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Engine sub assembly (CV-CX line1)
Engine Sub - assy.
E N G I N E S U B A S S E M B L Y
FITMENT OF TURNING TUBE ADJUSTMENT OF TURNING TUBE FITMENT OF SPEED SENSOR FITMENT OF REVERSE LIGHT SWITCH ( CMVR ENGINE ONLY ) FITMENT OF ‘ L ‘ BRACKET
STATION E-9A STATION E-9B STATION E-8 STATION E-7 STATION E-6A STATION E-6B STATION E-5 STATION E-3A STATION E-3B STATION E-2
INSPECTION OF ENGINE
FITMENT OF CLUTCH BOOSTER UPPER INSPECTION COVER FITMENT OF 6 DIA CLUTCH PLATE FITMENT OF CLUTCH HOUSING FITMENT OF GEAR BOX TIGHTENING OF CLUTCH HOUSING CHECKING OF TORQUE
GBS 600 & 750 … 4.5 MKG GBS 50 … 13.5 MKG
FITMENT OF POWER STEERING PUMP FITMENT OF PIPE TIGHTENING OF HARNESS WITH CABLE TIE EARTHING CONNECTION IN ALL MODEL FITMENT OF TURNING TUBE FITMENT OF AC HEAD SOCKET FITMENT OF AC HEAD PIPE ELBOW & 6 DIA PIPE
FITMENT OF ACC. PULL ROD FITMENT OF BABY FILTER FITMENT OF OIL PRESSURE SWITCH HARNESS CONNECTION STARTER EARTHING OIL PRESS SWITCH
FITMENT OF GEAR SHIFTING LEVER ENSURE TORQUE 6.9 MKG FITMENT OF EXHAUST FIRST PIECE FITMENT OF GEAR LEVER BKT. SILENCER HANGER BKT. & ‘ Z ‘ BKT ( ALL LPO ) FITMENT OF INTERCOOLER PIPE LH & RH WITH SOCKET FITMENT OF ALTERNATOR CONNECTION
FITMENT OF PRESSURE TORQUE CHECKING PLATE OF CLUTCH PLATE & CHECKING OF ORIENTATION FITMENT FITMENT OF HOUSING ( 330 DIA ONLY ) HARNESS CONNECTION IN CNG CMVR
9 •Cycle time – 5.21 Target •To reduce the work content and in turn cycle time of the engine sub assembly line •To make the fitments ergonomically safe and easier for the operator .assy. Summary •No of fitment – 40 •No.23 min •No. of station .Engine Sub . of operator .93 min •Work content – 53.
Most analysis OPERATING MOTION LOSSES Fitment wise analysis VA NVA ANALYSIS NVAN(min).34. 26% . 28.63. 21% VA(min). 11. 13. 53% NVAN(mi n) NVAE(mi n) VA(min) NVAE(min).26.
utilization = 47% .% Utilization Chart Avg.
Operator wise analysis .
Ergonomic analysis Initial analysis of all fitment of Sub – assy line .
25% Red Yellow Green Yellow . 19.Ergonomic analysis Ergonomics Status . 7% Green. 68% Red. 7. Red. 2. 2. Yellow .Engine sub-assy. 7. 68% . 25% Red Yellow Green Ergonomics Status . 19.Engine sub-assy. 7% Green.
no changes since then Material specifications Space problem.Major problems in sub assy area Frequent change in model 5S implementation improper Runner (bend and pick) problem Late delivery of engine (material shortage) Improper synchronization between engine and chassis line Material problem (sub assemblies) Bending problem in few fitments Blind and obstructed situation in few fitments Conveyor line designed since 1992. lot of congestion Tools and equipment shortage Line imbalanced Hammer is also used in few fitments .
Improper 5S implementation • • • Tools and parts are kept in the same kit Tool sharing by operators which are at different stations Manual kit movement Runner (bend and pick problem) • In most of the fitments operator has to bend and pick up the runner Runner is often shared accounting for the waiting time • .
blind and obstructed situations • More than 50% of the fitments include excessive bending postures Few fitments are even blind and obstructed Few fitments for ex clutch housing cover(lower) involves dangerous posture • • Space problem • • • Gap between two stations is just 1 meter Width of conveyor line is also 1 meter Operations are done on both sides of engine leading to congestion .Bend.
• .5 are under loaded and rest of the line is balanced Fitments do not take place according to station-fitment list. This involves excessive push force. whereas station 3.Line imbalanced • Station 1&2 are overloaded.4. • Material specification problem • Material provided should be as per the requirement of operation ‘L’ bracket attached with baby filter has to be tilted manually as shown alongside.
Inspection and quality assurance at stake at times of higher production rate .5 min and cycle time is 5.Effects Lesser productivity Increased chances of mishap Improper utilization of workforce Engine sub assembly has become a potential bottleneck as takt time is 5.93 min.
may be not For sure Not so effective Very effective .Improvements Type of improvement Cost effective Time consuming root cause eliminated Results effectiveness Process Engineering Yes No No Yes May be.
At least 20 m length. pegs height 3ft above ground level for same number of stations. This will reduce bending as well as space problem Changing palette design such that fitments which are difficult to be practiced on conveyor line can be done on palette Overhanging runners or runners kept at suitable height will reduce bending effort . 2 m width.Engineering improvements Changing conveyor design.
Few difficult fitments should be done by vendor like acc. . Few fitments that involves excessive bending and blind obstructed positions should be done before at pegs that are not on conveyor line. Presence of tools and material within reach of worker to reduce walking. Control cable plate etc. Following the station-fitment list.Process improvements Proper implementation of 5S principle.
Workspace should be neat.5S implementation • Worker’s tool kit and inventory should be well organized Parts in the kitting trolley should be at their fixed position. organized and spatial • • Tools and parts within reach • To reduce unnecessary movement. clean. Parts and other accessories should be in the reach of worker • . tool kit should be provided to each worker on line.
brackets. Cable control plate fitment is a minor activity but it takes sometimes more than 3 minutes to fit it due to it’s obstructed nature and small parts. oil pressure switch.Zero sub station • Few fitments such as rear engine mtg. Such fitments should be mentioned in the purchase specifications to be done by vendor. butterfly etc which involves bending and obstructed postures should be done at zero station where pegs are at suitable height Purchase specifications • Acc. .
Conveyor design change • Changing conveyor design. This will reduce bending as well as space problem Alongside is the fitment of clutch housing cover. of stations. At least 20 m length. pegs height 3ft above ground level for same no. such blind and difficult to reach type fitments can easily be done on conveyor after design change • Palette design change • Height at which engines are placed in palette can be raised by changing the palette design in such a way that difficult fitments on both sides of engine could be done on palette itself Purpose of the above change is at the times of higher production rate when there isn’t enough time to keep engine at 0 sub station • . 2 m width.
Depicting how this bending effort can be reduced by providing a stand for the runner at some height These runner stands can be provided at the sides of conveyor line Overhanging runners can also be provided to reduce bending.Runner placement • Presently runner is generally placed on conveyor line due to which there is lot of bending Alongside is the pic. This will reduce bending as well as space problem • • • • .
status of most of the fitments turned . •Efficient utilization of workforce. •Total %age of work content saved23%.67 minutes.12. •Productivity increased.green.Improvement %age chart Project outcomes •Total work content saved. will reduce the waiting and idle time of operator . •Ergonomics improvements. conveyor design change proper specifications mentioned in purchase list conveyor design change 20% Note:. asking vendor palette design change. 6% 12% 42% 12% providing tool kit and kitting trolley 8% providing raised platform use of 0 sub station.Other improvements mentioned. no red status left.
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