Tata Toyo Case Study

Continuously Raising the Bar
Tata Toyo Radiator Limited

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Welcome to
TATA TOYO RADIATOR LTD., Pune
To become the most preferred Worl d Class technology
and solution provider for heat exchange systems to
customers globally.
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Six Sigma Project
To increase HC
output/ person/ day by 40%
from 25 assy/ person/ day to 35
assy/ person / day
C D A I M
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DEFINE PHASE
C D A I M
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BUSINESS CASE
#
Why is this project worth doing ?
1) Average manpower required for Heater core assy line in the 1st quarter of year 2009-
10 is 99 persons for the Production of 2500 Heater cores / day, which is very high as
compared to other Production lines.
2) Output of the Heater core lines is 25 Nos /person/day.
3) Manpower cost of 99 persons @ Rs.6234 /person/month is amounting to Rs.75.13 lacs
per annum.
#
Why it is important to do now ?
1) By increasing the Productivity of the line by 40%, we can able to reduce the manpower
of the heater core line to 71 persons from 99 persons.
2) In the month of April & May 09, we observed 20% manpower absenteeism. The
proposed Productivity improvement will minimize the dependency on manpower.
3) Lot of new models are under development, by this productivity improvement we can
accommodate these models in the existing set up only.
C D A I M
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BUSINESS CASE
#
What are the consequences of not doing the project?
1) Capital Investment in installation of new line, as well as recruitment of additional
manpower.
2) If we increase the Productivity of the line by 40% assuming the same volumes as in
2008-09, we required only 71 persons for the production 2500 nos costing Rs.53.11
lacs/annum. Hence if we do not do this project we may end up loosing Rs. 20.94 lacs.
#
How does it fit with the operational initiatives & targets?
1) To contribute in achieving a business growth of Rs.40 cr. in terms of order booking.
2) To contribute in achieving a PAT of Rs.20.9 crores.
3) Improve productivity (Equivalent Radiator per person per month) by 10% over FY
2008-09.
4) It is in line with the objective of two Six sigma projects per Department.
C D A I M
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PROBLEM STATEMENT WORKSHEET
# What?
High manpower as compared to other production lines.
# Where?
Heater Core Assembly.
# When?
Since Apr09.
# How much?
99 Persons for 2500 heater cores @ of 25 heater cores/person/day.
# How do I know?
Based on Operational Results review.
C D A I M
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Six Sigma Project Charter
Business unit : Tata Toyo Radiator Ltd. Location : Hinjewadi, Pune Date:27/06/09
Project Title : To increase HC output / person/day by 40% from 25/person/day to 35/person / day.
Problem statement : Very high manpower of 99 persons required on Heater core lines as compared to other Production lines.
Aim / Objective of the project : To Increase Heater Core Output / Person / Day by 40% from 25 nos/Person /Day to 35 nos./Person/Day
Product Scope : Heater cores.
Process scope : Core assy, Fluxing, ALT testing
Project Champion : Mr.Alok Misra Project Leader : Sachin Shirmali
Green belts : Mr. Venugopal Maddel
Other members : Vinu Attacheryl, Vijayshankar, Narendra Asati, Sunil
Gawade, Vivek Mhaisane, Atul Shah, M. Premnath,
Characteristics of OUTPUTS / PROCESS and its measures
Characteristics Measures Defect Definition
Total Output/Person/Day (2500 nos/day) (2500/99)=25.23 HC/Person/Day >35 HC/Person/Day
B Model /Person/Day (1400 nos/day) (1400/34)=41 HC/Person/Day >57.4 HC/Person/Day
Indica /Person/Day (200 nos/day) (200/14)=14 HC/Person/Day >19.6 HC/Person/Day
X1 /Person/Day (300 nos/day) (300/15)=20 HC/Person/Day >28 HC/Person/Day
Ford Barra /Person/Day (600 nos/day) (600/36)=16 HC/Person/Day >22.4 HC/Person/Day
Source of the project : OR Review / daily production meeting declarations
Cost Impact :Saving of Rs.20.94 lacs /annum
Impact on Customers : 1) On time Delivery to Customer 2) Reduction in Production losses
Project milestones : Start date -18.07.09 , Define - 05.08.09 , Measure - 13.09.09 , Analyze - 21.09.09
Improve -11.01.10 , Control - 25.02..10 , Closure date - 28.02.10 Further monitoring - 15.03.2010
Team meeting frequency - Every wednesday 2.00~3.30 pm Review frequency - Every Tuesday 3.00~3.30 pm
Prepared by - Approved by -
Mr. Sachin Shirmali Mr. Alok Misra
( Project Leader ) (Project Champion)
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POTENTIAL IMPACT WORKSHEET
EXPECTED IMPROVEMENT BENEFIT OF IMPROVEMENT EXPECTED BUSINESS IMPACT
40 % Improvement in
Productivity
Reduction in Labor Cost.
Saving of 20.94 Lacs/Annum
Improvement in productivity.
C D A I M
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STRATEGY
Stakeholder Name Blocker Neutral Supporter Strategy
Alok Misra (C.O.O) Send a copy of MOM
Line Leader & Operator
Speak informally as
needed.
Heater Core Assly In charge
Invite to Team meetings
as & when needed.
Maintenance Section
as & when needed.
QA Section
as & when needed.
Customers
Inform about
improvement
Support departments
Speak informally as
needed.
C.F.O/C.E.O
as & when needed.
C D A I M
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ARMI MODEL
Key Stakeholders
Project Phase
Start Up/
Planning
Implementation Evaluation
Business Head/Project Champion
Champion
Facilitator
Production Line-Heater Core Assly
Purchase Department
Senior Operators
Team Members
C D A I M
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SIPOC
Suppliers Inputs Process Output Customers
Heater Core Assembly
Child parts,
Raw materials,
Machines,
Production
Aids, Human,
Electricity
Fin Forming
Heater Core
Final QA
Dispatch
End User
Core Assembly
Tube Expansion
Burn Off
Spin Riveting
Baffle Partition
Tank Clinching
Water Fluxing
Alcohol Fluxing
Brazing
Hole piercing
ALT
Torch Brazing
Gauge & Holder Fitment
Plastic Band Fitment
Foam Fitment
ALT/FLT
Continued.
C D A I M
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SIPOC (continued)
Suppliers Inputs Process Output Customers
Purchase Dept
M/c modification & automation
by outside vendor
PO release
New machines
at shop floor
Heater core
Assly line
Materials Dept
Child parts, Alcohol, flux,AF2A
oil,
PO release &
procurement
Heater core
assy
Heater core assy
line
Gas Supplier Oxygen,LPG,Freon
PO release &
procurement
Heater core
assy
Heater core assy
line
MSEB Electricity Measurement
Heater core
assy
Heater core assy
line
ME Dept
Cycle time study
Define bottleneck
stage
Line capacity
report
Heater core assy
line
Production Aids
J igs & fixture
procurement PR
Heater core
assy
Heater core assy
line
HR Dept Operators
HR report &
monitoring
Human
Heater core assy
line
Maint Dept
Aid in installation & commission
of new projects
I&C certificate
New m/c
installation
Heater core assy
line
Tube Mill Tube Tube forming Tubes
Heater core assy
line
C D A I M
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Project Title : To increase HC output / person/day by 40% from 26/person/day to 36/person / day.
