm Order Given + Next
Supplier Three Days Customer Requirement
Dept.

Single
Child Part
Supplier
PPC Dept.
OEM Customer +
Marketing
Market Customer Dept.
Raw Material for Production
Hot Process
Work Dept. Hot Raw Material for
Process
+ Heat Work OEM Customer +
Cold Production

Piece
Treatment +
Work Market Customer
Process Cold
Dept.
Work

Marketing + PPC +
I4 OPN-3 I6 OPN-5 OPN-9 OPN-10
Dispatch Dept.
5 Matching (P-15) 1 Primer Application 1 Assembly forming 1 Scragging (P-46)

1 2 1 2
per assy Chaine conyour per assy Assembly & per assy per assy
C/T (sec) = 17 C/T (sec) = 18 C/T (sec) = 44 C/T (sec) = 45

Flow
reduce from 18 scragging on
Heat same machine
C/O (sec)= 5 mt to 13 mt. C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0
Treatment Improve
Auto Primer of leaves
Process productuvity by Auto camber
Optr.Move. (mtr) = 1 Optr.Move. (mtr) = 0.2 will be done , for that Optr.Move. (mtr) = 2 2.50 Optr.Move. (mtr) = 2.5
four lleaves Mtr measuting by PLC
idea is generated.
Stress Peening stress peening Inspection & Rework Operation is Inspection & Rework Operation is Bottle neck operation Bottle neck operation
channel pushing bore due to no exact camber bore due to no exact camber Skill Manpower Require Skill Manpower Require
achieve as per requirement from achieve as per requirement from
system install

Your text here

Lift weight >15KG Lift weight >15KG
Heat Treatment Heat Treatment
and similar install Operator need to bend more for

53%
Make small 1.00 1.60
at outside Remove 8 fix rack Make small bush measuring camber of assemblt Bolt peening table
3.00 Skill Manpower is require 4.50 Replace to flate 2.50 Skill Manpower is require 0.00 Rivating machine Mtr Mtr
remove in beteen fitting machine size reduce by
Mtr Mtr to chaine Mtr Mtr
half
I4 OPN-3 I6 OPN-5 OPN-9 OPN-10
30 Matching (P-15) 10 Primer Application 1 Assembly forming 10 Scragging (P-46)

1 2 1 2

C/T (sec) = 17
I11
per assy C/T (sec) = 18 per assy C/T (sec) = 44 per assy C/T (sec) = 45 per assy
I1 OPN-1 I2 OPN-2 I3 OPN-3 I5 OPN-4 I7 OPN-5 I8 OPN-6 I9 OPN-7 I10 OPN-8 OPN-9 I12 OPN-10 I13 OPN-11 I14 OPN-12 I15 OPN-13 Total Manpower = 27
C/O (sec)= 5 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0
10 Shot Peening 5 Straightening (P-109) 5 Matching (P-90) 2 Combine Camber (P-76) 2 Primer Application 15 Riveting (P-43) 2 Bush Fitting (P-57) 2 Spacer Fitting 1 Assembly forming 1 Scragging (P-46) 2 Clamp Adjustment 2 Clamp Folding 2 Bolt Peening Bottle Neck TimeMin=
Optr.Move. (mtr) = 1 Optr.Move. (mtr) = 0.2 Optr.Move. (mtr) = 2 2.50 Optr.Move. (mtr) = 2.5 22.5
Mtr
Inspection & Rework Operation is Inspection & Rework Operation is Bottle neck operation Bottle neck operation 5 1 1 2 3 1 2 2 2 2 0 2 1 Total Process Time =
bore due to no exact camber bore due to no exact camber Skill Manpower Require Skill Manpower Require per assy per assy per assy per assy per assy per assy per assy per assy per assy per assy per assy 308
C/T (sec) = 23 C/T (sec) = 16 C/T (sec) = 23 C/T (sec) = 24 C/T (sec) = 19 C/T (sec) = 16 C/T (sec) = 18 C/T (sec) = 26 C/T (sec) = 44 C/T (sec) = 45 C/T (sec) = 6 C/T (sec) = 25 C/T (sec) = 23
achieve as per requirement from achieve as per requirement from
Lift weight >15KG Lift weight >15KG Total Lead Time =
Heat Treatment Heat Treatment
Operator need to bend more for
1036
2.00 1.60 C/O (sec)= 0 C/O (sec)= 120 C/O (sec)= 300 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0

