A Presentation On: -

“LEAN IMPLEMENTATION IN DT&R WORKSHOP”

PRESENTED BY: -

ARITRA RAY

SUMMER INTERN – (DT&R, NAVI MUMBAI)

Tuesday, April 30, 2019 1

ABOUT THE PRESENTER: -

Name: - Aritra Ray

• Studying MBA (Technology Management) – Chemical Engineering, MPSTME –

NMIMS University.
• Was Born in Mumbai, currently residing since 17 years.
• Spent 3 years in Sivsagar & Jorhat – Assam.

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 Problem Statement: -

“To study the Lean Implementation Techniques in

DT&R Workshop
& Suggest Improvements in DT&R Workshop Area”

Project Mentor: - Ravi Kumar Sharma, FSM-DT&R

Project Guide: - Pawadi Abrum, Workshop Personnel

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Project Description: -

• Project is based upon implementing various Time Saving methods in DT&R

Workshop, by Lean Manufacturing Method.
• The Lean Manufacturing principles are based upon giving value-added product
flow to customers/clients & increasing efficiency of the overall workshop system.
• The objectives of the project are: -

 To synchronize workshop operations so as to produce at the pace,

according to the customer’s demands.

 Implementation of the “Lean Concept” to workers so as to improve their

own working conditions.

 To improve workshop efficiency and product quality, meanwhile reducing

manufacturing wastes and the need to keep inventory.

 Increasing Segment Profitability.

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Proposed Methodology: - 5S Method of Lean Manufacturing Concept

“A list that describes how to organize a workspace for efficiency and

effectiveness by identifying and storing the items used, maintaining the area
and items, and sustaining the new order ”.

It consists of: -
• Sorting.
• Straightening (Setting in Order).
• Standardizing.
• Sweeping (Cleanliness).
• Sustaining.

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Workshop Description: -

Total Plot Area: - 2850 Sq. Meters Workshop Personnel: - 09 Persons.

 Mechanical = 06 Persons.
Workshop Bay Area: - 1105 Sq. Meters
 Welding Dept. = 03 Persons.
Workshop Area consist of: -

 Break-out Unit ( For Assembly/Disassembly of Hydraulic Jars)

 Oil Testing Area ( For Hydraulic Jar Testing).

 Internal Grinding Area.

 Inspection Bay Area.

 Welding Bay Area.

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Major Problems Currently Faced in Workshop: -

 Mismanagement of Hand Tools.

 Excessive Motion in Workshop Bay Area.

 Presence of Unnecessary Inventory in Workshop Area.

 Storage of Scraps and Used Equipment and Tools.

 Shortage of Trained Manpower.

 Proper Paper-Work Unavailability.

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 Mismanagement of Hand
Tools: -

 Tool storage sites are

disorganized & time
wasted searching for
required hand tools
and equipment.
 Due to searching,
motion waste is
inevitable.
 In some cases, hand
tools gets misplaced
leading to requirement
of new hand tools.
 Hand tools are
extremely dirty,
nothing is done to
clean it.

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 Excessive Motion in
Workshop: -

 As hand tools storage sites

are disorganized, workers
need to search for desired
tools, leading to excessive
movement in workshop.

 Due to this unnecessary

movement of workers that
adds no value is “Waste”.

 This is caused due to

disorganized workplace
organization.

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 Presence of Unnecessary
Inventory in Workshop Area: -

 With presence of excess

inventory leads to
accumulation of space in
workshop area.

 Due to the presence of

excess inventory, it hides the
variability and problems and
increases cost of storage and
maintenance issues.

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 Storage of Scraps and Used
Equipment and Tools: -

 Around 20-25 % of total

workshop area is used for
storage of scraps and used
equipment and tools, leading
to space crunch and restrict
free movement of workers.
 Disposal of scraps and used
equipment's aren’t done on
regular basis i.e. need to be
standardize.
 Majority of tools are stored
for future use, but due to
poor maintenance, time,
energy and money is
required.
 It is also non compliance to
safe working environment

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 Shortage of Trained Manpower.

 In current scenario, 10
workshop personnel are
present in workshop area,
divided in 2 work shifts.

 Due to shortage of manpower

leading to work-overload
resulting fatigue and more
prone to work-injury related
issues

 It is seen that, there is excess

motion among workers,
leading to decrease in worker
efficiency & more time period Current Workshop Personnel: - 10 Persons.
requirement for work
completion.  Mechanical = 07 Persons.

 Welding Dept. = 03 Persons.

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 Proper Paper-Work Unavailability.

 Here, workers are conducting

operations without proper work-
orders.

 Workers need to consult with the

supervisor about the job they have
to perform.

 If work-order is available,
information in not properly given
accordingly which work can be
proceeded.

 This leads to waste of time, motion

& miscommunication among the
personnel.

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 TIME STUDIES OF DT&R WORKSHOP

Discussion Equipment
Personal Time: Overprocessing
Time 4% 9%
9%
Unclean
Work
Surrounding
Idle: - s
On Work 15%
29%
58%
Disoragnize
d Tool
Crane Storage
Unavalibilty 46%
10%
Motion
Time Distribution in Workshop Waste
20%

Idle Time Distribution

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Requirement of 5S Implementation in Workshop: -

The 5S Manufacturing concept majorly focusses on: -

 Having proper visual order.

 Proper Organization.
 Maintain Cleanliness.
 Maintain Standardization.

The results we can expect, if the concept is applied in

the workshop are: -

Improved Profitability

Improved Efficiency

Excellent Service

Improved Safety.

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 Proper Tool Box System

 Proper handling of tools in

designated spots with
labelling and should be in
strategic locations for easy
access.
 Tools should be
segregated according to
usage and size for proper
reach and accessibility.
 Maintain tools’ checklist
so as to identify missing
tools from the set.
 Tools should be properly
cleaned to avoid rusting
problems.
 Mobile Toolbox
mechanism should be
used to reduce motion
waste & easy accessibility.

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 Mobile Tools Transfer System:

 Mobile Tools Transfer system

should be used for
storing/transfer of mid range
size heavy equipment.

 This would help in decreasing

crane requirement and will
reduce motion waste, by
storing and transferring all
required tools at one go.

 This would avoid storing

heavy equipment on work-
floor, thus taking valuable
work-space area.

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 Multiple Crane System: -

 Multiple crane system should

be used in a single belt in the
workshop area.

 With this system, time

wastage for crane availability
will decrease to minimum, as
the whole belt area have their
own crane for lifting.

 Also, it acts as a backup

during a crane breakdown or
during crane’s maintenance
work.

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 Equipment Tagging System: -

 Tagging mechanism will help

us to define whether the
equipment is ready for
shipment or requires
inspection.

 Here, the equipment’s

specification and current
scenario can be easily noted
thus avoiding
miscommunication and
motion waste among
workers.

Red: - Equipment requires

servicing/testing.
Yellow: - Equipment under
service
Green: - Equipment ready for
dispatch.

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 Report Panel Boards: -

 In report panel boards,

necessary and required
information should be
present so as to get a better
overview of the equipment
currently undertaken.

 Can be used in the inspection

area, where the inspection
status of the equipment/tool
can be easily known.

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 Trays for Equipment Spare
Parts: -

 Trays for equipment’s spare

parts should be used to keep
the spares which are reused in
different operations.

 This provide better segregation

and organized manner resulting
save of time and motion, due to
search of the spares.

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