Stages of the project Plan Actual
Define phase 10.07.09 18.07.09
Project selection 15.07.09 18.07.09
Business case 20.07.09 20.07.09
Project charter 22.07.09 22.07.09
SIPOC 22.07.09 24.07.09
CTQ tree 05.08.09 05.08.09
Measure phase 06.09.09 13.09.09
Data collection plan 05.08.09 10.08.09
Data collection 15.08.09 24.08.09
Data analysis 20.08.09 10.09.09
Base level measurement 30.08.09 11.09.09
Revision of charter / CTQ tree 06.08.09 13.09.09
Anal ysis phase 29.09.09 13.10.09
Potential Xs identification 13.09.09 19.09.09
Validation of Xs 20.09.09 26.09.09
Funneling of Xs 25.09.09 31.09.09
Y =f ( x ) 28.09.09 13.10.09
C D A I M
Dash Board for Six sigma project progress
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C D A I M
Improvement phase 15.10.09 16.02.10
Improvement plan 15.10.09 18.10.09
Risk and Benefit analysis 20.10.09 22.10.09
Piloting 25.10.09 28.10.09
Analysis of Piloting data 30.10.09 05.11.09
Verification of effectiveness 05.11.09 10.11.09
Before / After analysis ( w.r.t base line data ) 10.11.09 15.11.09
Implementation plan 15.11.09 20.11.09
Implementation 20.11.09 22.01.10
Cost Benefit analysis 20.01.10 16.02.10
Control phase 15.03.10 25.03.10
Planning for control mechanisms 16.02.10 17.02.10
Completion of planned activities 20.02.10 24.02.10
Release of documents 22.02.10 25.02.10
Sign off sheet 25.02.10 26.02.10
Handing over to user departments 26.02.10 27.02.10
Felicitation 27.02.10 28.02.10
Post closure monitori ng 01.03.10 15.03.10
Responsibili ty
Dash Board for Six sigma project progress
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Low Productivity
y1 Core Assly
y11 Fin forming
y111 Cut/min.
y112 Brake voltage
y113 Barrow setting
y114 Coil changeover
y115 Cutter unit
y116 Coil thickness
y117 Coil width
y118 Material properties
y119 Lubrication oil
y120 Coil diameter
y12 Core Assly
y121 Core support+Brazing+Fin+Tube Assly
y122 Placement in C/A fixture.
y123 Header plate fitment
y124 Core band fitment
y125 Operator skill
y126 Load/unload
y127 Tube-Fin Assly
y128 Access to C/O parts.
y129 Child component
y13 Tube Expn
y131 Pneumatic cylinder speed
y132 C/O time
y133 Operator skill
y134 Core Assly
y135 C/O Parts
y136 Expansion tool
Y tree
C D A I M
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Low Productivity
y2 Tank Assly
y21 Spin riveting
Y211 Stroke length
y212 Riveting time
y213
Loading/unloading
y214 Pneumatic pressure
y215 Motor RPM
y216
Lubrication time
y217 Child component
y218 Oil
y219 C/O part
y22
Baffle partition
Assly
y221 Pneumatic cylinder stroke
y222 Loading/unloading
y223 Pressing time (MCT)
y224 Changeover time
y225 Manual tank+baffle Assly
y226 Manual positioning of baffle Assly
y227 Piercing time
y228 C/O Parts
y229 Die
y221 Punch wear
Y221-1 Brazing layer
Y221-2 Baffle
Y221-3 Partition
Y221-4 Tank
Y tree
C D A I M
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Low Productivity
y3 Tank Assly
y23
Tank
clinching
y232
Loading/unloading
y233
Clinching time (MCT)
y234
Changeover time
y236 C/O Parts
y237 Ergonomy
y238 Tank Assly
y239 Unbrazed core
y231-1 Bottom tank
y24
Tank
clinching
y243 Clinching time (MCT)
y244 Changeover time
y246 C/O Parts
y247 Ergonomy
y248 Tank Assly
y249 Unbrazed core
y241-1 Bottom tank
y25
Wire
winding
y251 Wire tension
y252 No. of windings
y253 Position of windings
Y tree
C D A I M
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Low Productivity
y3
Unbrazed
core
y31 Burn off
y311
Conveyor speed
y312
Temperature
y313
Exhaust
y315 Trolley
y316
Tray
y317 Conveyor condition
y32
Water
fluxing
y321
Specific gravity
y322
Dipping time
y323 Cleaning time
y324 Fluxing time
y325 Turbulence (flux circulation)
y326 Flux
y327 Water
y328 Blower speed
y329 Core Assly
y33
Alcohol
Fluxing
y331 Ratio
y332 Fluxing time
y333 Turbulence (Flux circulation)
y334 Flux
y335 Alcohol
y336 Motor speed
y337 Core Assly
C D A I M Y tree
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Low Productivity
y4
Brazed
core
y41 Brazing
y411 Conveyor speed
y412 Temperature
y413 Placement of core (Pattern)
y414 Loading/unloading time
y415 Core band removal time
y416 Cooling time
y417 Brazing parameters
y42
Hole
piercing
y421 Piercing time
y422 Loading /unloading time
y423 Change over parts & fixtures
y424 Cores
y425 Piercing tool
y43 ALT
y431 Leak test time
y432 Leak test pressure
y433 Calibration time
y434 Loading/unloading time
y435 Consumables
y44
Torch
brazing
y441 Torch brazing time
y442 Oscillation
y443 Fitment time
y444 Change over time
y445 Cylinder changeover time
y446 Cooling time
y447 Gas
y448 Fixture
C D A I M Y tree
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Low Productivity
y5 Final Assly
y51
Gauge &
holder fitment
y511
Fitment time
y512
Loading & unloading time
y513
Plastic component
y514
Cores
y515
Gauge
y52
Plastic band
fitment
y521
Manual fitment time
y522
Plastic bands
y53 Foam fitment
y531 Manual fitment time
y532 Foam
y533 Cores
y54
ALT
y541 Leak test time
y542 Filling time
y544 Loading & unloading time
y545 Consumables
y55 FLT
y551 Leak test time
y552 Filling time
y554 Loading & unloading time
y555 Gas
y556 Consumables
C D A I M Y tree
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List of i nput & process variables
Driver Fin forming
Output variable Fin/hr
Weightage 9
Process Variables Weightage (A) Output variable Weightage (B) Total (AxB)
Cut/min 9
9
81
Break voltage 5 45
Barrow setting 9 81
Coil changeover 5 45
Cutter unit 5 45
Input Vari ables
Coil thickness 5 45
Coil width 1 9
Material properties 5 45
Lubrication oil 5 45
Coil diameter 5 45
C D A I M Prioritization Matrix
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Driver Core Assly
Output variable Core/Hr
Weightage 9
Core Supp+Fin+Tube Assly 9
9
81
Placement in C/A fixture 9 81
Header plate fitment 5 45
Core band fitment 5 45
Operator skill 9 81
Load/unload 5 45
Input Vari ables
Tube-Fin Assly 9 81
Access to C/O Parts 5 45
Child component 5 45
Prioritization Matrix
C D A I M
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Driver Tube expansion
Weightage 9
Pneumatic cylinder speed 5
9
45
C/O time 5 45
Loading/unloading 9 81
Input Vari ables
Core Assly 9 81
C/O Parts 5 45
Expansion tool 9 81
C D A I M
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Driver Burn Off
Weightage 9
Conveyor speed 9
9
81
Temperature 5 45
Exhaust 5 45
Input Vari ables
Trolley 5 45
Tray 5 45
Conveyor condition 5 45
C D A I M
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Driver Flaring/Spin riveting
Weightage 9
Stroke length 5
9
45
Riveting time 9 81
Pneumatic pressure 5 45
Motor RPM 5 45
Lubrication time 9 81
Input Vari ables
Child component 5 45
Oil 5 45
C/O Part 5 45
C D A I M
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Driver Baffle partition Assly
Output variable Output/Hr
Weightage 9
Pneumatic cylinder stroke 5
9
45
Pressing time(MCT) 5 45
Changeover time 5 45
Manual tank+baffle Assly 9 81
Manual position of baffle Assly 9 81
Input Vari ables
Piercing time 5 45
C/O Parts 5 45
Die 5 45
Punch wear 5 45
Brazing layer 5 45
Baffle 5 45
Partition 5 45
Tank 5 45
C D A I M
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Driver Tank clinching Assly
Weightage 9
Pneumatic cylinder stroke 5
9
45
Clinching time 5 45
Pneumatic pressure 9 81
Input Vari ables
C/O Parts 9 81
Ergonomy 5 45
Tank Assly 5 45
Unbrazed core 5 45
Bottom tank 5 45
C D A I M
