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End of Line Levelled Flow @140mins

RPC 2017

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Meeting Agenda
End of Line Balanced Flow

Tipper Assembly Single Line Flow

Yamazumi

Go & See

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End of Line Balanced Flow

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End of Line Vehicle Movement - Before

Test Track

550
meters

Brake Road
Wheel PDI
Test Test
Alignment,
Check
Headlamp
Aiming

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Methodology for Improvement @140Takt

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Method for Levelled Flow @140mins Takt

Time (mins.) Time (mins.)
240 Before 240 New
220 220

200 40 200
Road Test
180 180
20 Brake Test
160 160 FA 6.1 FA6.2
Headlamp
10 Aiming
140 140

120 120 40
60 Road
100 Test 100 Road Test
Check 10
Headlamp
80 80 Aiming
140 140
60 60 20 Road Test
70 Check

40 80 40 Wheel
Alignment
20 Wheel 20
Alignment PDI Brake Test PDI
20

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Method for Levelled Flow @140mins Takt

Time (mins.) Time (mins.)
Method New
240 Before 240
Change
220 220
Team Member: 03 Team Member: 03
200 40 200
Road Test
180 180
20 Brake Test
160 160 FA 6.1 FA6.2
Headlamp
10 Aiming
140 140

120 120 40
60 Road
100 Test 100 Road Test
Check 10
Headlamp
80 80 Aiming
140 140
60 60 20 Road Test
70 Check

40 80 40 Wheel
Alignment
20 Wheel 20
Alignment PDI Brake Test PDI
20

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Method for Levelled Flow @140mins Takt

40mins Road Test
Time (mins.) TimeCheck
(mins.) given to Line
240 Before Check
240 New
7 mins wheel
220 220
alignment time
Team Member: 03 Team Member: 03
reduced by relocating
200 40 200adaptor positions
Road Test 03 mins reduced by
180 180
placing Friction Plate
20 Brake Test
160 at wheel alignment
160 FA 6.1 FA6.2
Headlamp
10 Aiming Activities overlapped
140 140

120 120 40
60 Road
100 Test 100 Road Test
Check 10
Headlamp
80 80 Aiming
140 140
60 60 20 Road Test
70 Check

40 80 40 Wheel
Alignment
20 Wheel 20
Alignment PDI Brake Test PDI
20

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End of Line Vehicle Movement - New

Test Track

400
meters

Brake Wheel
Alignment, PDI
Test
Headlamp
Aiming,
Road Test
Check

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EOL Process Flow Comparison

Wheel
Alignment,
Headlamp Road Road
Brake
Test PDI Test
Test Aiming
Check Output
3 5 4
1 2

Before

FA 6.1 Wheel
Alignment,
FA 6.2
Headlamp
Aiming, Road
Brake
Road Test PDI Test
Test
Check Output
1 3
2 4

New

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EOL Process Flow Comparison

Wheel
Alignment,
Headlamp Road Road
Brake
Test PDI Test
Test Aiming
Check Output
3 5 4
1 2
550
meter

Before

FA 6.1 Wheel
Alignment,
FA 6.2
Headlamp 150
Aiming, Road meter
Brake
Road Test PDI Test
Test
Check Output
1 3
2 4
400
meter

New

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Tipper Assembly Single Line Flow

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Tipper Assembly - Before

Before

Brake Road
Wheel PDI
Test Test
Alignment,
Check
Headlamp
Aiming

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Tipper Assembly - Before

Before

Brake Road
Wheel PDI
Test Test
Alignment,
Check
Headlamp
Aiming

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Tipper Assembly - Before

Before

Brake Road
Wheel PDI
Test Test
Alignment,
Check
Headlamp
Aiming 450
meters

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Tipper Assembly After Single Line

New

Tipper Station 01
Brake Wheel
Alignment, PDI
Test
Headlamp
Aiming,
Road Test

Tipper Station 02
Check

Tipper Station 03
G:\RPC-MDI_Chassis_Assembly\Common\02.Production_New\03.EOL\EOL Levelled Flow @140mins Takt 9/18/2017
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Tipper Assembly After Single Line

New Saving
350meter
No
Reverse
100
meters

Tipper Station 01
Brake Wheel
Alignment, PDI
Test
Headlamp
Aiming,
Road Test

Tipper Station 02

Tipper Station 03
Check

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Yamazumi

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Yamazumi for Before Process

Before
200
10
180
20
160 Target: 140
10 10
140
10 10
Time in (mins.)

10
120 60 20
40
100

80
70 150
140
60 120
70 110
100
90
40

20 40
20
0
TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8
Team Members

Brake Test Wheel Alignemnt Road test Check Head light aiming Road Test Torque Check
Wheel Alignment R/w Tipper Hose fitment PDI Repair Audit Line Check
Tipper 1 Tipper 2 Tipper 3 Vehicle Movement

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Yamazumi for Before Process

Before
200 Target: 140
Vehicle
10 Movement
180 Torque
Check 20
160 Headlight
10 Aiming 10
140 Vehicle Vehicle
10 Movement 10 Movement
Time in (mins.)

