AUTOTÉCNICA COLOMBIANA S.A.S.

SETPACKING PROPOSAL

TVS MOTORS COMPANY

Cartagena, Colombia

March 2021
AUTOTÉCNICA COLOMBIANA S.A.S.
CARTAGENA, COLOMBIA

TVS Motor Company

March 2021

AUTECO SETPACKING PROPOSAL

Initially the plant was designed under unitized packing design, the racks, pallet structure and even assembly
line distribution follow an established sequence.

Cluster Packing design which is currently being supplied has increased the time for unloading the boxes,
arrangement of boxes according to available pallets, the box feeding process to the unpacking line and
arrangement of the materials on the floor which is 120% above the previous standard, Figure 1 Unloading
CKD process.

Figure 1 Unloading CKD process

Unloading CKD Process

(min)
200
172

150

100 90
78
47
50 30 35
23 25

0
Unloading Arrangement Store on the rack Total

Set Packing Sport 100ELS

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In addition to this, the reception capacity of daily containers was reduced by 57%. .Figure 2 Container
unloaded per day

.Figure 2 Container unloaded per day

Container unloaded per day

8 7

4 3

0
Set Packing Sport 100ELS

In addition to this, the supply headcount increased due to the re-arrangement process by 333% Figure 3 People
necessary (qty)

Figure 3 People necessary (qty)

PEOPLE NECESSARY (qty)

14 13

12

10 9

4 3 3
2
2 1 1
0
0
Unloading Arrangement Store on the rack Total

Set Packing Sport 100ELS

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And finally, the feeding times of the parts to the unpacking line are increased by 34 minutes with a percentage
of 123%.Figure 4 Feeding the parts to unpacking line

Figure 4 Feeding the parts to unpacking line

FEEDING THE PARTS TO UNPACKING LINE

(minutes)
120
96
100

80

60
43
40

20

0
Feeding the parts to unpacking line

Set Packing Sport 100ELS

Having said that, with the set packing proposal we seek to optimize the unloading times of containers and
increase the reception capacity of them.

To achieve the goal of set packing we propose to have 5 packing categories:

1. Main box

2. Plastic and paint parts

3. Engine

4. Seat bases and components

5. Fasteners

Next, we relate the proposal of the parts that should be packed by the previously related categories, in this case,
we make the example with a packing list of a container of the model Sport 100.