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Driver Water fluxing
Weightage 9
Dipping time 9
9
81
Cleaning time 9 81
Fluxing time 9 81
Turbulance(Flux circulation) 5 45
Input Vari ables
Flux 9 81
Water 5 45
Blower speed 5 45
Core Assly 5 45
C D A I M
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Driver Alcohol fluxing
Weightage 9
Ratio 1
9
9
Fluxing time 9 81
Turbulence (Flux circulation) 9 81
Input Vari ables
Flux 9 81
Alcohol 5 45
Motor speed 5 45
Core Assly 5 45
C D A I M
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Driver Wire winding
Output variable Cores/Hr
Weightage 9
Cycle time 9
9
81
Input Vari ables
Wire 5 45
Fixture 5 45
Cutter 5 45
C D A I M
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Driver Brazing oven
Weightage 9
Conveyor speed 9
9
81
Temperature 5 45
Placement of cores(Pattern) 9 81
Loading/unloading time 9 81
Core band removal time 9 45
Cooling time 9
Input Vari ables
Brazing parameters 5 45
C D A I M
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Driver Hole piercing
Weightage 9
Piercing time 9
9
81
Input Vari ables
Changeover parts & fixtures 9 81
Cores 5 45
Piercing tool 9 81
C D A I M
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Driver Air leak testing
Weightage 9
Leak test time 9
9
81
Leak test pressure 5 45
Calibration time 9 81
Input Vari ables
consumables 9 81
C D A I M
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Driver Torch brazing
Weightage 9
Torch brazing time 9
9
81
Oscillation 5 45
Fitment time 9 81
Cylinder changeover time 5 45
Cooling time 9 81
Input Vari ables
Gas 5 45
Fixture 0 0
C D A I M
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Driver Gauge & holder fitment
Weightage 9
Fitment time 9
9
81
Input Vari ables
Plastic component 5 45
Cores 5 45
Gauges 5 45
C D A I M
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Driver Plastic band fitment
Weightage 9
Manual fitment time 9
9
81
Input Vari ables
Plastic band 5 45
C D A I M
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Driver Foam fitment
Weightage 9
Manual fitment time 9
9
81
Input Vari ables
Foam 5 45
Cores 5 45
C D A I M
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Driver Air leak testing
Weightage 9
Leak test time 9
9
81
Leak test pressure 5 45
Input Vari ables
Consumables 9 81
C D A I M
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Driver Freon leak testing
Weightage 9
Leak test time 9
9
81
Filling time 9 81
Input Vari ables
Gas 5 45
Consumables 5 45
C D A I M
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The CTQ Tree
Need Driver CTQ Measure Defect Definition Kano Status
To increase
HC output /
person/day
by 40% from
26/person/da
y to
36/person /
day
Fin
Forming
Roller Speed Cut/Min Cut/Min <17 More the better
Core Assly
Core support +fin+
tube Assly
Cycle time in
Sec
More than 13 Seconds/Core
Less the better
Placing C/A in
fixture
Cycle time in
Sec
Less the better
Operator Skill
Cycle time in
Sec
Less the better
Cassette Assly
Cycle time in
Sec
Less the better
Tube
Expansion
Loading/Unloading
Cycle time in
Sec
More than 13 Seconds/Core
Less the better
Core Assly
Cycle time in
Sec
Less the better
Expansion tool
Cycle time in
Sec
Less the better
Continued.
C D A I M
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The CTQ Tree (Continued)
To increase
HC output /
person/day
by 40% from
26/person/da
y to
36/person /
day
Burn Off
Conveyor speed As per Ref.sheet
Speed not as per Ref.
sheet no:RS-1000-
002A
Must be
Riveting time Cycle time in Sec More than 13
Seconds/Core
Less the better
Spin riveting
Lubrication time Cycle time in Sec More than 13
Seconds/Core
Less the better
Baffle
partition
Assly
Manual tank+
baffle Assly
Cycle time in Sec More than 13
Seconds/Core
Less the better
Manual positioning
of baffle Assly
Cycle time in Sec Less the better
Tank
clinching
Loading/
Unloading
Seconds/Core
Less the better
Pneumatic
pressure
Pneumatic
pressure in
Kg/cm
Less air pressure than
reqd. level
Specification :4.0-5.0
Kg/cm2
Must be
C/o Parts Cycle time in Sec More than 13 Seconds Less the better
Continued.
C D A I M
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To increase
HC output /
person/day
by 40% from
26/person/da
y to
36/person /
day
Water
Fluxing
Dipping time Cycle time in sec. Not as per Ref sheet Less the better
Cleaning time Cycle time in sec. Not as per Ref sheet Less the better
Alcohol
Fluxing
Fluxing time Cycle time in Sec Not as per Ref sheet Less the better
Turbulence (Flux
circulation)
Air pressure in
Kg/cm
Not as per Ref sheet Must be
Flux Flux mix-up ratio. Not as per Ref sheet Must be
Continued.
C D A I M
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Continued.
To increase
HC output /
person/day
by 40% from
26/person/d
ay to
36/person /
day
Wire
winding
Wire winding
time
Cycle time in Sec
More cycle time ??? than other
process
Less the better
Cutting time Cycle time in Sec Less the better
Brazing
Oven
Conveyor
speed
Conv. Speed as
per ref. sheet
Not as per ref. sheet:RS-1000-
002A
Must be
Placement of
cores-Pattern
Loading pattern Not as per Work Instruction:
ME/WI/1000-002
More the
better
Loading/
Unloading
Cycle time in Sec More than 13 Seconds/Core Less the better
Core band
removal
Cycle time in sec Less the better
Cooling Less than 2 vpm
level
Purity of Nitrogen Must be
Hole
Piercing
Piercing time Cycle time in Sec More than 13 Seconds/Core Less the better
Loading/
Unloading
C/O Parts &
fixtures
Torch
Brazing
Fitment time Cycle time in Sec More than 13 Seconds/Core Less the better
Cooling time Cycle time in Sec Less the better
C D A I M
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To increase
HC output /
person/day by
40% from
26/person/day
to 36/person /
day
Gauge &
Holder fitment
Fitment time Cycle time in Sec More than 13
Seconds/Core
Less the better
Loading/
Unloading
Plastic band
fitment
Manual Fitment
time
Seconds/Core
Less the better
Foam fitment
Manual Fitment
time
Cycle time in sec More than 13
Seconds/Core
Less the better
ALT
Leak test time Cycle time in Sec More than 13
Seconds/Core
Less the better
Calibration time Cycle time in Sec Less the better
Loading/
Unloading
FLT
Leak test time Cycle time in Sec More than 13
Seconds/Core
Less the better
Calibration time Cycle time in Sec Less the better
Loading/
Unloading
C D A I M
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MEASURE PHASE
C D A I M
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C D A I M
Data collection plan for Project Date
Fin forming machine
To increase heater core output
/person/day by 40 % from
26/person/day to
36/person/day
17.09.09
1. What is the need of this data collection? 2. Who will collect this data?
3. Location of data
collection
To find out optimum roller speed & barrow setting
for higher productivity
Premnath,Vivek,Abhishek Heater core line
DATA OPERATIONAL DEFINITIONS AND PROCEDURES
What
Measure type
/ data type
How measured
Related
conditions
Sampling
notes
How / where recorded
Roller speed Continuous
Cuts/min using
stopwatch
All Subros &
AIR Int. models
One
reading/shift
for 10 days
Recorded in attached
format no.- ME_FT_49
Barrow setting Continuous Fin height
How will you ensure
consistency?
What is your plan for starting Data collection?
All the data will be collected by
trained persons at regular
intervals & verified by project
team member
Data collection from 17.08.09 to 17.09.09
How will the data be displayed?