space
3.00 Skill Manpower is require 4.50 2.50 Skill Manpower is require 0.00 Mtr
measuring camber of assemblt
Mtr
Process Inventory =
Mtr Mtr Mtr Mtr Optr.Move. (mtr) = 2 3.00 Optr.Move. (mtr) = 1 3.00 Optr.Move. (mtr) = 1 3.00 Optr.Move. (mtr) = 1 1.00 Optr.Move. (mtr) = 0.5 6.50 Optr.Move. (mtr) = 0 1.50 Optr.Move. (mtr) = 0 0.00 Optr.Move. (mtr) = 0 2.00 Optr.Move. (mtr) = 2 2.00 Optr.Move. (mtr) = 2.5 1.50 Optr.Move. (mtr) = 0 1.00 Optr.Move. (mtr) = 0 1.00 Optr.Move. (mtr) = 1 59
Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Distance Traveled =
Semi automatic process, loading and Semi automatic process, loading and
Inspection & Rework Operation is Inspection Operation Inspection & Rework Operation is 3C not implamented 3C not implamented Compeletely manual activity Bottle neck operation Bottle neck operation Assembly inspection stage Lift weight >15KG Lift weight >15KG 37.6
born due to no exact camber bore due to no exact camber
unloading done by manpower unloading done by manpower Skill Manpower is require Semi autometic Process Semi autometic Process 10Nos of spacer need to fit Skill Manpower Require Skill Manpower Require VAR Ratio =
achieve as per requirement from
Non Value adding activity
achieve as per requirement from
more effort is require for spacer Lift weight >15KG Lift weight >15KG
308
One of the main reason of noise One of the main reason of noise Heat Treatment Heat Treatment
I1 I2 I3 I5 I7 I8 I9 I10 I11 I12 I13 I14 I15 Total Manpower = fitting Operator need to bend more for
OPN-1 OPN-2 OPN-3 OPN-4 OPN-5 OPN-6 OPN-7 OPN-8 OPN-9 OPN-10 OPN-11 OPN-12 OPN-13 27 creation creation
1036
Skill Manpower is require measuring camber of assembly
5 Shot Peening 40 Straightening (P-109) 25 Matching (P-90) 30 Combine Camber (P-76) 10 Primer Application 12 Bush Fitting (P-57) 14 Riveting (P-43) 10 Spacer Fitting 3 Assembly forming 5 Scragging (P-46) 5 Clamp Adjustment 3 Clamp Folding 18 Bolt Peening Skill Manpower is require
Bottle Neck TimeMin
= 22.5 Floor is slippery & 3S not maintain Floor is slippery & 3S not maintain
5 1 1 2 3 1 2 2 2 2 0 2 1 Total Process Time = Unsafe working condition Unsafe working condition
29.73
C/T (sec) = 23
per assy
C/T (sec) = 16 C/T (sec) = 22 C/T (sec) = 24
per assy
C/T (sec) = 19
per assy
C/T (sec) = 18
per assy
C/T (sec) = 16
per assy
C/T (sec) = 26
per assy
C/T (sec) = 44
per assy
C/T (sec) = 45
per assy
C/T (sec) = 6
per assy
C/T (sec) = 15
per assy
C/T (sec) = 22
per assy 296
Total Lead Time =
4433 230 80 115 48 38 240 36 52 44 45 12 50 46 1036
C/O (sec)= 0 C/O (sec)= 120 C/O (sec)= 300 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 120 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0 C/O (sec)= 0
Process Inventory =
Optr.Move. (mtr) = 2 3.00 Optr.Move. (mtr) = 1 3.00 Optr.Move. (mtr) = 1 3.00 Optr.Move. (mtr) = 1 1.00 Optr.Move. (mtr) = 0.5 10.00 Optr.Move. (mtr) = 0 12.00 Optr.Move. (mtr) = 0 0.00 Optr.Move. (mtr) = 0 2.00 Optr.Move. (mtr) = 2 2.50 Optr.Move. (mtr) = 2.5 1.60 Optr.Move. (mtr) = 0 1.00 Optr.Move. (mtr) = 0 1.30 Optr.Move. (mtr) = 1 180 23 16 23 24 19 16 18 26 44 45 6 25 23 308
Distance Traveled =