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 1. MAIN BOX

Table 1 Main box parts

Box PART NO. DESCRIPTION QTY/VEH. QTY / NO OF

No.. CONSIGNMENT. BOXES.
1 N8120930 STAND COMP CENTER 1 108 108
1 ND160370 WIRING HARNESS ES 1 108 108
1 N8220720 BRKT COMP HEADLAMP HOUSING 1 108 108
1 N5220810 TAIL LAMP SUB ASSY 1 108 108
1 N8221090 MIRROR ASSY LH DUAL TONE - SPORT 1 108 108
1 N8221100 MIRROR ASSY RH DUAL TONE - SPORT 1 108 108
1 N8221480 HEADLAMP ASSY STAR SPORT CVTI 1 108 108
1 N8221260 SPEEDOMETER ASSY 1 108 108
1 N51107505D BRAKE PANEL ASSY REAR 1 108 108
1 N8090520 SWINGARM SUB ASSY 1 108 108
1 N8111740 CHAIN ASSY 108 LINKS STAR RANGE 1 108 108
1 N5220720 HOUSING HEAD LAMP REAR 1 108 108
1 N8040960 AIR CLEANER SUB ASSY SAI 1 108 108
1 N8080990 LEVER ASSY GEAR SHIFT 1 108 108
1 ND110370 PEDAL BRAKE COMP 1 108 108
1 ND110190 BRAKE PANEL ASSY FR 1 108 108
1 N8121920 BRKT FRONT ENGINE MTG 1 108 108
1 N8122850 PILLION FOOT REST LH - STAR 1 108 108
1 N8122860 PILLION FOOT REST RH -STAR 1 108 108
1 K6160340 MAINTENANCE FREE BATTERY CHARGED 1 108 108
WEGO
1 N80304005D COVER ENGINE SPROCKET BLK 1 108 108
1 N8123700 BATTERY HOLDER 1 108 108
1 N51113705D WHEEL ASSY FRONT BLK U143 SPORT 1 108 108
1 N8091100 SHOCK ABSORBER UP 121 2 108 108
1 N81123105D WHEEL ASSY REAR 1 108 108
1 N8100680 UNDER BRKT COMP 1 108 108
1 ND221630 PILLION HANDLE 1 108 108
1 ND150060 HANDLE BAR SUB ASSY DRUM ES 1 108 108
1 N8090900 CHAINCASE UPPER 1 108 108
1 N31023407D LEG ASSY L TITAN GREY 1 108 108
1 N31023507D LEG ASSY R TITAN GREY 1 108 108
1 N5040880 AIR CLEANER ASSY 1 108 108
1 N8112330 DRUM RR SPROCKET ASSY 39T UP 121 1 108 108
1 N8220240 BODY FRONT FENDER REAR 1 108 108
1 N8220820 FENDER REAR 1 108 108
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Box PART NO. DESCRIPTION QTY/VEH. QTY / NO OF
No.. CONSIGNMENT. BOXES.
1 N83000305D CRASH GUARD BLACK 1 108 108
1 ND120620 FRAME, M/CYCLE COMP 1 108 108
1 N8090910 CHAINCASE LOWER 1 108 108
1 N5226770 TURN SIGNAL LAMP REAR L 1 108 108
1 N5226780 TURN SIGNAL LAMP REAR R 1 108 108
1 N5226800 TURN SIGNAL LAMP ASSY FR L 1 108 108
1 N5226810 TURN SIGNAL LAMP ASSY FR R 1 108 108
1 N2100150 BRACE FRONT FENDER 1 108 108
1 N3210030 TOOL KIT - VICTOR 1 108 108
1 ND060020 COMBINED IDI & IGNITION COIL ASSY1 1 108 108
1 N5160570 FUEL SENDER ASSY 1 108 108
1 NA140060 FUEL COCK ASSY WITH HOSES 1 108 108
1 N8160900 HORN ASSY 12V DC 1 108 108
1 N8214260 LOCK SET 1 108 108
1 ND050020 MUFFLER SUB ASSY 1 1 108 108
1 N8124220 RIDER FOOTREST ASSY UP.121 1 108 108
1 N5170020 CABLE ASSY FR BRAKE STAR 1 108 108
BAS/DLX/CENTRA
1 N8110970 ROD COMP REAR BRAKE 1 108 108
1 N8170190 CABLE ASSY CLUTCH SPORT DLX/CVTI 1 108 108
1 N8170320 CABLE ASSY SPEEDO CITY/JIVE/MAX4R MOB 1 108 108
CH
1 ND170010 CABLE ASSY BRAKE 1 108 108
1 N5040900 CARBURETTOR ASSY 1 108 108
 The dimension of the box we need are 1140 X 850 X 360 mm

2. PLASTIC AND PAINT PARTS

How we received currently from TVS, we want it the same way for setpacking configuration.

Table 2 Plastic and paint parts

CASE NO. PART DESCRIPTION. BOX QTY/VEH. QTY / NO OF

NO. DETAILS. CASE. BOXES.
CASE001-004 N5220379 TAIL COVER CENTER WW3409 1 22 4
CASE001-004 N8221739 FENDER FRONT UNPAINTED- WW3409 1 22 4
N104&U140
CASE005 N5220379 TAIL COVER CENTER WW3409 1 20 1
CASE005 N8221739 FENDER FRONT UNPAINTED- WW3409 1 20 1
N104&U140
CASE006-009 N5220330 COVER FRAME LH WW2416 1 27 4
CASE010-013 N5220340 COVER FRAME RH WW2416 1 27 4
CASE014-017 N8220789 COVER SEAT TAIL L UNPAINTED WW2729 1 22 4