In Data Collection format no.- ME_FT_49
Data Collection Plan
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Core Assly
26/person/day to 36/person/day
17.09.09
3. Location of data
collection
To find & determine bottleneck stage Team Heater core line
What
Measure
/data type
How measured
Related
conditions
Sampling
notes
Core
Supp+Fin+
Tube Assly
Continuous
Cuts/min using
stopwatch
All Subros &
AIR Int.
models
10 samples/
shift
Placement of
C/A in fixture
Continuous Cuts/min using
stopwatch
Operator Skill
Continuous
Ok/Not o.k Skill matrix No:
Cassette Assly
Continuous Cycle time by
stopwatch
How will you ensure
consistency?
All the data will be collected
by trained persons at regular
team member
C D A I M
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C D A I M
Tube expansion
26/person/day to
36/person/day
17.09.09
3. Location of data
collection
To find out time required for tube expansion Team Heater core line
What
Measure
type / data
type
How measured
Related
conditions
Sampling
notes
Loading/
unloading time
Continuous
Cycle time using
stopwatch
All Subros &
AIR Int. models
One
reading/shift
for 10 days
Core Assly
cycle time
Continuous Cycle time using
stopwatch
Expn tool
cycle time
Continuous
Cycle time using
stopwatch
Skill matrix No:
How will you ensure
consistency?
team member
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Spin riveting
17.09.09
3. Location of data
collection
What
Measure
/data type
How measured
Related
conditions
Sampling
notes
Riveting time Continuous
Cycle time by
stopwatch
All Subros &
AIR Int. models
5 samples/
shift
Lubrication time
Continuous Cuts/min using
stopwatch
How will you ensure
consistency?
team member
C D A I M
www.tacogroup.com
Baffle partition Assly
17.09.09
3. Location of data
collection
What
Measure type /
data type
How
measured
Related
conditions
Sampling
notes
Manual
tank+baffle Assly
Continuous
Cycle
time using
stopwatch
All Subros & AIR
Int. models
5 samples/
shift
Manual position
of baffle Assly
Continuous
Cycle
time using
stopwatch
How will you ensure consistency? What is your plan for starting Data collection?
All the data will be collected by
trained persons at regular intervals
& verified by project team member
C D A I M
www.tacogroup.com
Tank clinching
17.09.09
3. Location of data
collection
What
Measure
/data type
How measured
Related
conditions
Sampling
notes
Loading/
unloading
Continuous
Cycle time by
stopwatch
All Subros &
AIR Int.
models
5 samples/
shift
Pneumatic
pressure
Continuous
By pressure gauge
C/O Parts
stopwatch
How will you ensure
consistency?
by trained persons at
regular intervals & verified
by project team member
C D A I M
www.tacogroup.com
C D A I M
Water fluxing
17.09.09
3. Location of data
collection
What
Measure
/data type
How measured
Related
conditions
Sampling
notes
Sp. gravity of
flux
Continuous
Sp. Gravity using
hydrometer
All Subros &
AIR Int.
models
Hourly Insp./
Hr
Check sheet format
no:
Dipping time
stopwatch
5 samples/
shift
Cleaning
time
Continuous
By pressure gauge
Flux
stopwatch
How will you ensure
consistency?
All the data will be
collected by trained
persons at regular intervals
& verified by project team
member
www.tacogroup.com
Alcohol fluxing
17.09.09
3. Location of data
collection
What
Measure
/data type
How measured
Related
conditions
Sampling
notes
Ratio Continuous
1:2 ratio by
Weightage
All Subros &
AIR Int.
models
Hourly Insp./
Shift
Check sheet format
no:
Fluxing time
stopwatch
5 samples/
shift
Turbulence
Continuous
By pressure gauge
Hourly Insp./
Shift
Check sheet format
no:
Flux
Continuous
Flux mix-up ratio
Hourly Insp./
Shift
Check sheet format
no:
How will you ensure
consistency?
All the data will be
collected by trained
persons at regular intervals
& verified by project team
member
C D A I M
www.tacogroup.com
Manpower Used- Model- wise
C D A I M
34
14
15
36
99
0
20
40
60
80
100
120
B

M
o
d
e
l
Z
e
n
/
I
n
d
i
c
a
/
S
p
r
i
n
t
S
a
f
a
r
i

/
U

m
o
d
e
l
V
E

/

F
o
r
d

B
a
r
r
a
T
o
t
a
l
M
a
n
p
o
w
e
r

U
s
e
d

i
n

N
o
s
Models
Manpower Status
www.tacogroup.com
Data Collection
C D A I M
www.tacogroup.com
Data Collection
C D A I M
Cycle time Vs Output/Hr summary
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Data Collection
C D A I M
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Data Collection
C D A I M
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C D A I M
DOC : ME_FT_41 Date : 16.08.09
Sachin shirmali M Premnath
PART NO : D0ACH0101D00 APPD. MADE
HAND TIME (Sec)
OFF line ON line
10
Fin forming (14cuts / min)
(16 fins / core)
Fin formingm/c
(HC assy)
1 0.0 0.0 4.3 4.3 334 44 23,350 3rdBottoleneck
20 Tube traypreparation&loading Assytable 1 62.0 0.0 0.0 62.0 370 49
30
Core assy(Forming)
(Tubes 15x2=30tubes / core)
Core assym/c 1 24.9 0.0 3.4 28.3 811 108 56,767
30 A Core assy(Header plate assy) Core assym/c 1 22.1 0.0 13.9 36.0 638 85 44,625
40 Tube expansion Exapansion m/c 1 7.6 0.0 4.5 12.1 1,897 253 132,769
50 Burn off (Throughput) Brazing oven 1 0.0 8.0 13.3 13.3 1,726 230 120,789
60 Spin riveting (Filler - I) Spin riveting m/c 9.0 0.0 7.3 16.3 1,408 188 98,558
70 Spin riveting (Filler - II) Spin riveting m/c 9.1 0.0 7.5 16.6 1,383 184 96,777
80
Baffle partiotion assy
(Tank assy)
Spin riveting m/c 14.7 0.0 1.5 16.2 1,417 189 99,167
90 Alcohal fluxing Assytable 1 24.2 0.0 0.0 24.2 948 126 66,384
100 Tank clinching Clinchingm/c 1 16.2 0.0 7.3 23.5 977 130 68,362
110 Water fluxing water fluxing m/c 1 40.3 0.0 0.0 40.3 569 76 39,864 6thBottoleneck
120 Alcohal fluxing Assytable 22.2 0.0 0.0 22.2 1,034 138 72,365
130 Core band fitment Assytable 15.0 0.0 0.0 15.0 1,530 204 107,100
140 Brazing(Throughput) Brazing oven 0 0.0 8.0 13.3 13.3 1,726 230 120,789
150 ALT ALT m/c 1 8.6 0.0 39.4 48.0 478 64 33,469 5thBottoleneck
160 Torch brazing (Throughput) Torch Brazingm/c 2 0.0 53.6 77.6 77.6 296 39 20,702 2ndBottoleneck
170 Plastic fitment Assyfixture 1 16.0 0.0 0.0 16.0 1,434 191 100,406
180 Foamfitment Assyfixture 1 32.0 0.0 0.0 32.0 717 96 50,203
190 ALT ALT m/c 1 6.1 0.0 60.4 66.5 345 46 24,158 4thBottoleneck
200 FLT FLT m/c 1 10.6 0.0 80.3 90.9 252 34 17,673 1st Bottoleneck
18 341 70 334 675
LINE CAPACITY CHART
Line capacity / Hr Chart
LINE CAPACITY /
Hr @85 %(Nos.)
