Refrigerator Cell Design Appliance Cell Design, 08

Objectives :

 Lead Time Improvement

 Streamline the process

 Enhance Productivity

 Better Quality product to compete.

Value Industries Ltd

Project Need Appliance Cell Design, 08

 VA & NVA Analysis

Value Added Movement

5% Loss
Inventory

Wrong
Defective
Methods
Product

Over/ Less ; Rework &

Early/Late Waiting Loss Rejection
Production
Value Industries Ltd
Roadmap Appliance Cell Design, 08

 Organizational Announcement

 Core Team Formation

 New Project  Plan segment for improvement

 Strategic Implementation
 Benefits & Celebrate

 Evaluation of the objectives

Value Industries Ltd

Strategy Appliance Cell Design, 08
 Organizational Announcement

 Clarity Of Vision to all concerned Person at common background

 Target setting.
 Better communication.
 Resources Availability

 Core Team Formation

Sr Department Availability Remark
1 Process Full Time Coordination
2 Operators (2) Full Time Positive attitude carriers
3 Fabricators Full Time Improvement activities
4 Production As Required Concern Engineer & HOD
5 Maintenance As Required Support Function
6 HR As Required Improved Communication
7 QA As Required Better Quality

 Plan cell (segment from line) for improvement.

 Discrete & micro focus by splitting the line in various segments

 Better understanding of process for smaller cells.
Value Industries Ltd
Strategy Appliance Cell Design, 08

 Strategic Implementation.

(C) Workstation Standardization

Tool : 5 S
 Improved workstation & healthy working atmosphere
 Ergonomic & safe working layouts.
 Operations with least efforts.

(B) Material Standardization

Tool : Process Mapping
 Right material; Right location & Right Container
 Optimized Material Handling.
 Enhanced VSM

(C) Process Standardization

Tool : Lean Manufacturing & Line Balancing
 VA & NVA analysis of the process.
 Easy & Equal amount of work to all.
 Implementation & operations balancing.

Value Industries Ltd

Scheduling Appliance Cell Design, 08

03.10.08

06.10.08

09.10.08

12.10.08

15.10.08
01.10.08
02.10.08

04.10.08
05.10.08

07.10.08
08.10.08

10.10.08
11.10.08

13.10.08
14.10.08

16.10.08
17.10.08
18.10.08
19.10.08
20.10.08
Sr Activity

1 Inauguration
2 Team Formation
3 Brainstorming & Training
4 Planning & Scheduling
5 Process Mapping
6 Relayout & Improvements
7 Material Flow analysis
8 Improvements & Standardization
9 Training for work study
10 Cycle time measurements
11 VA / NVA analysis
12 Lean implementation
13 Operations Balancing
14 Time study after balalcing
15 Re-balancing (If Required)
16 Work Instruction Notes
17 Documentation
18 Rewards & Recognition

Value Industries Ltd

Process Mapping Appliance Cell Design, 08

Process Mapping Symbols Map Analysis

Value Industries Ltd

TOS Template Appliance Cell Design, 08
VALUE INDUSTRIES LTD

TI ME OBSERVATI ON SHEET
Date: / / 200

Area:______________________________ Section:_____________________

Process Name:________________________ Study By :___________________

Time Observations Sorting

Sr No Element Description
1 2 3 4 5 Avge VA/NVA

10

11

12

13

14

15

Total

Checked By

Value Industries Ltd

Lean Technique Appliance Cell Design, 08

Value Industries Ltd

Thumb Rules Appliance Cell Design, 08

 The best result is observed working in team only.

 Define the problem clearly and identify the criteria to be met

 Stay Focused on the problem

 Ensure no one criticizes or evaluates ideas during this session.

 Encourage enthusiasm, uncritical attitude in the group

 Try to get everyone contribute including the quiet members.

 Let people have fun & like their work.

 Welcome Creativity.

Value Industries Ltd

Key To Success Appliance Cell Design, 08

Value Industries Ltd