Productivity improvement in Robotic Cell (6 nos.
) through Cycle Time reduction and
line re-layouting which will lead to shift optimization from 24 hrs to 16 hrs per day.
JBMA MVML
Reviewing of organization structure for internal transfers and deputations (2
manpower reduced)
NIPL
Transferred LPA Replaced LPA New LPA Diff
Babu Manager 14 Karthick 13.2 Balaji 12.2 1
Sandroo Sr. Executive 5.45 Vinod 4.8 Raja Pradip 3 1.8
19.45 2.8
Total Impact FY 25-26 22.25
Impact per month 1.85
Productivity improvement through cycle time reduction by load balancing (Operator
Motion) in 19 welded assembly of Nexon leads to reduction in cont. manpower 152 to
128 i.e. 24 mandays per day).
JBMA SND
Total Nos. Reduced Nos. Diff cost P.M Cost P.A.
152 128 -24 4.0 47.5
Conversion of Wooden Box packing to MS Structure of Railway’s Entrance Door
(Wooden box @ Rs.2635/box with 2 nos. capacity to MS Structure @Rs.4900 with
capacity of 6pcs.) (Total part cost reduced from Rs.1317 to Rs. 817 impact Rs.501/pc.)
JBMI
Wooden 2 2635 1318
MS 6 4900 817
-501
Productivity Improvement at Escorts Fender Line through cycle time reduction (253 to
185 secs ) by line balancing and welding fixture modification for easy part handling
leads to productivity improvement by 24% i.e. 220 nos./39 mandays to 272 nos/ 40
mandays.
JBMA FBD
Initial Cycle time Reduced Cycle Time Reduction %
253 183 -28%
220 39 5.641
272 40 6.8 1.2 60.267 39,173.33
470,080.00
Yield improvement through utilization of Channel Scrap material for manufacturing
Washer (it was manufacturing with fresh RM) and through die modification
productivity improvement from 1 part/stroke to 4 parts /stroke leads to savings in
Raw Material cost and Stroke Cost.
N-10 PNG
JBMA MVM
Working
SN Cell No. No. of Robot Part Name Part No.
Plan
1 2 3 4
1 PANEL ASSY REINF PLR B LH 1620N
Cell-01 1 R1 16 16 16 14 14
2 PANEL ASSY REINF PLR B RH 1630N
3
SUB ASSY PNL W/HOUSE FRT LH 0100N
4
R1 &
5 R2 SUB ASSY PNL W/HOUSE FRT RH 0120N
Cell-02 3 16 16 16 14 14
6
7
ASSY C PILLAR 0600N
8
R3
9
10 R1
11 R2 ASSY PANEL FRONT FLOOR TUNNEL 2540N
12 Cell-03 3 24 22 20 20 22
13 R3
ASSY CMBR REAR SEAT FRONT LWR 2530N
14
15 R1&R2 REINF ASSY PILLAR A INNER RH 3900N
16 Cell-04 2 R1 REINF ASSY PILLAR A INNER LH 3910N 24 22 20 20 22
17 R2 REINF ASSY SUNROOF 770N
18 REINF ASSY FLR TNL FRT 2490N
R1
19 1350N
PANEL ASSY HEADER REAR
20 1350N
Cell-05 2 24 18 18 18 18
21 REINF ASSY FLR TNL FRT 2490N
R2
22 PANEL ASSY CANTRAIL INR RH 4350N
23 PANEL ASSY CANTRAIL INR LH 4360N
24 REINFORCEMENT ASSY QTR OUTER REAR LH 3400N
R2
25 REINFORCEMENT ASSY QTR OUTER REAR RH 3510N
26
Cell -06 2 R1&R2 PANEL ASSY PILLAR A INNER RH 1030N 24 18 18 18 18
27
28
R1&R2 PANEL ASSY PILLAR A INNER LH 1040N
29
13
JBMA MVML BIW Robotic Working
Date
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
16 14 16 16 14 14 16 14 16 16 16 14 16 14 14 14 16 16 16 14
16 14 14 16 14 14 16 14 16 14 14 14 16 14 14 16 14 14 16 16
24 22 22 22 20 18 22 22 20 24 22 20 24 20 22 20 20 22 24 20
24 22 22 22 20 18 22 22 20 22 22 20 24 20 22 20 22 22 24 22
16 16 16 18 18 18 20 16 18 18 18 20 18 16 16 18 18 16 20 16
16 16 16 20 20 18 20 16 18 18 20 20 20 16 16 20 18 18 20 18
Total
Total Plan Difference
Actual
29 30 31
3 72
16 14 416 392 24
6 180
16 14 416 386 30
10 680
20 22 624 556 68
6 396
20 22 624 558 66
4 656
18 20 624 460 164
3 450
18 20 624 474 150
2434
502 304.25
62.75 248268
51204
JBMA MVM
Working
SN Cell No. No. of Robot Part Name Part No.
Plan
1 2 3 4
1 PANEL ASSY REINF PLR B LH 1620N
Cell-01 1 R1 14 16 14 14
2 PANEL ASSY REINF PLR B RH 1630N
3
SUB ASSY PNL W/HOUSE FRT LH 0100N
4
5 R1 & SUB ASSY PNL W/HOUSE FRT RH 0120N
R2
6 Cell-02 3 14 14 14 14
7
ASSY C PILLAR 0600N
8
R3
9
10 R1
11 R2 ASSY PANEL FRONT FLOOR TUNNEL 2540N
12 Cell-03 3 24 22 22 22
13 R3
ASSY CMBR REAR SEAT FRONT LWR 2530N
14
15 R1&R2 REINF ASSY PILLAR A INNER RH 3900N
16 Cell-04 2 R1 REINF ASSY PILLAR A INNER LH 3910N 24 22 22 22
17 R2 REINF ASSY SUNROOF 770N
18 REINF ASSY FLR TNL FRT 2490N
R1
19 1350N
PANEL ASSY HEADER REAR
20 1350N
Cell-05 2 20 18 18 18
21 REINF ASSY FLR TNL FRT 2490N
R2
22 PANEL ASSY CANTRAIL INR RH 4350N
23 PANEL ASSY CANTRAIL INR LH 4360N
24 REINFORCEMENT ASSY QTR OUTER REAR LH 3400N
R2
25 REINFORCEMENT ASSY QTR OUTER REAR RH 3510N
26
Cell -06 2 R1&R2 PANEL ASSY PILLAR A INNER RH 1030N 20 18 18 18
27
28
R1&R2 PANEL ASSY PILLAR A INNER LH 1040N
29
13
JBMA MVML BIW Robotic Working
Date
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
16 12 14 14 14 14 12 14 14 12
16 16 16 14 14 16 12 14 12 14
22 22 20 20 20 20 22 20 22
22 22 20 20 20 20 22 20 22
18 18 18 16 16 16 16 16 16
18 18 18 16 16 16 18 16 16
Total
Total Plan Difference
Actual
29 30 31
378 180 198
378 186 192
648 254 394
648 254 394
540 204 336
540 206 334