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 CASE NO. PART DESCRIPTION. BOX QTY/VEH. QTY / NO OF
NO. DETAILS. CASE. BOXES.
CASE018 N8220789 COVER SEAT TAIL L UNPAINTED WW2729 1 20 1
CASE019-022 N8220799 COVER SEAT TAIL R UNPAINTED WW2729 1 22 4
CASE023 N8220799 COVER SEAT TAIL R UNPAINTED WW2729 1 20 1
CASE024-025 N5220410 VISOR HEADLAMP UNPAINTED WW2729 1 54 2
CASE026 N5220619 COVER FRAME INNER LH WW2729 1 108 1
CASE027 N5220629 COVER FRAME INNER RH WW2729 1 108 1
CASE028-033 N5220409 HOUSING HEAD LAMP FRONT WW2729 1 16 6
CASE034 N5220409 HOUSING HEAD LAMP FRONT WW2729 1 12 1
CASE035-055 N8140518 FUEL TANK COMP EPOXY BLACK WW3324 1 5 21
PAINTED - N4
CASE056 N8140518 FUEL TANK COMP EPOXY BLACK WW3324 1 3 1
PAINTED - N4

3. ENGINE

Table 3 Engine BOX

ONE BOX PART. No DESCRIPTION BOX QTY/VEH. QTY/ NO OF

DETAILS. CASE. BOXES.
1 ND180280 ENGINE ASSY 100 ES EXP AHO WW0809 1 1 1

 We need to receive one engine per box. We want to include the carburetor, battery and battery holder
in the main box.

4. SEAT BASES AND COMPONENTS

How we received currently from TVS, we need the same way for setpacking configuration.

Table 4 Seat BOX

CASE NO. PART NO. DESCRIPTION. BOX QTY/VEH. QTY / NO OF

DETAILS. CASE. BOXES.
CASE001-004 N3130040 SEAT REST REAR WW1858 2 48 4
CASE001-004 N8130240 CUSHION SEAT BASE WW1858 4 96 4
CASE001-004 N8130290 SEAT BASE -STAR SPORT WW1858 1 24 4
CASE001-004 N8130320 SEAT REST REAR -STAR SPORT WW1858 2 48 4
CASE005 N3130040 SEAT REST REAR WW1858 2 24 1
CASE005 N8130240 CUSHION SEAT BASE WW1858 4 48 1
CASE005 N8130290 SEAT BASE -STAR SPORT WW1858 1 12 1
CASE005 N8130320 SEAT REST REAR -STAR SPORT WW1858 2 24 1

