A Study on Effective Space Optimization & Time Reduction in Part Feeding System

Objectives of the project

To reduce the overall delay time (DT) in the part feeding system. To design the layout models for storing cases in warehouse and in assembly

stores. To reduce labor's walking time during unpacking cases. To reduce the materials replenishment time in frame assembly .

-Deecan Sanyo Chillachi A.,MBA 2013-2015, Operations.

Process flow diagram of part feeding activities

Process flow diagram includes various processes from moving cases from 40’’ shipping containers to replenishing materials in assembly line.

Identification of the overall problem

The first two process accounts for approx. 64% of delay time (DT)

The rest of the processes accounts for approx. 36% of the delay time(DT)

Majority of the problem is caused by the first two process

*Graph 1 – Pareto chart

Analysis of the problem

Process C – Rearranging, Sorting & Transferring D-MAX Cases before Unpacking

► Problem Identification ► Reasons for the problem

► Prevent the problem

Process time (PT) – approx. 91 Mins

► ResultsProcess time (PT) after proposing layout model for storing cases – approx. 23 Mins

Time Reduced by 76% - 68 Mins

Process C – Rearranging, Sorting & Transferring Pajero Sport - CR45 Cases before Unpacking

► Problem Identification ► Reasons for the problem

► Prevent the problem

Process time (PT) – approx. 200 Mins

► ResultsProcess time (PT) after proposing layout model for storing cases – approx. 51 Mins

Time Reduced by 74% - 149 Mins

Process A – Moving D-MAX & CR-45 Cases from Shipping Containers to Warehouse & Assembly stores

► Problem Identification ► Reasons for the problem

► Prevent the problem

Process time (PT) – approx. 58 Mins

► Results

Process time (PT) after proposing layout model for storing cases – approx. 42 Mins

Time Reduced by 30%

Process - D Unpacking D-MAX Cases in Assembly Store

► Problem Identification ► Reasons for the problem

► Prevent the problem

Process time (PT) – approx. 221 Mins

► ResultsProcess time (PT) after proposing layout model for storing cases – approx. 169 Mins

Time Saved by 23% - 51 Mins

Process - D Unpacking Pajero Sport CR-45 Cases in Assembly Store

► Problem Identification ► Reasons for the problem

► Prevent the problem

Process time (PT) – approx. 225 Mins

► ResultsProcess time (PT) after proposing layout model for storing cases – approx. 154 Mins

Time Saved by 39% - 100 Mins

Process E & F – Parts Feeding to Assembly line & Remodeling Material Storing Shelf ‘s

► Problem Identification ► Reasons for the problem

► Prevent the problem

CT – 394, PT – 343, DT - 51 Mins

► ResultsWalking time (WT) before proposing shelf design – 47Mins, Walking time (WT) after – approx.25 Mins

Time Saved by 48% - 22 Mins

Overall Improvement Results

22.3 Total DT = 601 MIN

214.1 296.4 652.3 324.46 47.49 Total CT= 1487 MIN

168.87 296.4 476.41 324.46 47.49 Total PT= 1314 MIN

123.53 79.17 324.89 192.4 25.11 Total PT= 745 MIN

Process time = 47.49 MIN

Moving cases from container to warehouse

No cases moved

45.34 217.23 175.92 140.6

No cases moved

Before proposing the overall improvement techniques

144.35

Cycle time = 58.14 MINProcess time = 41 MIN

Improved PT = 25.11 MINTime saved after

increasing storage pallets in frame

assembly

48%

Process EMaterial feeding activity in

frame line

Process time = 324.46 MINImproved PT = 192.4MIN

Process A

83.83 MIN

Process cSorting, rearranging,

transfering cases before unpacking for D-MAX model

72.88 MIN

140.6 Min

Process FStorage pallets increasing &

reducing replenishing time in frame assembly

Sorting, rearranging, transfering cases before

unpacking for CR-45 model

Process time= 200.45 MIN 92.09 MIN

Process DUnpacking D-MAX cases in

assembly store and seperating acc. to stage wise

cycle time = 305.15 MIN

Time saved after using trolly's & other vehicles =

23%

Improved PT = 169.9 MINTime saved = 51.4 MIN

Process time = 221.31 MIN

cycle time = 347.20 MIN

process time = 95.95 MINImproved PT = 23.07 MIN

Time reduced after proposing the storage layout

model =

76%

Time saved = 100.11 MINTime saved after using trolly's & other vehicles =

40%

Improved PT = 154.99 MIN

Unpacking CR-45 cases in assembly store and seperating

acc. to stage wise

Process time = 255.10 MIN

By implementing proposed layout rearranging & sorting

time can be reduced

Rearranging time

Cycle time = 156 MINProcess time = 127.87 MIN

Process BMoving cases from warehouse

to assembly store

Delay time

Time saved in rearranging cases

after proposing storage layout

model =

30%Delay time

Moving cases from container to assembly store

Process A

28.2 MIN

17.14 MIN

No cases moved

After proposing the overall improvement techniques

Improved PT = 56.1 MINTime reduced after

proposing the storage layout

model =

74%

Process Time(PT) before implementing proposed models – approx. 1314 MinsForecasted Process Time (PT) after implementing proposed models – approx. 745 Mins

Total Time Saved by – approx. 43% - 569 Mins