IMPROVEMENT PLAN

FOR
MATERIAL HANDLING
A). IMPROVEMENT DONE
B). NEXT IMPROVEMENT PLAN

PROCESS TEAM:
Mukesh Ingole
Shivam' Mishra
Bhupendra Singh
A). IMPROVEMENT DONE
 1) Implemented Corrugated Bin for bearing at grease
application cell(RBD)
Before After
Packed
Bearing

Unpacked
Bearing Bearings
boxes under systematically
table arranged

Corrugated bins provided as per (75nos/bin) storage capacity for

supplying materials from store to assembly stations.
BENEFITS:-
1) Time will be Saved = 30 min/shift (approx) improve
productivity
Sleeve bearing unpacking is done on 2). Better working condition
grease application cell. Wasting of 30 3). Easy counting(75nos/bin) & Better part handling.
min/shift in unpacking.
 2) Implemented Release Lever 0095/0107 handling
from H.T to Pre-R .L Assembly stations
Before After

Release
levers in
mix
condition

Release levers

systematically
arranged

Corrugated bins provided as per 105nos/bin storage capacity

for supplying materials from store to assembly stations.
Release lever is supplied from Heat
BENEFITS:-
Treatment in this above shown condition.
1) Reduce rejection
Direct metal to metal contact. Dejection
2). Easy counting(105nos/bin) & Better part handling.
due to damage also.
3). No metal to metal contact
 3) Implemented Release Lever Assembly Bins handling
from Pre R.L. Assembly cell to Lever Assembly cells
Before After

Release
Lever
Assembly

Release lever
assemblies
systematically
arranged

Corrugated bins provided as per 63nos/bin storage capacity

for supplying materials from store to assembly stations.
Release lever assembly is supplied from
BENEFITS:-
pre-assembly station in this above shown
1) Reduce rejection
condition.
2) Easy counting(63nos/bin) & Better part handling.)
3). No metal to metal contact
 4). Implemented Collector Ring (1212) handling from
H.T to Build Rig stations
Before After

Collector
Rings
1212

Collector
Rings
systematically
arranged

Corrugated bins provided as per (75nos/bin) storage capacity for

supplying materials from H.T to Build Rig stations.
BENEFITS:-
Non standard practice of collector ring 1) Reduce rejection
handing as shown above & unsafe 2). Better working condition
condition 3). Easy counting(42nos/bin) and Better part handling.
 5) Implemented Racks & Bins for part storage near DP
& CA Assembly Line
Before After
DP & CA parts
stored in DP Part
wooden box Storage
& bags on Area
floor

CA part
Storage
Area

Implemented Racks & Bins with proper identification near

Part stored in unorganized condition , time
wastage for searching parts. Difficult for
handling.
DP & CA Assembly Line
BENEFITS:-
1). Less Sq. meters space required.
2). Searching time for material will be eliminated.
4). Better work environment(2S implemented).
 6) Implemented Roller Conveyors in Assembly line
(380 Line)
Before
3 man
moving
materials
Their is no conveyor system between cells
or stations, due to this lots of inventory
found in each cell. For transportation of
this huge inventory 2-3 operator has to
move clutches from one cell to other cell.
Due to heavy weight of clutches operator
feel fatigue and also time waste.
After
Easy
movement
of material
To Implemented gravity type Roller conveyors in between cells.
BENEFITS:-
1). Reduced lead times.
2). Lower inventory levels.
3). Reduced requirements for transportation and associated . . . . .
. people and equipment..
4). Smooth material flow in between cells.
5). Operator unwanted movement and fatigue will be eliminated.
6). Reduced space required.
 7) Implemented Tow truck and carts in between shops
& Assembly line
Before After

Manual
material
handling

Easy & Fast

& safe
material
handling

Implemented Tow truck & carts for material transportation.