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 5. FASTENERS

Table 5 Fasteners box

CASE NO. PART NO. DESCRIPTION. BOX QTY/VEH. QTY / NO OF

DETAILS. CASE. BOXES.
CASE001 M1200480 HEX FLANGE BOLT M8X25 WW3425 8 864 1

CASE001 M1200500 HEX FLANGE BOLT M6X40 WW3425 2 216 1

CASE001 M1200520 HEX FL BOLT M6X16 WW3425 5 540 1

CASE001 M1200530 HEX FLANGE BOLT M6X20 WW3425 2 216 1

CASE001 M7101020 SPACER FRONT FENDER WW3425 4 432 1

CASE001 M7101170 DUST SEAL STEERING UPPER WW3425 1 108 1

CASE001 M7121680 BRKT COMP HOUSING HEADLAMP WW3425 2 216 1

CASE001 M7160120 REFLEX REFLECTOR WW3425 1 108 1

CASE001 N2100180 ARRESTER STEERING STEM WW3425 1 108 1

CASE001 N2110680 DUST SEAL FRONT BRAKE CABLE WW3425 2 216 1

CASE001 N2140060 CUSHION FUEL TANK FRONT WW3425 2 216 1

CASE001 N3090700 BOLT REAR TORQUE LINK REAR WW3425 1 108 1

CASE001 N3091280 AXLE 12 249 SWING ARM WW3425 2 216 1

CASE001 N3100140 PACKING WW3425 4 432 1

CASE001 N3100220 GUIDE CABLE WW3425 1 108 1

CASE001 N3110390 SPACER COMP WW3425 1 108 1

CASE001 N3110990 AXLE FRONT 12X221 5 WW3425 1 108 1

CASE001 N3120130 GROMMET HEADLAMP WW3425 6 648 1

CASE001 N3120860 SPRING CENTER STAND WW3425 1 108 1

CASE001 N3121540 SPACER CENTER STAND WW3425 1 108 1

CASE001 N3200100 HEX FL BOLT M8X80 WW3425 2 216 1

CASE001 N3200190 HEX SCREW M6X30 WW3425 2 216 1

CASE001 N3200220 HEX FL BOLT M6X16 ZNG WW3425 4 432 1

CASE001 N5120820 GROMMET HEADLAMP WW3425 2 216 1

CASE001 N8200150 HEX BOLT M8X60 WW3425 1 108 1

CASE001 N8220400 CUSHION FUEL TANK WW3425 2 216 1

CASE001 N9140530 CUSHION FUEL TANK REAR MTG WW3425 1 108 1

CASE001 N9140540 BUSH FUEL TANK REAR MTG WW3425 1 108 1

CASE001 N9227200 REFLEX REFLECTOR WW3425 2 216 1

CASE001 ND110360 SPRING STOP LAMP SWITCH WW3425 1 108 1

CASE001 ND120330 BRKT IGN COIL MTG WW3425 1 108 1

CASE001 S1111930 PIN REAR BRAKE ROD LEVER WW3425 1 108 1

CASE001 S1125320 CLAMP OIL HOSE NO.2 WW3425 2 216 1

CASE001 S1200790 HEX FLANGE U NUT M12X1.25 WW3425 1 108 1

CASE001 S1201000 CRR PAN HD TAP SCR ST4.2X25 ZNK WW3425 4 432 1

CASE001 T4050180 GASKET PIPE EXHAUST WW3425 1 108 1

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CASE NO. PART NO. DESCRIPTION. BOX QTY/VEH. QTY / NO OF
DETAILS. CASE. BOXES.
CASE002 330028 SPLIT PIN 3.2X25 ZNB WW3425 2 216 1