Saving
Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr Mtr

Semi automatic process, loading Semi automatic process, loading Inspection & Rework Operation is Inspection Operation Inspection & Rework Operation is 3C not implamented 3C not implamented Compeletely manual activity Bottle neck operation Bottle neck operation Assembly inspection stage Lift weight >15KG Lift weight >15KG 56.5
and unloading done by manpower and unloading done by manpower born due to no exact camber bore due to no exact camber Semi autometic Process Semi autometic Process 10Nos of spacer need to fit Skill Manpower Require Skill Manpower Require VAR Ratio =
achieve as per requirement from
Skill Manpower is require
Non Value adding activity achieve as per requirement from more effort is require for spacer Lift weight >15KG Lift weight >15KG
296 17 18 44 45
One of the main reason of noise One of the main reason of noise
Heat Treatment Heat Treatment fitting Operator need to bend more for
creation creation Min.
Skill Manpower is require measuring camber of assembly
4433 Min. M/C 541 = 12.93
Floor is slippery & 3S not Floor is slippery & 3S not Skill Manpower is require
maintain maintain
Unsafe working condition Unsafe working condition Nos.
6.68
+ = Kaizen Idea = Operation Clubbing = Transportation = Opn. Flow = No. Of Operator I
= Inventory A = Continuations = Information Flow
115 640 1060 720 370 216 224 260 132 225 30 45 396 4433 max. 100 pieces

23 16 22 24 19 18 16 26 44 45 6 15 22 296
FIFO = First In First Out = Pull Out 20
= Production Kanban '= Buffer Stock = "Go See" & Monitor '= Kanban Port

17 18 44 45
Min. Min. M/C 541 = 12.93

Percentage improvement
Parameters
range
Troughput Time 34% 62%
Space Saving 20% 54%
Distance travel 30% 83%
VAR 36% 100%
WIP 42% 88%
Productivity 20% 351%
Helping companies move up the value chain
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 Advance Cluster
Advance 5S
6 Ms 1S 2S 3S 4S 5S
Man Only trained person to Do-Retraining New Entrant Training , Establish – Do periodic audits
be put on job ( for all changes made re-training , Develop a)Training System ,
at workplace ) Coaches
b) SOP,
c) Multi-skill Matrix
Machine Wet to dry , Free form Arrangements for Implement CLITA for Establish – Do periodic audits for
damages , Discard used hoses , pipes , place machines , jigs , fixtures a) Standards for Step Step 1 , 2 , 3 and PM
tooling for all required tooling and tooling 1
B , 2SOP
,3 for Preventive
Maintenance
Material Damage free , Oil free , Appropriate place for Transfer only defect Establish SOP for Defect Do dock audits
( Input material + burr free components , Material and parts on free parts to next free parts and Clean parts
Parts ) Produce required parts machines & in process or customer
only between processes
Method and Improve by removing Use improved Sustain all improved Establish Do process audits
processes unnecessary processes processes a)QCPC
movements , manual
b)Operation Standard
unloading
c)Inspection Standard
d)FPP
Measuring Use only calibrated Pre-fixed location Calibration at set Establish Do periodic audits ,
equipments measuring equipments during use and for frequency a)Calibration SOP Schedule adherence
( Fit for use and free storage , Appropriate
from damages ) handling to maintain b)Handling instructions
Accuracy
c)Calibration
instructions

d)Calibration schedule

Material handling Wet to dry material Pre-fix location for all Shining material Establish Audits for adherence
equipments handling , Clean and types of material handling equipments , a)SOP for material for set standards
damage free containers handling CLITA for Material handling equipments
Handling Equipments
b)SOP for PM for
Material handling
equipments

