work measurement solutions
DESCRIPTION
Started in 2006, by Industrial Engineers with a will to make a difference to the field of Industrial Engineering, SNic India is today India’s leading firm in providing Industrial Engineering Solutions through consulting, IT and outsourcing services with Annual revenues of More than $ 1 Million in 2011 having today 100 plus clientele across India. SNic India has strong base in Industrial Engineering, Operations Management and Supply Chain Management with core expertise in Work Measurement, Simulation Modeling and Planning & Scheduling solutions. SNic India is the All India Representative for Arena Simulation Software by Rockwell Automation, Timer Pro Professional – Work Measurement software and a Solutions Partner to Preactor – Worlds No: 1 Scheduling Software. Consultants at SNic India have a strong background and practical experience in the application of Industrial Engineering tools and techniques, Lean Manufacturing concepts, Simulation Modeling and Operations Management across Manufacturing, IT, and Distribution Sectors. Specialties Work Mesurement Solutions, Ergonomic Design Solutions, Manufacturing Simulation Modeling and Analysis, Line / Flow Balancing, Valu Stream Mapping Simulation, Layout Simulation and Improvement, Preactor Implementation - Advanced Planning and Scheduling SoftwareTRANSCRIPT
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SN Industrial Consultants
Work Measurement Solutions
Contents
Company Profile
Accomplishments
Clientele
Solution Verticals
Case Studies
Plan of Action
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SNic India
Industrial Engineering, Operations consulting & Advanced Scheduling Solutions firm since 2006.
Experience Team of Consulting Engineers with diverse industry sectors integrated with a young pool for highly skilled Industrial Engineers.
Usage & Implementation of cutting edge IT tools and technology for analysis.
Knowledge transfer through a team based approach, equipping client organizations to sustain cost reductions, process improvements and increase in profitability.
Core Expertise in aiding client organizations in Cost Reduction.
YOU SAY IT, WE SOLVE IT
Quality
Cost
Delivery
Technology
Culture
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Work Measurement Accomplishments
Annual Cost Savings of Rs. 57 Lacs per annum Through Cycle Time Reductions, Lead Time Reduction and WIP Reduction.
Plant Capacity Estimation & Simulation leading to Savings of Rs. 2.5 Crore by deferring the new machine purchase
Standard Time Baseline formation correcting Capacity Estimation, Scheduling, Costing, Production Planning and Incentive Scheme.
Manufacturing Process Standardization – Cycle Times, Ergonomics, Work Station Design, Work Instructions for World Class Manufacturing Systems Audit
Waste Identification, Ergonomics, Cycle Time Generation, Line balancing leading to Man, Material and Machines Optimization
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All logos are trademarks of their respective owners
Extended Clientele
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Your Challenge
Identification and Waste Reduction is our Goal
Cost Reduction is the Outcome
Challenge AreasWork Measurement
& Standardization
Effective Capacity Planning
&Scheduling
Inventory Reduction
Increasing On-Time Delivery
Layout Improvement
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Work Measurement & Standardization
Video Time & Motion Study
Estimated Time Study
Work
Sampling
Flow Charts, Control Charts, SOP generation
Manpower Assessment /
Job Evaluation
Ergonomics
Resource Optimization
Assembly
Line Balancing
Supply Chain Alignment
Layout Improvement
Advanced Planning and Scheduling
Scheduling
Software Implementatio
n
Lean Planning
&
Scheduling
WIP
Reduction
ERP Integration
With
Scheduler
Lean Manufacturing
Aids
Value Stream Mapping
Simulation
5s, SMED, Kaizen
Analysis
Waste Identification
software
Cellular Layouts software
Simulation
Modeling
Business Process Re-Engineering
Capital Equipment
Justification
Manpower / Output
Justification
Bottleneck Analysis
SNic Solutions
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Our Assets
Core Expertise on Work Measurement and Lean Analysis Software’s and its usage in all assignments ensuring traceability and validation for the client.
SNic India elemental time database of Elemental times based on MTM standards especially for Indian industries like Automotive, Electrical and Electronics and
Engineering
Expertise on Simulation Modeling and Analysis using Process Simulator and ProModel
Expertise in Successfully Executing Scheduling software Implementations and Integrations.