CASE002 330048 SPLIT PIN 2.0X20 ZNB WW3425 2 216 1

CASE002 330328 WAVE SPRING WASHER M10 ZNG WW3425 5 540 1

CASE002 331058 HEX BOLT+WAVE SPR WASHER M8X16 WW3425 2 216 1

CASE002 334038 HEX NUT M10 8 ZNB WW3425 5 540 1

CASE002 334158 NUT REAR SWING ARM PIVOT WW3425 2 216 1

CASE002 334218 HEX NUT M8 SESP1301 ZNB WW3425 3 324 1

CASE002 334278 NUT RR BRK ROD ADJ WW3425 1 108 1

CASE002 K3200830 RETAINER CLIP M5 WW3425 2 216 1

CASE002 K6111340 SPRING BRAKE RETURN DRUM WW3425 2 216 1

CASE002 K6111350 BRAKE ADJUSTER WW3425 2 216 1

CASE002 N8160520 STARTER RELAY ES - CITY REF WW3425 1 108 1

CASE002 N8200030 HEX FL BOLT M8X75 WW3425 1 108 1

CASE002 N8200050 BOLT CENTER STAND WW3425 1 108 1

CASE002 N8220970 BRACKET LOWER WW3425 1 108 1

CASE002 N9040300 HOSE AIR CUT VALVE WW3425 1 108 1

CASE002 N9100840 CAP LOCKNUT WW3425 1 108 1

CASE002 N9101110 BALL CAGE COMP LOWER WW3425 1 108 1

CASE002 N9160380 ELECTRONIC FLASHER UNIT WW3425 1 108 1

CASE002 ND040010 PIPE COMP SAI EXP WW3425 1 108 1

CASE002 ND110230 BRKT BRAKE PEDAL MTG COMP 1 WW3425 1 108 1

CASE002 ND110290 SPRING BRAKE RETURN DRUM 1 WW3425 1 108 1

CASE002 ND110380 SPRING BRAKE RETURN DRUM WW3425 1 108 1

CASE002 ND120640 ABUTMENT BRKT BOTTOM WW3425 1 108 1

CASE002 ND120780 BRKT STOPLAMP SWITCH WW3425 1 108 1

CASE002 P1200050 WAVE SPRING WASHER 6.5 WW3425 7 756 1

CASE002 P1200140 PUNCHED WASHER A5.5 ZNG (TSDS-0003) WW3425 2 216 1

CASE002 P150270 DAMPER RUBBER LOWER WW3425 2 216 1

CASE002 R4060030 REGULATOR CUM RECTIFIER WW3425 1 108 1

CASE002 S1101150 RACE STEERING OUTER WW3425 1 108 1

CASE003 202118 ADJ COMP CHAIN'R' WW3425 1 108 1

CASE003 254038 PIN FR.BR.LEVER-BR ZNB WW3425 2 216 1

CASE003 258570 CLAMP REAR FENDER WW3425 1 108 1

CASE003 330318 WAVE SPRING WASHER M8 ZNB WW3425 7 756 1

CASE003 331278 BOLT ENGINE MOUNT L.115 WW3425 2 216 1

CASE003 331308 BOLT CHAIN ADJUSTER WW3425 2 216 1

CASE003 331718 CRPH SCR M5X16 6.8 ZNB WW3425 1 108 1

CASE003 332275 SCREW - CRPH M6X16 6.8 ZNK WW3425 9 972 1

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CASE NO. PART NO. DESCRIPTION. BOX QTY/VEH. QTY / NO OF
DETAILS. CASE. BOXES.
CASE003 335608 PUNCHED WASHER 6 5X16 0X1 2 ZNB WW3425 8 864 1