SEQ.NO DESCRIPTION
PRODUCT : Heater core
LINE : Heater core assy line # 2 MODEL : Ford Barra
MACHINE NAME
MONTHLY
CAPACITY /
SHIFT
Remarks
1
PRESENT
OPERATOR
DEPLOYED
M/C TIME
(Sec)
CYCLE TIME
(Sec)
LINE CAPACITY
/SHIFT @ 85 %
1
0 50 100 150 200 250 300
10
20
30
30A
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
Data Collection
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C D A I M
DOC : ME_FT_41 Date : 01.09.09
Sachin shirmali M Premnath
PART NO : D0AAH0101D00 APPD. MADE
HAND TIME (Sec)
OFF line ON line
10
Fin forming (16 cuts / min)
(17 fins / core)
Fin forming m/c
(HC assy)
0.0 0.0 3.8 3.8 360 48 25,200 1 st Bottoleneck
20 Cassette assy Core assym/c 33.6 0.0 3.4 37.0 620 83 43,419
20 A Core assymanual Core assym/c 1 36.5 0.0 0.0 36.5 629 84 44,014
50 Spinriveting (Filler - 1&2) Spin riveting m/c 16.5 0.0 16.8 33.3 689 92 48,243
60
Baffle partiotion assy
(Tank assy)
Press 10.6 0.0 0.8 11.4 2,013 268 140,921
80 Alcohal fluxing Assy table 1 11.3 0.0 0.0 11.3 2,031 271 142,168
90 Tank clinching Clinchingm/c 1 19.1 0.0 1.7 20.8 1,103 147 77,236
100 Water fluxing water fluxingm/c 1 41.9 0.0 0.0 41.9 548 73 38,341 5th
110 Alcohal fluxing Assy table 25.9 0.0 0.0 25.9 886 118 62,027
120 A Core bandfitment Assy table 23.9 0.0 0.0 23.9 960 128 67,218
120 Brazing (Throughput) Brazing oven 0 0.0 8.0 13.3 13.3 1,726 230 120,789
130 Hole piercing ALT m/c 1 14.0 0.0 0.0 14.0 1,639 219 114,750
140 ALT ALT m/c 4.9 0.0 30.1 35.0 656 87 45,900
150 Air blow Air blowm/c 5.0 0.0 10.1 15.1 1,520 203 106,391
160 Torchbrazing (Throughput) Torch Brazing m/c 2 0.0 14.0 50.5 50.5 454 61 31,812 3 rd
170 Plastic fitment Assy fixture 1 28.9 0.0 0.0 28.9 794 106 55,588
180 Foamfitment Assy fixture 1 29.2 0.0 0.0 29.2 786 105 55,017
190 ALT ALT m/c 1 5.6 0.0 45.2 50.8 452 60 31,624 2nd
200 FLT (2 JOB @TIME) FLT m/c 1 19.0 0.0 80.3 99.3 462 62 32,356 4 rd
18 334 30 274 607
Remarks
1
PRESENT
OPERATOR
DEPLOYED
M/C TIME
(Sec)
CYCLE TIME
(Sec)
LINE CAPACITY
/SHIFT @85 %
1
MACHINE NAME
MONTHLY
CAPACITY /
SHIFT
LINE CAPACITY /
Hr @85 %(Nos.)
SEQ.NO DESCRIPTION
LINE : Heater core assy line # 2 MODEL : AIVE
2
1
LINE CAPACITY CHART
0 50 100 150 200 250 300
10
20
20A
30
40
50
60
80
90
100
110
120A
120
130
140
150
160
170
180
190
200
Data Collection
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DOC : ME_FT_41 Date : 01.09.09
Sachinshirmali M Premnath
PART NO : D0AAH0101D00 APPD. MADE
HAND TIME (Sec)
OFF line ON line
10
Finforming (30cuts / min)
(27 fins / core)
Finformingm/c
(HC assy)
1 0.0 0.0 1.0 1.0 850 113 59,500
20 Cassette assy Core assym/c 1 31.6 0.0 0.0 31.6 726 97 50,839 5th
30 Core assy Core assym/c 1 30.2 0.0 11.2 41.4 554 74 38,804 3 rd
60
Spinriveting(Tube - 1&2)
consider 2m/c availablity
Spin riveting m/c 1 19.1 0.0 12.3 31.4 1,462 195 102,325
70 Alcohal fluxing Assytable 1 11.3 0.0 0.0 11.3 2,031 271 142,168
80 Tank clinching Clinchingm/c 1 19.0 0.0 1.7 20.7 1,109 148 77,609
90 Water fluxing water fluxing m/c 1 42.2 0.0 0.0 42.2 544 73 38,069 2 nd
90 Alcohal fluxing Assytable 1 23.0 0.0 0.0 23.0 998 133 69,848
100 wire winding Assytable 1 33.1 0.0 0.0 33.1 693 92 48,535 4th
110 Brazing(Throughput) Brazing oven 0 0.0 8.0 13.3 13.3 1,726 230 120,789
120 WLT WLT m/c 1 16.5 0.0 30.3 46.8 490 65 34,327 1 st Bottoleneck
130 Dryoff Dryoff m/c 1 8.0 0.0 25.0 33.0 695 93 48,682 1 st Bottoleneck
12 234 16 88 321
LINE CAPACITY CHART
LINE CAPACITY /
Hr @ 85 %(Nos.)
SEQ.NO DESCRIPTION
LINE : Heater core assy line MODEL : Indica / Indigo / sprint
MACHINE NAME
MONTHLY
CAPACITY /
SHIFT
Remarks
PRESENT
OPERATOR
DEPLOYED
M/C TIME
(Sec)
CYCLE TIME
(Sec)
LINE CAPACITY
/SHIFT @ 85 %
0 50 100 150 200 250 300
10
20
30
40
50
60
70
80
90
90
100
110
120
C D A I M
Data Collection
www.tacogroup.com
DOC : ME_FT_41 Date : 20.09.09
Sachin shirmali MPremnath
PART NO : B9ADH0101D00 APPD. MADE
HAND TIME (Sec)
OFF line ON line
10
Fin forming (30 cuts / min)
(20 fins / core)
Finformingm/c
(Rad. CA #7)
0.0 0.0 2.0 2.0 574 77 40,163 3rd
20 A Cassette assy Core assy m/c 33.1 0.0 0.0 33.1 693 92 48,535
20 Core assymanual Core assy m/c 1 36.8 0.0 0.0 36.8 624 83 43,655 4th
30 Tube expansion Exapansionm/c 1 23.3 0.0 0.0 23.3 985 131 68,948
50 Spin riveting(Filler - 1&2) Spinrivetingm/c 1 16.0 0.0 15.0 31.0 740 99 51,823
60 Alcohal fluxing Assytable 1 12.0 0.0 0.0 12.0 1,913 255 133,875
70 Tank clinching Clinching m/c 1 20.3 0.0 1.7 22.0 1,044 139 73,089
80 Water fluxing water fluxingm/c 1 42.7 0.0 0.0 42.7 537 72 37,623 2 nd
90 Alcohal fluxing Assytable 30.6 0.0 0.0 30.6 750 100 52,500
100 Core bandfitment Assytable 23.9 0.0 0.0 23.9 960 128 67,218
100 A Wire winding Assytable 1 18.1 0.0 0.0 18.1 1,268 169 88,757
110 Brazing (Throughput) Brazing oven 0 0.0 8.0 13.3 13.3 1,726 230 120,789
120 WLT WLT m/c 1 5.0 0.0 30.1 35.1 654 87 45,769 5th
130 Dry off &Gauge inspection QA gauge 1 14.0 0.0 25.0 39.0 588 78 41,192 1st
140 Foamfitment (2 station) Assytable 2 40.6 0.0 0.0 40.6 1,131 151 79,138
15 316 16 100 417
MONTHLY
CAPACITY /
SHIFT
Remarks
PRESENT
OPERATOR
DEPLOYED
M/C TIME
(Sec)
CYCLE TIME
(Sec)
LINE CAPACITY
/SHIFT @85 %
2
1
LINE CAPACITY CHART
LINE CAPACITY /
Hr @ 85 % (Nos.)