Ability to execute assignments as KPO/offshore assignments.
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Area of Expertise
• Advanced Planning and Scheduling
• Work Measurement & Lean Analysis
• Lean Concepts Implementation
• Simulation Modelling & Analysis
• Contract Industrial Engineering
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Process Transformation
Optimized Inventory
Optimized Resource Utilization
Reduced Rework / Scrap
Scientific &
StandardizedOperations
MANUFACTURING CASE STUDIES
Work Measurement Case Study - 1
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Business
Case
•The Company was using roughly estimated cycle times for costing, planning, scheduling, and man power calculation and found estimates leading to inefficiencies and tangible losses.
Solution
•Work Sampling, Methods study, Time Study, Ergonomics Study and Lean Analysis.
Outcome
•1/1000th of a second accuracy to establish time standards on a 95% confidence level.
•Increase in manpower efficiency by 7%
•Overall Throughput Increase by 15%
•Reduction in throughput time by 10%
Work Measurement Case Study - 2
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Business
Case
•Standardization, cycle time reduction, resource optimization and Lead time reduction for a Plant having Assembly lines for a UPS Manufacturer who wanted to drastically optimize resources to reduce Input Cost.
Solution
•Work Measurement, Lean Analysis, Bottleneck Analysis, Line Balancing and Value Stream Mapping.
Outcome
•Low Cost Automation to reduce cycle times by 22% of bottleneck areas leading to increase in throughput by 8%.
•Standard times data library for costing, scheduling and efficiency calculations.
•Average Man power reduction of 10% across 41 lines.
•Lead time reduction through Value stream mapping from 60 days to 53 days
Work Measurement Case Study - 3
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Business
Case
• A Leader in the Power Automation Industry, the client providing custom products to its clients was facing a challenge in estimating the completion time, time for rework, manpower planning, lead time, capacity justification, and Testing Capacity Utilization.
Solution
•Work Measurement, Manpower Assessment, Lean Analysis and Bottleneck Analysis.
Outcome
•Estimation of Completion time and rework time at the design stage
•Standardized Working methods eliminating the possibility of operator based rework (about 5% of the total throughput time)
•Increased testing capacity Utilization by 48%
•Reduced throughput time by 13% through reduction of man movement for material procurement
Work Measurement Case Study - 4
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Business
Case
•A Pharmaceutical Client was facing the difficulty in realizing the planned capacity from all it Machines in a particular section of it manufacturing facility. The Challenge was high input costs for the current productivity levels leading to identifying ways of increasing the output and thereby increase productivity.
Solution
•Motion and Time Study, Man Machine Charts, Lean Analysis, Simulation Modeling for bottleneck and throughput analysis
Outcome
•Establishment of Facts governing Production from Each Machine
•Product wise Production Norms for each machine.
•Lean Analysis leading to Improvements in Machine Design leading to an estimated average cycle time reduction across all processes by 11%.
•Identification of bottlenecks through Simulation Modeling representing current scenario and scenario after cycle time reductions giving key inputs to top management on expansion plans.
Work Measurement Case Study - 5
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Business
Case
•Estimated Time study vs. Actual Time study comparison for Vendors of a large automotive unit to revise the financial understandings.
Solution
•Onsite (Vendor) – Video Motion and time study, Quick Time (MTM based) estimations, gap analysis, waste identification, revised costing.
Outcome
• Identification of Gaps between estimated times and actual times at vendor sites.
•Fair assessment and revision of sub-contract rates.
•Increase in Vendor On-Time-delivery from 73% - 92% leading to overall increase in OTD for the client from 60% - 78% .
Work Measurement Case Study - 6
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Business
Case
•Estimated Time study for Greenfield Assembly lines
Solution
•MTM based Motion and time Study using Timer Pro Professional Software & ProModel Simulation for validation of throughput.
Outcome
• 95% accurate Estimated times validated through Assembly line simulation using Pro Model.
