CABIN

PRODUCTIVITY
IMPROVEMENT

Initiated By : - Production
Team

Team Members

Mr. Bheemeshwer S. Mourya ( Cabin Prod.

Incharge)
Mr. Ravi Verma ( Cabin quality.incharge)
Mr. Shakti Singh (Paint shop Head)
Mr. Parag Poonia (Weld Shop Head)

Under Guidance by :-Mr. N.K.Aggarwal & Mr. Niteen

Parwal

CONTENT

Summary ( Existing avl. Facilities Vs

proposed plan).
Existing process flow
Existing Layout
Time study ( station wise)
Bottleneck identification
Proposed process flow
Time study comparison sheet ( existing
Vs Proposed)
Bottleneck details along Before and After
with photo graphs

SUMMARY
EXISTING
FACILITIES

MODIFIED
FACILITIES

Number Of Stations : 18
Nos

Number Of Stations :
Nos

27

Number of MAG M/C : 15

Nos

Number of MAG M/C :

Nos

18

Number of Man Power

100 Nos

Number of Man Power : 114

Nos

Production/ Shift
Nos

: 3

Production per Shift(12hrs) :

5 Nos

BENEFIT : We can achieve the Leyland RPD (10 Nos) requirement from
single line.
Cost saving
Area Utilization

Before Improvement
Fabrication Line
Layout
PR
FL OC
O ES
W

1. Structure mounting (Cubin),

Inference :

Bottle Neck Study

Fabrication Line
Before improvement

Average cycle
time

90

85

85

80
Cycle time in Min

70
60

60
58

60

60
55

60
52

60
55

60
55

60

50
40
30

cycle time
Target (Min)

20
10
0

Stage

Bottleneck
-1

PREVIO
US

Wind Screen and interior

panel

1. Earlier Wind shield and

interior panel fitment both
work was being done at single
stage.
2. Only two orbit sander was
used for putty sanding.

MODIFIE
D
1. Now one new station created
for interior panel fitment.
2. One additional MIG welding
machine and one MIG welder
provided for interior panel
fitment

Bottleneck
2

Cutting & Grinding

PREVIO
US
1. Earlier cutting and grinding
both work was being done at
single stage.
2.

Only two grinder was used

for cutting.

MODIFIE
D
1.Now one new station created
for grinding.
2.One additional grinder and one
grinder
man provided for interior panel
fitment.

After Improvement
Fabrication Line
Layout
PR
FL OC
O ES
W

1. Structure mounting (Cubin),

Inference :

Fabrication Line-After
improvement
Cycle time in Min

Average cycle
time

62
60
58
56
54
52
50
48
46
44

60
58

60

60
58

60

60

55
52

52

60

60

55

55

60

52

60

50

cycle time
Target (Min)

Stage

Comparison of Cycle time on

Fabrication Line Before /After

Process Flow Of The

Paint Line
BEFORE
LAYOUT
Black
painting

SHIFT
TO TRIM

Top coat

Putty,
sanding,
Masking

Baking

PROCES FLOW

Sealant &
Primer

Finished
Shell

START

FINIS
H

GANG WAY

Putty &
sanding

GANG WAY

Inference : Action to be taken on baking stage on Painting Line.

Bottle Neck Study Paint

Line
Before process
250

220

220

200
Cycle Time in min

150
100
50

120

120
100

120

30

120

120

120

Average
Cycle time

30

Stage

Total manpower
30 Nos. used in 24
hour .

Bottleneck
-1

PREVIO
US

Putty application and

sanding

1. Earlier putty application and

putty sanding both work was
being done at single stage.
2. Only two orbit sander was
used for putty sanding.

MODIFIE
D
1. Now one new station created
for Putty
sanding.
2. One additional orbit sander
provided provided for putty
sanding.
3.
One additional manpower
added for putty sanding.

Bottleneck
-2

PREVIO
US

Putty Checking, Masking

& Top Coat

1. only one stage was available

for Putty checking, Masking &
Top Coat .
2.

Earlier Masking was being

done with the help of news
paper and masking tape.

MODIFIE
D
1.Now two new stages created
by shifting new baking oven
towards trim line.
2.Fix masking introduced for time
saving.
.

Bottleneck
-3

Black Painting

PREVIO
US
1. Only one manpower was done
black Painting and final touch
up.

MODIFIE
D
1.
Two additional manpower
provided for black painting and
final touch up.

Process Flow Of The

Paint Line

After Improvement Layout

PROCES FLOW

FINISH

Black
painting

Top
coat

Bakin
g

Additional
Oven

GANG WAY

Sanding
&
Masking

Putty

Baking

Sealant &
Primer

Sanding

Putty

START

GANG WAY

Improvements: 2 new stages (*) added and Dedicated Fork lift for Cabin line.

Paint Line-After
Improvement Process
140
120

120 120 120 120 120 120 120 120 120

100

Cycle Time in min

100
75

80
60
40

30

30

Average Cycle time

Target

20
0

100 105 100

80 75

stage

Total
manpower 30
Nos. used in
12 hour .

Comparison of Cycle time on

Paint Line Before /After
Comparison of Cycle time on Paint Line Before /After
250

220

220

200

150

120

Cycle Time In HRS

100

50

120
100 100105

120

120

120

100

120

120

100
80

30

120

30

30

stage

120
100

75

Before
After

75

Target
30

Bottle Neck Study Trim

Line
Before Improvement
200
180
160

180

180

60

60

process

140
Cycle Time in min

120
100
80
60

220
Target (Min)

40
20
0

stage

Inference : : 2 stages on painting Line are found bottle necked. Action to be has
been taken by bifurcating the stages.

Cycle Time in min

Bottle Neck Study Trim

Line
After Improvement
61
60
59
58
57
56
55
54
53
52

60

60

process
60

60

55

55

58
55

cycle time
Target (Min)

stage

Inference : : 2 stages on painting Line are found bottle necked. Action to be has
been taken by bifurcating the stages.

Process Flow Of cabin Trim

Line

PROCES FLOW

BEFORE
LAYOUT

FINIS
H

PDI
stage-2

PDI
stage-1

GANG WAY

Door assy., All

lights &
handles, Chair
& floor mate
fitment

Shower
Process done
at Near Main
gate
Roof fitment,
FES Trim, All
glasses Fitment

START

GANG WAY

Inference : Action to be taken on baking stage on Painting Line.

Process Flow Of The Paint

After Improvement Layout
Line
PROCES FLOW

Shower

Chair
& floor
mate
fitmen
t

Door
Assy. and
all lights
fitment

FINISH

GANG WAY

All Glass
and
handles
fitment

pdi
2

pdi
1

Roof
Fitmen
t&
FES
Trim

START

GANG WAY

Improvements: 2 new stages (*) added and Dedicated Fork lift for Cabin line.

Improvement
no-1
Before

Inference :

After

Improvement
no-2
Before

Inference :

After

Improvement
no-3
Before

Inference :

After

Improvement
no-4
Before

Inference :

After

IMPROVEMENT IN PIPE LINE

Low height Trolley for ease in working during
fabrication. (Oct-2016)
Cabin all child parts out source
Tooled up door
Trolley for movement to be with MS Wheels.
(As PU wheel get damaged in oven) (Oct
-2016)
Arrangement for lifting cabin to be provided
for Underbody paint and despatch. (Oct-2016)
Cubing Structure to be outsourced.
Monorail to be installed for lifting Cubing
Structure.

Thanks

Initiated By : - Production
Team