BEHR INDIA LIMITED PUNE

Value Stream Analysis of Processes and Use of Six Sigma Methodology for Improvement of Layout

Submitted ByAbhishta401007002

Submitted To

Dr. Vipul Gupta

L.M. Thapar School of ManagementThapar UniversityDera Bassi Campus Table of ContentsAcknowledgement1-3Company Profile1-41.About the Project1-52.Value Stream Mapping2-62.1 What is value?2-62.2 Current State Map2-72.3 Value of a Heat Exchanger2-83.Project3-103.1 Methodology3-103.1.1 Define3-113.1.2 Old Layout3-123.1.3 Measure3-123.1.4 Analysis3-133.1.5 Improve3-153.1.6 Control3-16

Acknowledgement

The splendour and exquisiteness that accompany the successful accomplishment of any task would not glorify if there is no expression of gratitude to the people who made it possible. So with due humility, reverence, veneration and honour I acknowledge all those whose guidance and motivation have marked the triumph and attainment of the project. I am thankful to my teachers Dr. Vipul Gupta and Prof. Kannan for giving me this opportunity to explain the work done by me at the firm.

Company Profile

Behr GmbH & Co. KG, Stuttgart, is a systems partner of the international automobile industry. A specialist for automotive air conditioning and engine cooling systems, the Behr Group is one of the worlds leading manufacturers and suppliers of original equipment for light vehicles and trucks. Group sales in the 2011 business year came to EUR 3.7 billion. Currently, Behr employs some 17,400 staff at 36 production locations and 17 R&D centers worldwide. Since its foundation in 1905, Behr has developed from a small family-owned operation into a globally active automotive industry supplier that is active worldwide - with continually increasing success. Today, the Behr name is synonymous with a seal for future- oriented innovations and top-quality products.

Anand is known for its established and successful partnerships with leading global automotive front runners, each one being a global leader in its area of operation. The group has 15 Joint Ventures and 6 Technical Collaborations with these world leading companies.Today, with nineteen companies spread across 49 locations and eleven states of the country, Anand also has a business vertical operating in the area of Luxury Hotels. Anand has provided a number of technology firsts to the Indian Automotive Industry over the five decades of its existence starting with being the pioneer of Ride Control products in the country.

About the Project

The project Value Addition in Assembly Processes is about studying the various processes in the assembly line and then improving either the process or the machine so that it is able to add maximum value to the product. Improvement in the process involves improving the line layout or the way in which the operations are being carried out.

Value Stream Mapping

Before understanding value stream mapping we should understand what we mean by the term Value.2.1 What is value?A product or service is generally considered to have good value if that product or service has desired performance and appropriate cost. Or, by reverse definition, a product or service is considered not to have good value if it lacks in either desired performance or appropriate cost. It can almost truthfully be said that, by this definition, value can be increased either by decreasing the cost or increasing the performance. More precisely: Value is always increased by decreasing costs (while, of course maintaining performance). Value is increased by increasing performance if the customer needs, wants, and is willing to pay for increased performance.alue Increasing PerformanceFigure 1: What effects Value

2.2 Current State Map

A current state value stream map is basically a diagrammatic representation of how the material flows from one process to another gaining value. The input comes from the suppliers and the final finished product is sold to the customer. The basic necessity of making a current state map is to visualize the lead time and the success in the application of lean manufacturing is represented by how much we are able to reduce this production lead time. As a part of my project I made a current value stream map for the CAC assembly line. The charger air cooler assembly line has the following processes: Core Building Brazing Crimping Leak Testing Fire Wall ShippingIt was interesting to note that Behr India was successful in implementing sequential pull. The increase in the production lead time is only because of the time for which the brazed cores were kept in the super market.For the current value stream map I got the data by requesting the production control department of the company.The details that I was able to show in the current value stream map were:

Cycle Time Takt Time Setup Time Up time Scrap Percentage Rework PercentageAs explained earlier that the production lead time depended upon the customer requirements hence a time line was not shown in the chart.Now we should understand how the value of a Heat Exchanger is defined.2.3 Value of a Heat Exchanger