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 Advance Cluster
Advance 5S Mapping and Improvement Plan

Methods
Improve
ments

Weak Areas : Method & Material

handlings.

Numerous Projects are triggered

to address Weak areas

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 Advance Cluster

Integrated Material Handling and Storage

Material Stored in Gunny Bags

Systematic Arrangement in M.S Reduced Inventory and

Tray Saving Space

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 Advance Cluster
Integrated Material Handling
Material Handling and Storage

Inventory
Reduction
through
addressing
Prerequisites for
Matl Handling

1. Reduction in Dent / Damage

2. Space Utilization
3. Cash flow improvement
4. Facelift of Plant
5. Smooth Material Flow

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 Advance Cluster
Integrated Material Handling
Material Handling and Storage

Before After
Who Own
Super
Material
market
Handling ?

Finally we will have

Trolley’s Only in
Supermarket and First
Operations of each line

Operation wise Bins, Trolleys & Stacks, Total No. 271 Operation wise Bins, Trolleys & Stacks, Total No. 120

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 Advance Cluster
Integrated Material Handling
Star Diagram

Inventory
storage Points
at Countless
Location

Inventory
storage Points
at minimal
Location

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 Advance Cluster

Material Handling and Storage

Before After

Super
market

Finally we will have

Trolley’s Only in
Supermarket and First
Operations of each line
Who Own
Material
Handling ?

Operation wise Bins, Trolleys & Stacks, Total No. 271 Operation wise Bins, Trolleys & Stacks, Total No. 120

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 Advance Cluster
Integrated Material Handling
Contenerisation

Dent & Damages During Transportation Dent & Damages Free Transportation

“Part s Touching Each Other” 3C container

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 Advance Cluster
Cellular Manufacturing
Lean Layout
Before After
Cell Layout:
Previously the PCE This line has been
Line was in a Looped transformed into a
Structure causing a Straight Line .
lot of hindrance in Benefit: Material
working Transportation easy.
environment. Space save;2250-
Space Utilized: 2250 1510=740 Sq. Ft.
Sq. Ft. Material Distace-15
Material Distance-33 Mtr
Mtr

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 Advance Cluster
Cellular Manufacturing
Lean Layout
TAPER DIE Cover Coning
ROLLING W ORK rolling

DRILLING

….CEO’s job to End heating furnace

TAPER
ROLLING
DIE
W ORK

End heating furnace

TAPER
ROLLING
DIE
W ORK

DRILLING PUNCHING

bring Business
ACMA will create
DRILLING PUNCHING

EYE EYE
RADIUS ROLLING RADIUS ROLLING
CUTTING CUTTING

space in company
Single Piece Flow Layout

Space Saved
For New Business
Zig - Zag Layout Single Piece Flow Layout

Layout has immense Impact on PQCDSM

Helping companies move up the value chain
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 Advance Cluster
Cellular Manufacturing
Line Balancing
Cycle Time ( Mins ) Prod. Target / Shift ( Qty. )
25
19.8 50 46
20
40 37 37
15 13.1112.83
10.39 30 24
10
20
5 10
0 0
Before After Before After

Tack welding and Full welding Cycle time

24x7 working to Productivity balancing done
fulfill Customer Improved by 58%
Demand 2 shift working Productivity Improved by 54%
for 6 days per wk.