•Identification of material and movement constraints leading to effective allowances over and above the estimated studies
NON-MANUFACTURING CASE STUDIES
Work Measurement Case Study - 7
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Business
Case
•A Warehouse of an online retail internet portal was looking to improve its warehouse capacity by identifying improvement opportunities. Using Industrial engineering techniques SNic India was given the task to achieve at least 25% capacity improvement.
Solution
•Identified non-value-added process steps and manually intense materials handling methods that were the cause of bottlenecks and increased product cycle times. A number of process steps were eliminated and/or modified to allow for the design and implementation of an improved WMS and materials handling system. Areas evaluated included: computer systems, warehouse methodology, receiving, quality control, replenishment/put-away, ticketing, put system, pick system, shipping, and returns.
Outcome
•Improve facility capacity 40% by increasing the number of pallet positions and replacing existing racking with new, more space efficient Narrow Aisle (NA) pallet racking.
•Implement pick-to-belt and pick-to-carton for additional sets of case flow racking needed to support picking of all SKUs.
Work Measurement Case Study - 8
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Business
Case
•An Embedded IT Services Development company wanted to reduce the overall lead time of the project which was currently 6 months. SNic India was given the task to study the current system and provide recommendations for lead time reduction.
Solution
•Time and Motion study and Value Stream Mapping were used to Map the existing processes and asses the time for the each process.
•Process Simulator was used to simulate the maps with the cycle times to identify bottlenecks.
Outcome
•Out of 4 Bottlenecks the most critical bottleneck was analyzed using statistical distributions for the bottleneck stations.
•Many process taking less time were clubbed to align to the bottleneck which eventually decreased input cost on the project by 12%.
•Over Lead Time was reduced from 6 months to 3 months by reducing the bottleneck cycle time.
Work Measurement Methodology
Note:
Pilots can be carried out for first time clients, where in a pilot area is identified to carry out the study achieving the required objective during the preliminary visit.
Client bears all the expenses for the pilot except the consulting fees which is to be paid only on satisfactory completion of the pilot as an inculcation into the commercial proposal.
Phase 1• Video Capture –
Methods Study• Methods
Correction
Phase 2• Analyses using
Time study Software
Phase 3• Waste
Identification• Standardization• Recommendation
s
Phase 4 (as per Objective)• Capacity
Estimation• Costing• Scheduling• Manpower
Planning
Phase 5• Coordinating
Implementation• Operator Training• Audits
Video Time Study- Timer Pro Software
• Sampling is done to arrive at the number of cycles for observation after method study.
• Videos of the observed method are imported in timer pro for analysis.
• Operations are broken down into elements.
• Basic elements are classified into Lean categories(VA,RNVA,NVA).
• Necessary Allowances are added to the basic work content.
• Standard Time for the operation is arrived.
Video Time Study- Timer Pro Software
Select video
VA RNVA &NVA Break up
Break up of activities into elements
Cycle time for corresponding element
Screen Shot from Timer Pro Software.
Video Time Study- Timer Pro Software
Report Summary from Timer Pro Software.
Video Time Study- Timer Pro Software
Standard Time report from Timer Pro Software.
Man Machine Charts- Timer Pro Software
Man Machine Chart Screen ShotGantt Chart for Man Machine Activitiesfrom Timer Pro Software
Android Based Time Study – Using PDA’s
• Time Study can be done by installing Timer Pro Software on Mobile Devices (Android & Windows mobiles).
• Screen Shot from the Android mobile is as shown.
• By clicking the Timer Pro icon on screen the application is opened.
• Last used study is selected to open a dynamic Timer Pro Screen to start time study.
Android Based Time Study- Using PDA’s
PDA Time Study- Using PDA’s
• Click on the Start tab to run the predefined sequence of elements and start stopwatch.
• By clicking on the Sub tab the element is stopped and next element is started.
• Results from the PDA based Time Study can be downloaded to the PC is Excel Format as Standard Time Report.
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SNic India#831/60, 1st floor,
4th Main, Vijay Nagar,Bangalore 560 040
Ph: +91 80 4127 5612 / 98459 09492Email: [email protected]
Business Hours: 9.30 am – 05.30 pm (Mon-Fri)
For Business Inquiries, References and Testimonials visit www.snic.co.in