Radiators, CACs and Condensers cool down the air that passes through it. Hence value of the product is in how effectively the product cool down the heated up medium. It basically depends upon the amount of air that comes in contact with the cooling portion of the product in one unit time and the material of the product. Hence increase in surface area would result in more volume of air getting cooled down per unit time. So, all of these products have a basic structure of fin tube matrix allowing a very large surface area to come in contact with the air. All of these products are made up of aluminum as it is a good conductor of heat and is also cost effective as compared to copper. As a matter of fact copper radiators also exist in the market.Secondly the air that is an input to the device is needed back by the system for cooling, hence it is very important that during the cooling procedure minimal amount of air is lost. For this brazing of the core is done. As for a fact we cannot achieve zero leak hence it is taken care that the leak remains on the lower side.Finally as all these products are manufactured for the automotive industry hence there performance should not be affected by shocks and jerks during the travel; thereby strength of the joints and proper crimping of the manifold to the header adds value.Summarizing it all we can conclude that the value of radiators, CACs and condensers depend upon the following properties: Surface area and the material used. Leak proof nature. Joining at the contact point of tubes and fins in the matrix. Overall strength of the product against the shocks and jerks.

Figure 2:Current State Value Stream MapProject

3.1 Methodology

The methodology used to execute the project is derived from the way in which six sigma improvement projects are executed. Hence the methodology used in the projects can be abbreviated as DMAIC. The six sigma approach has been adopted worldwide in the manufacturing sector in order to enhance productivity and quality performance and to make the process robust to quality variations.Six Sigma is considered as a methodology of implementing total quality management. It is an innovative approach to continuous process improvement and TQM methodology. Since quality improvement is the prime ingredient of TQM adding a six sigma program to the companys current business system covers almost all the elements of TQM. Six Sigma has become much broader umbrella as compared to TQM.3.1.1 Define

The existing layout of the post brazing process of the radiator line was to be changed. The new wheel crimping machine was to be introduced in the new line. I will first be introducing the old layout and the processes involved so that we understand how the product is being assembled step by step. The new layout had to be designed keeping in mind the following constraints. New wheel crimping machine to be introduced. Least number of machines to be moved. Maximum utilization of the area available keeping in mind the future expansions.1.1.1.1 Process

3.1.2 Old Layout

3.1.3 Measure

This phase of the project was completed with the help of a meter tape. The dimensions of all the stations of the assembly line had to be taken and then had to be represented with the help of auto CAD. The dimensions of bins, gibos and in process inventory racks were also taken to calculate the space available for material and man movement. The following measurements were taken into consideration: Measurement of the area required for existing stations. Measurement of the new wheel crimping machine. Measurement of bins and racks on the assembly line. Estimate the measurement of future stations. Estimate the area required for man and material movement.Movement of the die takes a lot of space. For man movement a space of .25 sq meters (.5m x .5m) was taken to be sufficient. 3.1.4 Analysis

Analysis of the old layout was done and it was found that most of the poorly utilized space was because of the following reasons: Tool racks on the shop floor. Dies of the hydraulic die crimping machine.The new layouts were made considering the following requirements: New crimping machine was introduced in a new line. Racks were shifted to make space. Some dies were also shifted as they were no more to be used. The fire wall was placed in such a way that it could serve two lines.In this way six new layouts were suggested over the existing one. Decision of the chosen one was made on the following criteria: Minimum change in the present layout. Optimal material travel. Optimized use of available area.

3.1.4.1 New Layout

3.1.5 Improve

The new layout has been practically implemented with the help of the members of the manufacturing engineering department. The new layout implemented has given a dedicated line for the production of ace radiator and hence improved the line in the following ways: The setup time of the new wheel crimping machine is low. Efficiency and reliability of the line has increased. Increase in production rate of ace radiator by 40% in a single shift because of a dedicated line. Now the hydraulic crimping machine is less loaded. Better utilization of the available space. Creation of a new line has in a way increased capacity for future projects.

3.1.6 Control

This segment of the project will always need our attention as there will always be a scope of improvement. I hereby present a solution for further improvement in the layout and design of the stations.If the bins and gibos are kept at such distances from the operator that they are under his reach then there will be less fatigue for the working person.

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