Road Test 10
120 60 20 Repair
Check
40 Road Test
100

80
70 PDI 150
140
60 Wheel 120
70 110
Alignment Wheel 100
90
40 Alignment Tipper Tipper Tipper Audit
Line Check Assembly Assembly Assembly
Torque
20 40 Check
20 Brake Test
0
TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8
Team Members

Brake Test Wheel Alignemnt Road test Check Head light aiming Road Test Torque Check
Wheel Alignment R/w Tipper Hose fitment PDI Repair Audit Line Check
Tipper 1 Tipper 2 Tipper 3 Vehicle Movement

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Yamazumi for New Process

After
200 Target: 140

180
FA 6.1 FA 6.2 Tipper Assembly
160
Tipper 01 Tipper 02 Tipper 03
140
10 10 10 5 5 5
Time in (mins.)

120 20
40 40
100 20
10 10
80 20
20 140 140
132 130 130
60
10
70
40
30 70
20
20
10
0
TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8
Team Members

Brake Test Wheel Alignemnt Wheel Alignment R/w Road Test Check Head light aiming Road Test

PDI Torque Check Repair Tipper Hose fitment Audit Line Check

Tipper 1 Tipper 2 Tipper 3 Vehicle Movement

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Yamazumi for New Process

After
Target: 140
200

180
FA 6.1 FA 6.2 Tipper Assembly
160
Tipper 01 Tipper 02 Tipper 03
140 Vehicle Vehicle Vehicle
10 Movement 10 Movement 10 Movement 5 Vehicle 5 Vehicle 5 Vehicle
Time in (mins.)

Tipper Movement Movement Movement

120 20
Torque Hose
40 Road Test 40 Fitment
Check
100 20
Headlight Repair
10 Aiming 10 Rework Torque
80 20
Road Test Check
20 140 140
Check 132 130 130
60
10 Rework
Line Check Tipper Tipper Tipper
70 Assembly Assembly Assembly
Audit
40 Wheel
30 Wheel 70 PDI
Alignment
Alignment
20
20 Brake Test Brake Test
10
0
TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8
Team Members

Brake Test Wheel Alignemnt Wheel Alignment R/w Road Test Check Head light aiming Road Test

PDI Torque Check Repair Tipper Hose fitment Audit Line Check

Tipper 1 Tipper 2 Tipper 3 Vehicle Movement

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Yamazumi Comparison
Before After
200 200 Target: 140
Target: 140
180 10 180
20 FA 6.1 FA 6.2 Tipper Assembly
160 160
10 10 Tipper 01 Tipper 02 Tipper 03
140 140
10 10 10 10 10 5 5 5

Time in (mins.)
Time in (mins.)

120 60 20 10 120 20
40 40 40
100 100 20
80 80 10 10 20
70 150 140 20 140 140
132 130 130
60 120 60
70 100 110 10
40 90 40 70
30 70
20 40 20
20 20 10
0 0
TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8 TM1 TM2 TM3 TM4 TM5 TM6 TM7 TM8
Team Members Team Members

Brake Test Wheel Alignemnt Road test Check Brake Test Wheel Alignemnt Wheel Alignment R/w
Head light aiming Road Test Torque Check Road Test Check Head light aiming Road Test
Wheel Alignment R/w Tipper Hose fitment PDI PDI Torque Check Repair
Repair Audit Line Check Tipper Hose fitment Audit Line Check

Tipper 1 Tipper 2 Tipper 3 Tipper 1 Tipper 2 Tipper 3

Vehicle Movement
Vehicle Movement

G:\RPC-MDI_Chassis_Assembly\Common\02.Production_New\03.EOL\EOL Levelled Flow @140mins Takt 9/18/2017

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Yamazumi for Tipper Assembly

Tipper Assembly Single Line Process
160
Target: 140

140
5 5 5
120 20
30
12
Time in (mins.)

100 65
15
30
80 10
15
60
30 40
40
60
20 15
35
15
0
TM7 TM8 TM9
Team Members
Tipper Preparation Tipper Docking Tyre fitment Jack fitmentTail lamp & Hydraulic

Side marker lamp fitment Electrical Hydraulic Connection Attachment plate tightening

Painting Final Inspection Vehicle Delivery Rework

Vehicle Movement

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Benefit of Levelled Flow in EOL

Takt @140mins. balance in stations
Fixed output defined as per takt.
Work balance for all employees
Vehicle movement reduced to 500 meters.
Throughput time defined
EOL Throughtput Time : 700mins (P410)
Takt: 140
EOL: 140*02 = 280mins
Tipper Assembly: 140*03 = 420mins
Total Time: 700mins

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Benefit of Tipper Levelled Flow

No reverse movement of vehicle
Straight Line flow
Takt of 140 mins. fixed station wise.
Vehicle Movement reduced to 350 meters.
Each team member work equally distributed in takt.
Define output as per takt
Andon System made in use

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Challenges for Single Tippler Line Flow

Supply of regular tipper body as per demand/day.
Supply of tipper body pre-assy. air hose pipe.
Andon System should have Tipper Station 03.
Possibility to be check for removing crane stopper.

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Status of Improvement

Act Plan

Check Do

G:\RPC-MDI_Chassis_Assembly\Common\02.Production_New\03.EOL\EOL Levelled Flow @140mins Takt 9/18/2017

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Thank You

G:\RPC-MDI_Chassis_Assembly\Common\02.Production_New\03.EOL\EOL Levelled Flow @140mins Takt 9/18/2017