CASE003 335708 PUNCHED WASHER 15.5X26X2.3 ZNB WW3425 2 216 1

CASE003 335928 PUNCHED WASHER 6.5X18.0X1.6 ZNB WW3425 8 864 1

CASE003 3184048 SPACER RR AXL 'L' WW3425 1 108 1

CASE003 3202318 ADJ. COMP. CHAIN 'L' WW3425 1 108 1

CASE003 410043700 SPECIAL WASHER WW3425 1 108 1

CASE003 410058700 STEERING LOCK NUT WW3425 1 108 1

CASE003 420404000 3/16 BALLS WW3425 22 2376 1

CASE003 420452700 HEX SCREW M6X12 8.8 ZNB WW3425 3 324 1

CASE003 420454700 HEX SCREW M8X20 8.8 ZNC WW3425 6 648 1

CASE003 420462700 HEX SCREW M6X20 8.8 ZNB WW3425 10 1080 1

CASE003 420464700 HEX SCREW M6X16 8.8 ZNB WW3425 5 540 1

CASE003 A200050 HEX SOC HD CAP SCR M6X25 P 8.8 WW3425 2 216 1

CASE003 G5200280 PUNCHED WASHER 8.5 X 25 X 2 WW3425 2 216 1

CASE003 G5200400 PUNCHED WASHER 8.5 X 20 X 2 WW3425 6 648 1

CASE003 J200030 HEX NUT M18 8 ZNB WW3425 1 108 1

CASE003 K200690 HEX NUT M10 8 ZNB WW3425 4 432 1

CASE003 K3200860 CRR PAN HEAD SCREW M6X30 WW3425 1 108 1

CASE003 N5200170 HEX FL BOLT M6X35 WW3425 2 216 1

CASE003 N5226120 CUSHION, HEADLAMP WW3425 3 324 1

CASE003 N8040340 O-RING AIR INJECTION WW3425 1 108 1

CASE003 N8040350 HOSE CLIP AIR INJECTION WW3425 2 216 1

CASE003 N8040640 BRACKET SEC AIR INJ WW3425 1 108 1

CASE003 N8111720 SPACER R REAR AXLE WW3425 1 108 1

CASE003 N8122610 CUP WASHER WW3425 8 864 1

CASE003 N8140530 CUSHION FUEL TANK L WW3425 1 108 1

CASE003 N8140540 CUSHION FUEL TANK R WW3425 1 108 1

CASE003 N8140550 CUSHION FUEL TANK CENTER WW3425 1 108 1

CASE003 N8200040 HEX FL BOLT M8X65 WW3425 1 108 1

CASE004 335538 PUNCHED WASHER 12.5X22X2.3 ZNB WW4718 5 540 1

CASE004 335628 PUNCHED WASHER 10.5X24X2.3 ZNB WW4718 4 432 1

CASE004 335678 PUNCHED WASHER 12.5X24X3.2 ZNB WW4718 3 324 1

CASE004 409198000 DUST SEAL CHAIN COVER XT WW4718 1 108 1

CASE004 414147000 HOSE CLIP WW4718 2 216 1

CASE004 420001700 PUNCHED WASHER A6.6 ZNB WW4718 7 756 1

CASE004 420305700 HEX NUT M6 8 ZNB WW4718 6 648 1

CASE004 420955700 HEX SCREW M8X40 8.8 ZNB WW4718 2 216 1

CASE004 8200120 CRPH SCREW M5 12 WW4718 4 432 1

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CASE NO. PART NO. DESCRIPTION. BOX QTY/VEH. QTY / NO OF
DETAILS. CASE. BOXES.
CASE004 G5200380 HEX SCREW M8X 20 WW4718 2 216 1

CASE004 K140720 HOSE FUEL 220 WW4718 1 108 1

CASE004 K200320 SCREW SELF TAPPING 4.2X16 ZNK TSDS0209 WW4718 7 756 1

CASE004 K200540 HEX SCREW M6X38 8.8 ZNB WW4718 1 108 1

CASE004 K200700 CRPH SCR M6X25 8.8 ZNBH WW4718 2 216 1

CASE004 M1200660 CRPH SCR M5X16 ZNG WW4718 2 216 1

CASE004 M1200890 U NUT M8X1.2 WW4718 8 864 1

CASE004 N2041670 CUSHION VALVE MOUNTING WW4718 2 216 1

CASE004 N2110600 PIN REAR BRAKE CONNECTOR WW4718 1 108 1

CASE004 N2200500 HEX FLANGE BOLT M6X25 ZNG WW4718 2 216 1

CASE004 N3100230 CLIP WW4718 1 108 1

CASE004 N3110360 SPRING REAR BRAKE ROD ADJUSTER WW4718 1 108 1

CASE004 N3120410 PLUG TUBE UPPER WW4718 2 216 1

CASE004 N3140120 GASKET OIL LEVEL PLUG WW4718 2 216 1

CASE004 N3160060 BAND BATTERY WW4718 1 108 1

CASE004 N3160220 SPACER R.C.LAMP MOUNTING WW4718 2 216 1

CASE004 N3160250 SWITCH ASSY STOP LAMP WW4718 1 108 1

CASE004 N3160340 CLAMP WIRING HARNESS BIG SIZE WW4718 2 216 1

CASE004 N3200340 CRR FLANGED PAN HD TAP SCREW ST4.2X13 WW4718 4 432 1

CASE004 N5210630 STICKER INFO WW4718 1 108 1

CASE004 N8040250 SEC AIR INJECTION VALVE WW4718 1 108 1

CASE004 N8040620 HOSE SAI OUTLET WW4718 1 108 1

CASE004 N8111580 SHAFT SPROCKET MTG DRUM WW4718 1 108 1

How we received currently from TVS, we need the same way for setpacking configuration.

In conclusion, with this proposal we would obtain the following benefits:

 Decreased unload time by 51%, equivalent to 24 minutes

 Decrease in headcount by 77%, equivalent to 10 people
 Increased daily container reception capacity by 57%, equivalent to 4 containers
 Recovery of productive area: 168 m2, unpacking area to floor 92 m2 and 76 m2 used in the activity of
unpacking of parts which are not able to be done in the unpacking line
 Decrease in tiebreaker line assortment time. At 55% equivalent to 53 min

Additional request:

 To assure the complete packing of CKD parts avoiding shortages or mismatch

 To assure the quality of CKD parts avoiding appearance defects like dents, scratches and rust.

Auteco SAS | Km 6 Mamonal Cartagena

To PQR: 01 8000 52 00 90 E-mail: servicioalcliente@auteco.com.co