Helping companies move up the value chain

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 Advance Cluster
Cellular Manufacturing
Equipment Step 1 2 3

Model
Machine
Cleaning With Meaning
Abnormality Tagging and correction
Easy to Access
Establish CLIT standard
Zero Break Down , Easy to maintain , Easy to Operate

Helping companies move up the value chain

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 Advance Cluster
Cellular Manufacturing
Low Cost Automation
Before After

Comment –Automation of
Comment: Manual Tumbler
Tumbler assembly process
assembly.
leading into saving of five man
powers.

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 Advance Cluster
Cellular Manufacturing
Low Cost Automation

Bush Fitting Press

Machine replaced with
Portable fitting unit.
Machine eliminated

Horizontal Deployment
eliminated 13 Machines

Bush Fitting Machine

Bush fitting unit

Helping companies move up the value chain

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 Advance Cluster
Cellular Manufacturing
Modern Manufacturing Plant checklist
Best possible Your score- May- Best
Sr. No Parameter Before Your score-
score 15 Sr. No Parameter possible Before
May-15
score
1 Company practices flow Manufacturing 4 2 3
Senior managers playing leadership roles -
2 No racks in company ( Score 0 or 4 ) 4 0 0 21 4 2 3
Mentoring younger employees
3 No pallets in company ( Score 0 or 4) 4 0 0
4 Extensive use of LCA 4 2 3 22 5 % time is spent on training of all employees 4 1 2
5 Extensive use of Mistake –Proofing 4 2 3
6 Multi-skilling working by operators 4 4 4 Multi-Function and Flexibility working in office area
23 4 0 2
– Office Maintenance
7 Operators engaged in Value added activities 4 2 3
8 Quick Changeovers are practiced 4 2 4 24 Regular audits and Corrective actions for PQCDSMI 4 2 3
9 All manpower is educated and trained 4 2 3 All improvements must be productive and
25 4 2 4
10 Company has high degree of 5 S 4 2 4 innovative
11 Operators own Quality , Cost and Delivery 4 2 3 Employees work standing posture and keep moving (
26 4 4 4
Score 0 or 4 )
Practice of Hourly management of QCD ( Score 0 or
12

13
4)
Supervisors are improvement engineers
4

4
0

2
Target Before After
4

3
27
20 % of resources should work for future , Thinking
and innovative
4 3 4

SOPs are written by operators and revised (Score 0 28 Compressed air is not used for cleaning and drying 4 3 4
14

15
or 4 )
Only calibrated tools / Instruments used
4

4
0

4
85% 44 % 80 %
4

4 29
IT integrated to improve performances of all
processes
4 3 3
16 Minimum verities of containers ( Pallets / bins ) used 4 2 4
Company improvement activities are integrated to
Company rhythm and pace of work to match takt 30 4 4 4
17 4 0 4 it’s business plan (Score 0 or 4 )
time (Score 0 or 4 )
18 No artificial lights used during day time (Score 0 or 4 ) 4 0 4 Management has implemented Best Practices to
31 create a “ Better work environment for the 4 0 4
19 100 % employees involved in improvement 4 2 2 employees”. ( Score 0 or 4)
Plant split in manageable size - Factory within factory
20 4 0 4 Total 124 54 100
(Score 0 or 4 )

Helping companies move up the value chain

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Advance Cluster

We Believe in Transformation …
Dream Big.
Helping companies move up the value chain
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 Advance Cluster
Dream Layout

Distance Travelled
Reduced by
66 %
Before

WIP Inventory
Reduced by
78 %

After
Productivity Improved by
97 %
Helping companies move up the value chain
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Advance Cluster
Hospital Clean Shop floor

Sitting on Floor
near Shot
Blasting
Machine

Helping companies move up the value chain

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 Advance Cluster
Garden Green & Dust Free Outskirts

Helping companies move up the value chain

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 Advance Cluster
Garden Green & Dust Free Outskirts

Work Less to Gain More

THANK
YOU……!
It’s All about Lean
Thinking.
Back to Home Page

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