SEQ.NO DESCRIPTION
LINE : Heater core assy line # 2 MODEL : U model / Safari
MACHINE NAME
0 50 100 150 200 250 300
10
20A
20
30
40
50
60
70
80
90
100
100A
110
120
130
140
C D A I M
Data Collection
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DOC : ME_FT_41 Date : 18.10.09
Sachinshirmali M Premnath
PART NO : D0AA APPD. MADE
HAND TIME (Sec)
OFF l i ne ON l ine
10
Fin forming (30cuts / min)
(20 fins / core)
Fin formingm/c
(HC assy)
1 0.0 0.0 2.0 2.0 574 77 40,163 5th
20 Cassette assy Core assy m/c 1 41.6 0.0 3.4 45.0 510 68 35,700 3 rd
20 A Core assy manual Core assy m/c 1 36.5 0.0 0.0 36.5 629 84 44,014
40 Burn off (Throughput) Brazingoven 1 0.0 8.0 13.3 13.3 1,726 230 120,789
50 Spin riveting (Filler - 1&2) Spin rivetingm/c 1 15.7 0.0 12.8 28.5 805 107 56,368
60 Alcohal fluxing Assy table 1 11.3 0.0 0.0 11.3 2,031 271 142,168
70 Tank clinching Clinching m/c 1 19.1 0.0 1.7 20.8 1,103 147 77,236
80 Water fluxing water fluxingm/c 1 41.9 0.0 0.0 41.9 548 73 38,341 4th
90 Alcohal fluxing Assy table 25.9 0.0 0.0 25.9 886 118 62,027
100 Wire winding Assy table 25.0 0.0 0.0 25.0 918 122 64,260
110 Brazing(Throughput) Brazingoven 0 0.0 8.0 13.3 13.3 1,726 230 120,789
120 Wire cut +Core band removal Assy table 1 19.2 0.0 0.0 19.2 1,195 159 83,672
130 Gauge inspection Assy table 10.2 0.0 1.0 11.2 2,049 273 143,438
140 WLT ALT m/c 15.5 0.0 30.1 45.6 503 67 35,230 2 nd
150 Dry off Torch Brazing m/c 1 2.7 0.0 25.0 27.7 829 110 57,996
160 Foamfitment Assy fixture 1 51.8 0.0 0.0 51.8 443 59 31,014 1st
14 324 16 107 431
MONTHLY
CAPACITY /
SHIFT
Remarks
PRESENT
OPERATOR
DEPLOYED
M/C TIME
(Sec)
CYCLE TIME
(Sec)
LINE CAPACITY
/SHIFT @85 %
1
1
LINE CAPACITY CHART
Li ne capaci ty / Hr Chart
LINE CAPACITY /
Hr @85 % (Nos.)
SEQ.NO DESCRIPTION
LINE : Heater core assy l ine MODEL : X1
MACHINE NAME
0 50 100 150 200 250 300
10
20
20A
30
40
50
60
70
80
90
100
110
120
130
140
150
160
C D A I M
Data Collection
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C D A I M Measure phase Summary Report
Bottle neck Stages
Model Name : Ford Barra
Process Cycle Time
Fin forming 70.0 Sec
Water fluxing 40.3 Sec
ALT 48.0 Sec
Torch Brazing 77.6 Sec
FLT 90.9 Sec
Min: Cycle time 12.1 Sec
Max: Cycle time 90.9 Sec
Model Name : AIVE
Process Cycle Time
ALT 50.8 Sec
Torch Brazing 50.5 Sec
FLT 90.9 Sec
Model Name : Indica/Indigo
Process Cycle Time
Cassette Assly 31.6 Sec
Core Assly 41.4 Sec
Wire winding 33.1 Sec
WLT 46.8Sec
Dry Off 33.0 Sec
Model Name : U Model/Safari
Process Cycle Time
Core Assly 36.8 Sec
WLT 35.1 Sec
Dry Off 39.0 Sec
Model Name : X1
Process Cycle Time
Cassette Assly 45.0 Sec
WLT 45.6 Sec
Foam fitment 51.8 Sec
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C D A I M
ANALYSIS PHASE
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Identified Bottle-Necks
Bottle neck at FLT machine
Bottle neck at torch brazing machine
Bottle neck at fin forming machine
Bottle neck at ALT machine
Bottle neck at water fluxing machine
C D A I M
www.tacogroup.com
Material
Man
Machine
Layout is not
O.K
Unskilled
Operator
Only single job can be
inspected at a time
BN at FLT M/c
in Ford Barra
Line
Loading & unloading
time is high
Single fixture is
used for testing.
Cycle time is high
Pipe end is
damaged
NID coupler is
worn out
Method
Cause & Effect Diagram C D A I M
CO time is high
(model~model)
Setting procedure is
not user friendly
Operator fatigue due to
improper bin storage
Environment
Process
Heater cores can
malfunction after
torch brazing
Pipe end is
damaged
www.tacogroup.com
Material
Man
Machine
Layout is not
O.K
Unskilled
Operator
Flux is needed for
some heater cores
BN at Torch
brazing M/c i n
Ford Barra
Line
Loading & unloading
time is high
Single pipe is
brazed at a time.
No fixture lifting
provision for diffuser
& connector
Pipe Dia is
not O.K
Lead ring
fitting
Method
No auto clamping
provision
not user friendly
Environment
Process
No humidity
controller
LPG pressure
is not O.K
No cooling provision
after torch brazing
Temp. setting
is not O.K
www.tacogroup.com
Material
Man
Machine
BN at Fin
forming M/c i n
Ford Barra
Line
Cuts/Min or
speed is low
No stopper provision
to build core
Child part is
not O.K
Coil diameter
is low
Method
Tube dropping
problem
Operator idle time @
core Assly~tube Expn
Environment
Process
Machine setting is
not O.K
Skilled operator is
required to do the
setting
Frequent breakdown
of the machine
www.tacogroup.com
Material
Man
Machine
Layout is not
O.K
Unskilled
Operator
Single job can only be
inspected at a time
BN at ALT M/c
in Ford Barra
Line
Loading & unloading
time is high
Single fixture for
testing.
Change over time is
High (Model~Model)
Connector
damage
NID coupler
worn out
Method
Cycle time is high
not user friendly
Environment
Process
Heater cores can malfunction
after torch brazing
Machine setting is
not O.K
ALT pressure rating
is not O.K
Air pressure is low
www.tacogroup.com
Material
Man
Machine
Manual dipping
human oriented may
vary opr to opr
Only single job can be
inspected at a time
BN at water
fluxi ng M/c in
Ford Barra
Line
Loading & unloading
time is high
Single fixture is
used for testing.
Blower air flow
rate not o.k
Nocolok flux
condition is not
good
Flux specific
gravity is not o.k
Method
Improper flux agitation or
flux block on air pipe
not user friendly
Operator need to rotate
each job for removing the
water
Environment
Process
Flux spillage on the
floor looks dirty
No mass flow
Cleaning changeover
time is high
www.tacogroup.com
Identified Effects- Indica/Sprint Line
Bottle neck at WLT machine
Bottle neck at Dry off machine
Bottle neck at Water fluxing machine
Bottle neck at Core assembly machine
Bottle neck at Wire winding
Bottle neck at Cassette assembly
C D A I M
www.tacogroup.com
Material
Man
Machine
Layout is not
O.K
Operator with good
eyesight is reqd.
Water removal
from core is unsafe
BN at WLT M/c
in Indigo Li ne
Loading & unloading
time is high
Single fixture is
used for testing.
Cycle time is high
No clean water
Coupler bush
is worn out
Method
Fixture not
O.K
not user friendly
Environment
Process
Heater cores can
malfunction after
torch brazing
Pipe end is
damaged
Timer is
malfunctioni ng
Diffuser/pipe
end damage
Diffuser/pipe
CD not O.K
www.tacogroup.com
Material
Man
Machine
Operator Fatigue
No hot air provision
is available
BN at Dry Off
M/c in Indigo
Line
At a time only si ngle
job can be dried off
No interlock for
cleaning time.