BENEFITS:-
1) Time will be Saved ( Fast material movement).
Material trolley is transport from one shop
2). Material Handling will be improved.
to other & Assembly shop manually.
3). Less Fatigue to operator in material handling.
4) Safe working & Ergonomic design, user friendly
 8) Implemented part storage in bins on each Assembly
stations
Before After

Material in
Plastic
Bags & box

Materials in
Bins

Bins Implemented as per required storage capacity with proper

Non standard methods are use for material
storage at assembly station like cardboard
box or plastic bags, there are chances of
item mixing.
identifications on each Assembly station.
BENEFITS:-
1). Searching time for material gets eliminated.
2). Improves quality & eliminates chances of item mixing
3). Better work environment.
4). Employee moral will be increased.
 9) Implemented Material storage in MS bins in shops
Before After
Material in
Plastic Bags
& Wooden
boxes

Materials
in MS Bins

MS Bins with color coding implemented for storing of

material in shops
BENEFITS:-
Material are laying on the floor, occupying 1). Less Sq. meters space required.
more sq meter area. Wooden boxes & 2). Searching time for material will be eliminated.
plastic bags used for storage of materials. 4). Better work environment.
 10) Implemented Plastic Pallet for Finish Goods
Handling & storage.
Before After
Wooden
Pallets

Plastic
Pallets

Implemented Plastic Pallets for finish goods handling & storage.

BENEFITS:-
At present there is no Factory 1) Reduce Finish goods damages
communication board at assembly area 2). Better working condition(Better part handling)
3). Safety improved
 11) Implemented PP Plate for partition in CA Assembly
Before After

Corrugated
Paper plate

PP
Plates

Implemented PP Plate for finish CA storage.

BENEFITS:-
Direct metal to metal contact, corrugated 1) Reduce Finish goods damages
paper sheet is under between CA 2). Better working condition(Better part handling)
Assembly 3). Safety improved
 12) To improve Coil storage In press shop
Current status Proposed Status: WIP

Coils on
Floor Coil
Rack

Coil Rack with identification implemented for storing of

coils
BENEFITS:-
Steel coil are laying on the floor, occupying 1). Less Sq. meters space required.
more sq meter area. Unorganized storage. 2). Searching time for material will be eliminated.
4). Better work environment.
B). NEXT IMPROVEMENT
PLAN
 1) To be implement bearing sleeve Bin (0070)
for in-house movement .
Current status Proposed Status: WIP

Bearing
Sleeves

Corrugated bins to be provided as per 20 nos/bin storage capacity

for supplying materials from M/C shop to UKD & assembly stations.
BENEFITS:-
1) Reduce rejection(Quality improve)
Direct metal to metal contact. Part 2). Easy counting(20nos/bin) and Better part handling
damage 3). No metal to metal contact
 2) To implement Pick & Drop Arrangement of clutch.
Present status Future status

To be Implement Pick & Drop arrangement of clutch. The tools can

be moved up or down with very little effort.,
At present manually Clutch is lifting. To
BENEFITS:-
load or unload on cells, Clutch is heavy, so
1). Operator unwanted movement and fatigue will be eliminated.
it is a fatigues job, ergonomically not good
2). Space saving & manpower will be saved. Less Fatigue.
for operator.
3). Safe working & Ergonomic design, user friendly
 3) To improve CA & PP handling in Assembly shop
Current status Proposed Status: WIP

CA
handling
in trolley

CA & PP
Trolley with
PVC Pipe
partition

Trolley with PVC Pipe partitions for CA & PP implementation.

BENEFITS:-
CA & PP handling in without partition trolley. 1). Systematic handling of part.
Direct metal to metal contact in trolley. Part 2). No direct metal to metal contact.
damage & unsafe condition 3). No Damage on M/C surface (improve quality)
4). Safe handling.
 4) To implement PP & CA Trolley between M/C & Press
shop trolley.
Current status Proposed

Trolley

Pressure
Plate CA &
Pressure
Plate in
Trolley

Trolley for CA & PP to be implement.

