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CYCLE TIME REDUCTION OF SEPERATE PH
ASE ASSEMBLY (SPA)
USING VALUE STREAM MAPPING.
Introduction of VSM: (VALUE STREAM MAPPING)

• VSM is the representation of materials.

• It is a lean manufacturing technique.

• Quality value stream mapping is often used in process cycle time improvem
ent.

 “If you can’t describe what you are doing as a process, you don’t know
what you’re doing.” -W. Edwards Deming
 STEPS OF VSM:

• Select process to be mapped.

• Set Boundries.

• Collect data and produce current state map.

• Critique Current state.

• Map Future State.

 VSM of SPA
Observation conducted on 3rd unit of M/s KAILASH GROUP
ROCESS MAPPING – SPA.
SPA INSULA
TION UNLOAD ED SELECT SPA REFERED
PLACE D SELECT LIFTING
WDG. CHANNELS INSL,
PERMAWOOD FIXTURE
CLAMPED ARRANGE ASSLY.
BOTTOM FOR WDG
WINDINGS & OVEN DECLAMPED DRAWING/
RING HEIGHT
LOADED AFTER OVENING LIST

SECURE LIFTING
CHECK OUTSIDE FIT OUTER
LIFT WINDING FOLLOWING ARMS WITH SPANSET
DIAMETERS OVER WEDGES,
SEQUENCE OF PHASE WDG FROM OUTSIDE WDG.
CYLINDERS.ADJUST CYLINDERS,
ASSEMBLY , BENDING AND AND PROTECTION AGAINST
ON WEDGES WITH COLLARS AS
INSULATING BOTTOM LEAD DAMAGE OF WINDING
TOLERANCE PER DESIGN
INSULATION

INSULATION
ASSEMBLY DRG
Ref: WI/PRD/ 06
WI/PRD/ 09
CLAMPED & REMOVE D SPA
SER PREAPARED&
PRESSED FROM OVEN WI/PRD/ 10
FILLED TOP
LIFT EDSPA & AFTER DRYING
INSULATION Check list: PRD/01
LOADED IN AND PRESSING
OVEN DECLMPING

Enkay Consultants
Materials:
The materials used to make SPA are As:

• coils (LV,HV & HVT),

• Insulation Kit (Cylinder,Wedges,Blocks,Washer,Wing Washer,Disc Collar),
• Coil Clamping & Bottom Support Rings),
• SER Rings,
• Pressing plates, Tie Rods, Clamps, Wooden Blocks etc.
They are classified in four groups are as follows:

(Cont.)
Materials Havi Consumable Measuring In
Materials Ha Available Resources
ng high Cost Material struments
ving low Cost

Crepe paper, J Hydraulic Pressing

Measuring tap
Copper(PICC) Insulation Kit ari Tape, Nom Machine with Jack, S
e
ex paper etc oldering Machine

Plates,Rods, Clamps,
Fevicol, Patch
Copper(CTC) CCR & BSR water Level wooden blocks,wash
Strips
ers, Spansets etc
 CURRENT STATE OF
SEPERATE PHASE ASSEMBLY
CURRENT STATE ANALYSIS-

Waiting Period Non Value Added Activties

Waiting For LV co Loading Coils Sep

2 Days 2 Days
il Completion erately for Drying

Waiting for HV C Shifting of Coils &

opper 8 Days Fixtures from 1 sh 0.25 days
op to other

10
CYCLE TIME ANALYSIS-
•Total Waiting time = 10 Days

• Process time of the process = 133.22 hr

• Working hrs in a shift = 8(hours):30(min.) - 0:50(min.) =7(hours):40(min.)

• No.of shifts worked = 133.22/ 7.66 hours =17.4 shifts.= 8 Days.

(2 Shift per 6 Days & 3 shifts per 2 days)

• Total Cycle Time= 10+8=18 Days.

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 FUTURE STATE OF
SEPERATE PHASE ASSEMBLY

12
FUTURE STATE ANALYSIS:

Areas of Improvement:
• Pressing Clamps straightening.

• Chart preparation for the combinantion of pressing plates for a perticular oven loadi
ng.

• Modifying old ones & buiding new coil lifting fixtures.

FUTURE STATE ANALYSIS:

CYCLE TIME CALCULATION:

• Waiting time before the process Starts = 0 Days(Considering Ideal State)

• Cycle time of the process = 84 hr (No waiting time)

• Working hrs in a shift = 8(hours):30(min.) - 0:50(min.) =7(hours):40(min.)

• No.of shifts worked = 84 / 7.66 hours=11 shifts.= 5.5 Days.

COMPARISON:

CURRENT STATE FUTURE STATE

(Days) (Days)

PROCESS TIME 08 5.5

WAITING TIME 10 0

CYCLE TIME 18 5.5

Conclusions:
By
• Minimising waiting time,

• Doing activities In Parallel,

• Minimising the Shifting of Coil From 1 shop to other, &

• Using right combination of skilled & semiskilled SFE's in both shifts.

The total time required for the completion of process can be reduced by 75 %. and co
st involved in oven loading can be saved.

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