Method
No fixture to
hold the job
Environment
Process
Low air flow
rate
www.tacogroup.com
Material
Man
Machine
Unskilled
Operator
BN at Core
Assl y M/c in
Indi go Line
Loading & unloading
time is high
Manual cassette
assembly
Operator need to
operate toggle clamp
& pulley
Fin/tube/header
plate-size variation
Method
No automatic set-up
Environment
Process
Air pressure low for
top cylinder
No counter system
for fin/tube missing
www.tacogroup.com
Material
Man
Machine
Unskilled
Operator
BN at Cassette
Assl y
Operation is done
manuall y
Cycle time is skill
dependant
Fins & tubes are in non
counted condition
Method
Environment
Process
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Identified Effects- Safari Line
Bottle neck at Dry off & Gauge inspection
Bottle neck at Water fluxing machine
Bottle neck at Fin forming machine
Bottle neck at Core assembly machine
Bottle neck at WLT machine
C D A I M
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Summary of significant causes
Sr
No
Significant Causes Area
1 Only single job can be inspected at a time FLT
2 Single fixture is used for testing FLT
3 During testing Heater cores can malfunction after torch brazing FLT
4 Single core is brazed at a time Torch brazing
5 No cooling provision after torch brazing Torch brazing
6 No auto clamping provision available in the fixture Torch brazing
7 No humidity controller Torch brazing
8 No fixture lifting provision for diffuser & connector Torch brazing
9 Cuts/min is low Core builder
10 Tube dropping problem Core builder
11 No stopper provision to build core Core builder
12 Single fixture is used for testing ALT
13 Single job can only be inspected at a time ALT
14 Cycle time is varying for different models ALT
15 Cleaning changeover time is high Water fluxing
16 Single fixture is used for testing Water fluxing
17 Blower air flow is not o.k Water fluxing
C D A I M
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Sr
No
Significant Causes Area
18 Operator need to rotate each job for removing water Water fluxing
19 Manual dipping is human oriented may vary operator to operator Water fluxing
20 No mass production Water fluxing
21 Flux spillage on the floor looks dirty Water fluxing
22 Operate need to operate toggle clamp & pulley Core Assly
23 No automatic set up Core Assly
Summary of significant causes C D A I M
www.tacogroup.com
Sr
No
Process Manual Automatic Semi Automatic
1 Fin Forming
2 Cassette Assembly
3 Core Assembly
4 Tube Expansion
5 Burn Off
6 Spin Ri veting
7 Baffle Assembly
8 Alcohol fluxi ng
9 Tank Clinchi ng
10 Water Fluxing & Blowing
11 Brazing
12 ALT
13 Torch Brazing
14 Plastic Band Fitment
15 Foam Fitment
16 FLT
17 Dry off
C D A I M
Identify Manual Processes
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IMPROVEMENT PHASE
C D A I M
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Process Selected for Automation
C D A I M
1)Core Assembly-AIVE
Operator has to manually operate pulley
& toggle clamps
2) Alcohol Fluxing
Operator has to dip brush in the solution
& apply
3) Water Fluxing & Blowing
Operator has to dip heater core in the
solution & then dry using blower
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Old Process Selected for Improvement
C D A I M
1)Core Assembly-Ford Barra
Operator has to hold the cassette thus
creating idle time
2)Burn Off
Heater cores are taken for burn off
process
3)Torch Brazing
Brazing of one heater connector done at
a time.
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Old Process Selected for Improvement
C D A I M
4) WLT & Dry Off
WLT & Dry Off can be replaced with
ALT based on revalidation trials
5) FLT
New fixture can be accommodated in the
chamber
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Old Process Selected for Standardization
C D A I M
1)ALT
Different models found to have
different cycle time in the same process.
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Old Process Selected for Line balancing
C D A I M
1)ALT
Idle time found .
2)Plastic band fitment
Idle time found .
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Improvement Plan
New Folder\Improvement Plan.xls
C D A I M
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Gantt Chart
Gantt Chart.xls
C D A I M
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Improvement Plan v/s Status
S No Task Status Remarks
1 Provide additional fixture in FLT M/c Additional fixture is validated Completed on 12.01.10
2
Ford Barra Cuts / min (Speed
increase) revalidation
Cuts/Min is increased Completed on 10.01.10
3 Core assy idle time elimination Implement automation Not Success ful
4
ALT Standardize cycle time based on
re-validation trials (30 sec)
All the models are having 30 Secs Completed on 20.01.10
5
Make a new Water fluxing machine
(Conveyerised).
New water fluxing machine is
commissioned
Completed on 30.03.10
6 Semi automatic core assy machine
Existing fixture is provided with
pneumatic cylinders
7 Manpower deployment Re-planning Manpower replaning done Completed on 10.02.10
8 Eliminate Burn off process
Burn off process eliminated &
validated
9
Eliminate Alcohol fluxing operation &
introduce Air fluxer unit
New machine is procured Completed on 20.02.10
10
Eliminate (WLT) water testing machine
& Incorporate additional ALT fixtures in
the same cell.
Trials are going on to eliminate
WLT with ALT
11
Seq. of foam fitment operator also
deployed in ALT (Final)
One operator will do both ALT &
plastic band fitment
C D A I M
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Implementation - 1 C D A I M
BEFORE AFTER
Single fixture used inside FLT chamber
Cycle time: 1 job @ 99.3 Sec
Addl. fixture provided in FLT chamber
Cycle Time:2 job @ 99.3 Sec
Providing Additional fixture at WLT
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BEFORE AFTER
Manual Process used for Flux Application
Cycle Time: 42 Sec.
Conveyerised water fluxing
Cycle Time: 8.6 Sec
Elimination of Manual Fluxing
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BEFORE AFTER
Manual fixture used for core assembly
Cycle Time: 36.5 Sec
Automated fixture used for core assembly
Eliminating Manual Core Assembly in Aive Line
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BEFORE AFTER
Cores waiting in trolley for burn-off
Cores are taken for clinching directly
Cycle Time: 0Sec
Eliminating Burn Off Process
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BEFORE AFTER
Alcohol fluxing
Cycle Time: 11.3 sec
Eliminating flux application using brush
Powder Fluxing Machine
Cycle Time: 8.3 Sec
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BEFORE AFTER
Water leak testing (Cycle time:44.1 Sec)
Dry-Off (Cycle Time:27.7 Sec)
Air leak testing (Cycle Time: 43.9 sec)
Replacing WLT Process in B Model with ALT
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BEFORE AFTER
Two operator used for two process
Single operator used for two process
Line balancing in Foam fitment & ALT Process
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Manpower chart -Before V/S After C D A I M
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GOOD
C D A I M
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C D A I M
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C D A I M
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C D A I M
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CONTROL PHASE
C D A I M
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Control Phase Acti vity Planning
Improvement
actions / tasks
implemented
Process
where
implement
Dependency
identify
What control
mechanism
deci ded
Date of control
mechanism
implementation
Relevant
documents /
records prepared
/ modi fied
Provide additional
fixture in FLT M/c
FLT Machine
P.M Check
sheet
12.01.10 NA
Ford Bara Cuts / min
(Speed increase)
revalidation
Heater core
building
Machine
Reference
sheet
15.01.10 NA
ALT Standardize
cycle time based on
re-validation trials
(30 sec)
ALT Method
Update in the
Program ;
Reference
Sheet
20.01.10 RS /1600-302
Make a new Water
fluxing machine
(Conveyerised).
WLT Method
Machine
condition,
Quality check
sheet, work
instruction
31.03.10
RS / 0900-001 ;
CS-0900-001 ;
ME-WI-0900-007
C D A I M
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Control Phase Acti vity Planning
Improvement
actions / tasks
implemented
Process
where
implement
Dependency
identify
What
control
mechanism
deci ded
Date of control
mechanism
implementation
Relevant
documents /
records prepared /
modifi ed
Semi automatic core
assy machine
Aive core
building
Method
WI 30.03.10
ME/WI/0700-301
Rev.01
Eliminate Burn off
process
Burn Off Method PFD 30.03.10 ME/PF-01 Rev. 09
Eliminate Alcohal
fluxing operation &
introduce Air fluxer
unit
Flux Appln Method
PFD,WI 30.03.10 ME/PF-01 Rev. 09
Eliminate (WLT)
water testing
machine &
Incorporate
additional ALT
fixtures in the same
cell.