BENEFITS:-
Pressure plate is moved in pallets from
1). Systematic handling of part.
M/C shop & press Shop.
2). No direct metal to metal contact.
3). No Damage on M/C surface (improve quality)
4). Safe handling.
 5) To implement MS Bins in between Heavy Press M/C.
Current status Proposed

Covers WIP
CA in MS
in Between
bin
Press M/C

To be Implementation MS bins for covers in press shop.

BENEFITS:-
Cover s are kept as shown above in 1) Reduce rejection
between Heavy press shop. 2). Better working condition
3). Safe and Better part handling.
 6) To be implement Corrugated bins for ceramic
(0590/2329) buttons at assembly shops
Current status Proposed
Unpacking
done on
M/C

To be Implementation Corrugated bins for ceramic buttons at assembly

shop.
BENEFITS:-
Ceramic buttons unpacking is done on
assembly station. Wasting of 30 min/shift 1) Reduce rejection
in unpacking. 2). Better working condition
3). Easy counting(150nos/bin) and Better part handling.
 7) To be implement corrugated bin for Spider in
Assembly cell(RBA)
Current status Proposed
Spider in
box

To be Implementation Corrugated bins for spider at assembly shop.

BENEFITS:-
Spider unpacking is done on assembly 1) Reduce rejection
station. Wasting of 30 min/shift in 2). Better working condition
unpacking. 3). Easy counting(30nos/bin) and Better part handling.
 8) To be implement Corrugated bins for
Bearing Housing (0005)
Current status Proposed
Bearing
Housing in
bin

Corrugated bins provided as per required storage capacity with

proper identifications for supplying materials from store to M/C
shop & from M/C shop to assembly stations.
BENEFITS:-
Direct metal to metal contact. Part 1) Reduce rejection
damage. Unsafe handling. 2). Better working condition(Better part handling)
3). No metal to metal contact
 9) To be implement Corrugated bins for Lock
Nut Sleeve (0043/44)
Current status Proposed

Lock nut
sleeve

Corrugated bins provided as per required storage capacity with

proper identifications for supplying materials from H.T to assembly
stations.
BENEFITS:-
Direct metal to metal contact. Part 1) Reduce rejection
damage 2). Better working condition(Better part handling)
3). No metal to metal contact
 10) To implement RBA bins in Assembly Shop
Current status Proposed

RBA

Corrugated bins provided as per required storage capacity

with proper identifications for supplying materials from
RBA station to assembly stations.
BENEFITS:-
Direct metal to metal contact. Part 1) Reduce rejection
damage, possibility of part damage. 2). Better working condition(Better part handling)
3). No metal to metal contact
4). Unsafe condition
 11) To implement eye bolt (0028/1877) bins in
Assembly Shop
Current status Proposed

Eye Bolt

Corrugated bins provided as per required storage capacity with

proper identifications for supplying materials from store to assembly
Direct metal to metal contact. Part stations.
damage, possibility of part damage.
BENEFITS:-
1) Reduce rejection
2). Better working condition(Better part handling)
3). No metal to metal contact
 12) To implement adjusting nut 0(037/1876) bins in
M/C shop & Assembly stations
Current status
Adjusting
Nut
Direct metal to metal contact. Part
damage, possibility of part damage.
Proposed
Bins to be provided for adjusting nut as per required storage
capacity with proper identifications.
BENEFITS:-
1). Improves quality & eliminates chances of item mixing
3). Better work environment.
4). Employee moral will be increased.
 13) To implement adjusting nut & eye bolt assembly
bins in M/C shop & Assembly stations
Present status Proposed

Eye Bolt &

Adjusting Nut
Assembly.

Corrugated bins for Eye bolt & adjusting nut provided as per
required storage capacity with proper identifications for supplying
materials from store to assembly stations.
Direct metal to metal contact. Part
BENEFITS:-
damage, possibility of part damage.
1) Reduce rejection
2). Better working condition(Better part handling)
3). No metal to metal contact
 14) To implement Hub trolley (2688/2581) in shops
Current status Proposed

HUB

Trolley for hubs to be provided as per required storage

capacity with proper identifications for supplying materials
between shops.
BENEFITS:-
Direct metal to metal contact. Part 1) Reduce rejection
damage, possibility of part damage.
2). Better working condition(Better part handling)
3). No metal to metal contact
 15) To implement dedicated bin Hub Flange
(4078/4115) on Assembly stations
Current status
Hub Flange
Direct metal to metal contact. Part
damage, possibility of part damage.
Proposed
Bins for hub flange to be provided as per required storage
capacity with proper identifications for supplying materials from
store to assembly stations.
BENEFITS:-
1) Reduce rejection
2). Better working condition(Better part handling)
3). No metal to metal contact
 16) To implement Red-Bins for rejection on each
Assembly stations
Present status Proposed

RED bins to be provided on each station for keeping rejection on

assembly stations and this rejected materials should be shifted to
Quarantine Area with proper identification & cause of rejection.
Rejected
BENEFITS:-
Bearing 1) Deffected material should be highlighted .
Housing 2). On daily bases or shift bases rejected material moved to
Quarantine area.
Red bin is not provided on each cells for keeping 3). Daily record of rejected material for taking action on
rejection material, due to this rejection material quality issues.
is laying on assembly station without 5). Corrective & preventive action should be take
identification.
 17) To implement Damper plate in Assembly line
Current status Proposed

Bearing
Housing

Implementing Just In Time, Creating “single piece” flow at the

Large amounts of WIP or inventory is there on
each cell. Every time we have a defect in cell, we
have to scrap the whole lot
pull of the customer using a flow line approach.
BENEFITS:-
1) Minimum flow times(Reduced lead times).
2 ). Minimum floor space required.
3). High quality (Problems seen sooner and reacted to,
not . . . hidden by the inventory sea!.
4). No inventory in between assembly stations
5). High flexibility to cope with fluctuations in production
 18) To implement Lock nut Bins (0023/0007)
Current status Proposed

Lock Nut

Bins for hub Lock Nuts to be provided as per required storage

capacity with proper identifications for supplying materials
Lock nut is moved to assembly station in abuve
from store to assembly stations.
shown condition, Possibility of thread damage.
BENEFITS:-
1) Reduce rejection
2). Better working condition(Better part handling)
3). No metal to metal contact
 19) To implement Hub trolley for movement in shops
Current status Proposed

Hub

Trolley for hub to be provided as per required storage

capacity with proper identifications for supplying
materials from store to assembly stations.
BENEFITS:-
1) Reduce rejection
Non standard practice of fitting lock nut.
Rod is used for lifting collector ring and 2). Better working condition(Better part handling)
lever. 3). No metal to metal contact
 20) To implement PP Pins Bins (0028/0020) for
movement from M/C shop to Assembly shop
Current status Proposed

PP Pin

Bins for PP Pins to be provided as per required storage capacity

with proper identifications for supplying materials from store to
assembly stations.
BENEFITS:-
PP Pin’s Direct metal to metal contact. Part
1) Reduce rejection
damage
2). Better working condition(Better part handling)
.
3). No metal to metal contact
 21) To be implement Hub Trolley (0365/0366) in
Assembly line
Current status Proposed

Bearing
Housing

Trolley for Hubs to be provided as per required storage

capacity with proper identifications for supplying
materials from H.T to assembly stations.
BENEFITS:-
1) Reduce rejection
Hub in Wooden Box. Possibility of damage.
2). Better working condition(Better part handling)
3). No metal to metal contact
 22) To implement Cushion ceramic Bins for Assembly
shop
Current status Proposed

No Bin for cushion ceramic

assembly

Bins for Cushion ceramic assembly to be provided as per required

storage capacity with proper identifications for supplying materials
from store to assembly stations.
Cushion ceramic assembly is kept in
BENEFITS:-
corrugated paper box.
1) Reduce rejection
2). Better working condition(Better part handling)
3). No metal to metal contact
Thank You