WLT Method
PFD,WI 10.03.10
ME/WI/1600-301
RS/1600-301
CS/1600-301
Seq. of foam fitment
operator also
deployed in ALT
(Final)
Band fitting Man
PFD,WI NA NA
C D A I M
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Documents Change
Document No. Descriptio
n of
Document
Description of changes Revision
No.
Revision
Date
RS/1600-301 Reference
sheet
Included new parameters for fill
time & fill pressure
New
document
09.03.10
ME/PF-01 Rev. 09 PFD Updated the process flow
changes
09 30.03.10
RS / 0900-001 ; Reference
sheet
New reference sheet for
conveyorised water fluxing
New
document
31.03.10
CS-0900-001 ; Check
Sheet
New check sheet for
New
document
31.03.10
ME-WI-0900-007 Work
Instruction
New work instruction for
New
document
31.03.10
ME/WI/1600-301 Work
Instruction
New work instruction as WLT is
replaced by ALT
New
document
09.03.10
RS/1600-301 Reference
sheet
New reference sheet as WLT is
replaced by ALT
New
document
09.03.10
CS/1600-301 Check
Sheet
New check sheet as WLT is
replaced by ALT
New
document
09.03.10
C D A I M
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Control Plan C D A I M
PROTOTYPE PRELAUNCH PRODUCTION
Control Plan No. : CP/0900-H
Product Name : HEATER CORE
Characteristics Class :
Si ze Frequency
1
Flux present on
specified area
Refer the
ME/WI/0900-
001,
ME/WI/0900-002
& ME/WI/0900-
004
Visual 100% Each J ob
2
Specific gravity
for Water fluxing
1.17 ~1.20
Specific gravity
meter
Once per hour
3
Flux ratio with
alcohol for
alcohol fluxing
1:2 Manual Once per shift
0900
Fluxing
(Alcohol &
Water)
Fluxing
(M/C No. 327
& 328)
Product
Characteri sti c
Process
Characteristi c
Product/Process
Speci ficati on/
Tol erance
Eval uati on
Measurement
Techni ques
Sr.
No.
Process Name
/ Operati on
M/c, Device,
Ji gs, Tool s for
Manufacturi ng
CHARACTERISTICS
Sr.
No.
Speci al
Char.
Cl ass.
METHOD
Sampl e
CONTROL PLAN
Key Contact / Phone:
Mr. Alok Misra , 09881097853
Core Team :
Alok Misra, S Kulkarni,PP Kulkarni, RN Shete, B Ghule, R Kulkarni,
Shetkar
- Significant (Sc) --Critical (Cc)
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One Point Lesson C D A I M
OPL CREATED DATE 30.03.10
BASIC KNOWLEDGE
TROUBLE CASE
IMPROVEMENT CASE
S.NO ITEM NAME KEYPOINT / WHY
Cuts/Min
(Before)

Cuts/Min
(After)
CREATED BY SECTION HEAD MANAGER - MANUFACTURING TRAINING GIVEN BY
NAME - Vinu A NAME - Narendra A NAME - Parikshit Kulkarni NAME - Ankush Pawale
Ford Barra Heater core Fin forming Machine is capable of
running at 17 cuts/Min
CATEGORY : P Q C D S M
ONE POINT LESSON
SUMMARY
Ford Barra Heater core Fin forming Machine is running at 14
Cuts/Min.
TATA TOYO RADIATOR LIMITED
PLANT AREA : CL CA BRZ TC ICW HC
NO OF EMP TRAINED & DATE
OTHER AREA( OFFICE )
Fin forming machine
Heater core - Core Building EQUIPMENT AREA
EQUIPMENT NAME
EDUCATION RECORD NO
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Training Imparted C D A I M
Date of
Training
Type of
Training
Topic Trainee Trainer Duration
30/03/2010 On J ob
Training done.
Standard Operating
Procedure for
conveyorised water
fluxing.
Mr.Gajanan Karne,
Mr.Pravin Kshirsagar,
Mr.Sunil Gawade
Vivek
Mhaisne
&
Narendra
Asati.
25 minutes
10/01/2010 OPL & On job
training
Cuts/min on ford
barra fin forming
machine
Mr.Sagar Pawar,
Mr.Ajit Gage
20 minutes
25.02.10 On the job
training
Standard Operating
Procedure for
Powder fluxing.
Mr.Ashok Navsupe,
Mr.Prakash B More 30 minutes
15/02/2010 On the job
training
Standard Operating
Procedure for Aive
core builder
Mr. Vijay Chinchole,
Mr.Ganpati Sutar 30 minutes
05.03.10 On the job
training
Standard Operating
Procedure for
B model ALT
Mr.Shivanand J adhav,
Mr.Dattatray Mahadik
20 minutes
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Cost Benefit Analysis- Combined Plan
C D A I M
Benefit Before After Net gain
Manpower/ Day
99 82
17
Productivity/Person
25.00 31
22 %
Cost Saved/ annum Rs. 12.65 lacs / annum
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Cost Incurred & Pay Back Period
Sr.
No
Task Status Remarks Cost
Pay Back
Period
1 Provide additional fixture in FLT M/c Additional fixture is validated Completed on 12.01.10 0 NA
2
Ford Barra Cuts / min (Speed increase)
revalidation
Cuts/Min is increased Completed on 10.01.10 0 NA
3
ALT Standardize cycle time based on re-
validation trials (30 sec)
All the models are having 30 Secs Completed on 20.01.10 0 NA
4
Make a new Water fluxing machine
(Conveyerised).
New water fluxing machine is
commissioned
Completed on 30.03.10 528000 6 Months
5 Semi automatic core assy machine
Existing fixture is provided with
pneumatic cylinders
Completed on 12.02.10 160000 2 Months
6 Manpower deployment Re-planning Manpower replaning done Completed on 10.02.10 0 NA
7 Eliminate Burn off process
Burn off process eliminated &
validated
Completed on 15.01.10 0 NA
8
Eliminate Alcohol fluxing operation &
introduce Air fluxer unit
New machine is procured Completed on 20.02.10 30000 0.5 Month
9
Eliminate (WLT) water testing machine &
Incorporate additional ALT fixtures in the
same cell.
Trials are going on to eliminate WLT
with ALT
Completed on 05.03.10 100000 1 Month
10
Seq. of foam fitment operator also deployed
in ALT (Final)
One operator will do both ALT &
plastic band fitment
Completed on 18.03.10 0 NA
Total 818,000 9 Months
C D A I M
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Present Concerns C D A I M
Sr No Description
1 Machines Preventive Maintenance plan need to adhere.
2
Discipline from production operatives to follow Standard Operating
Procedure.
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Lessons Learnt C D A I M
Achieve business goal by improving the product quality, Customer
PPM & reducing the in house rejection.
Cross functional team working for achieving the goal.
Use of statistical tools for validation.
Learn systematic DMAIC methodology for proper analysis &
sustainable improvements.
Fact based & data driven decision making.
Proper Planning can help to achieve milestones.
Team felt motivated after achieving the business goal.
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Dashboard C D A I M
CTQ's monitoring through DASHBOARD -6 months
Base Parameters
Period (each period -1 month)
Mar-10 Apr-10 May-10 Jun-10 July-10 Aug-10
CTQ's
(Output)
Y
1
Qty/Man/Day
30.2 31.4 31.2 30.9
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Recommendations for Future C D A I M
Sr No Description
1 New automated core builder for every model can reduce manpower.
2 New online brazing process can reduce material handling time.
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Thank you..
Tata Toyo Radiator Ltd.
Survey No.235/245, Village-Hinjewadi,
Taluka-Mulshi,Dist-Pune-411 027.India
Phone No.-+91 20 66524100

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