Anda di halaman 1dari 8



The proposed project is concerned with work to be carried out at a XXXX Company. The company is in the business of manufacture of XxXXX for XXXXXXXXXXXXX industry (or XXXXXXX product) .The proposal is to work on one module (or line or equipment or plant) where xxxx product groups are manufactured or processed or maintenance carried out. The preliminary focus is on the problems faced by the company listed below: falling short of XXXXXXx(customer demand, power requirement, output, etcc) cycle time of few operations like high compared to competitors bottlenecks quality / customer complaints.

XXXXX Ltd is a division of a larger group of companies head quartered in XXXX. They also specialize in manufacture of XXXXXXXXX, yyyyy, zzzzzz etc. The total turnover of the group is US$xxxx million, while XXXXX, during the same is US$31

million. The XXXXXXXXl division has 4 plants located in the southern states of India with total workforce of 825 people. Company XXX, manufacture XXXXX for HCV, LCV & passenger cars, disc pads for two wheelers, composite brake blocks for railways and clutch facings (moulded & cord woven) for HCVS & LCVS. The product range offers both asbestos& non asbestos products. XXXXXXXXXs clients in India are as follows: Toyota motors, Suzuki, Hyundai motors, Mahindra & Mahindra, Ashok Leyland, Tata Motors and Eicher Motors. They also export to countries like USA, UK, Australia, New Zealand, Dubai, Kuwait, Saudi Arabia, Singapore, Indonesia, Turkey, Sri Lanka, Bangladesh and Africa. XXXXXXXX was certified with ISO 9001(since 1993) & ISO 14000(since 2002). They received the prestigious XXXXXXX prize given by the Japanese union of scientists & engineers for total quality management practices.

XXXXXXXX Limited is facing the following difficulties with regard to productivity. Customer demand is not getting fulfilled Cycle time of some operations is greater required Quality rejection (28%)

The company obtains schedule from customer by the last week of the month or max by the first working day. If they are not able to fulfill the customer demand it will be further added to next month schedule. So, it will be further burden to production department. Moreover, the cycle times of some operations is more than the takt time,

which stacks up inventory at some work stations and creates disturbance in the line. One more factor that is affecting productivity is XXXXXrejection, which is 28% of overall rejections.

Before proposing any methodology for problem solution, understanding the process itself is necessary to determine the system boundary, input variables and decision parameters. The following discussion highlights the process carried out at the study site and eventually, establishes the scope of this study. As mentioned earlier, this study was carried out at XXXXX Company. Henceforth this location will be referred to as study site. They are seven Production modules AAAAAAAAAAAAAAAAAAAAA BBBBBBBBBBBBBBBBBBBBBBBBBb CCCCCCCCCCCCCCCCCCCCCCCCCCc DDDDDDDDDDDDDDDDDDDDDDDDDDDDDDDD EEEEEEEEEEEEEEEEEEEEEEEEEEEEEEE FFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFFF GGGGGGGGGGGGGGGGGGGGGGGGGGGG Presently I am working in CCCCCCCCCCCCCCCCCCC Module BasicproductionFlowchart The following is the sequence of operations for the production of XXXXXXXXXXXX








Fig 1 Production Flow Chart Descriptionofeachoperation Step-1: Various Ingredients are mixed in definite proportion by weight in a lodigie mixer with particular time Step-2: It is a process where definite weight of mix is pressed under pressure to get required size and shape Step-3:

It is a process where Preform cake is cured under temp and pressure for fixed time in the relevant moulds. Here the physical and chemical properties are build in to the product. Step-4: In the Process the cured blocks are baked under specified temperature and time to further consolidate the physical and chemical properties Step-5: In finishing operation Blocks are cut into customer specified dimensions Finishing has operations as specified in Fig-2

Fig 2 Finishing process flow chart

The principle objective of this study is to reduce the ideal time and minimize the XXXXX rejection which mainly contributes productivity. The steps to achieve the above mentioned objective are as under: 1) To investigate and understand the existing operation procedures at the project site with focus on requirements and determine the scope of study. 2) To study the available research literature on the subject and determine a solution methodology, in accordance with the scope of study established, to tackle the problem. 3) To determine the input and decision variables to be analyzed; based on the methodology chosen. 4) To collect relevant data, based on variables determined. 5) To analyze the data and suggest actions to mitigate risks identified.

Douglas C.Montegomery & George C.Runger, Applied statistics and probability for Engineers Book gives an idea about statistical techniques like Pareto analysis, Histograms, cause and effect diagrams, Control Charts, Run charts, Flow charts and Scatter Charts.

The machine that changed the world by James P. Womack and research paper Theory of constraints and Lean Manufacturing by Richard Moore and Lisa Scheinkopf. From this book and paper, I got idea about Lean Fundamentals like Value stream, Value flow, Pull, Takt time, Single piece flow, Kaizen and Continuous improvement. Industrial Engineering and Management by O.P.Khanna and Some of the simple heuristics for line balancing are HelgesonBirnies [1961] positional weight method, MoodieYoung [1965] method, Immediate Update First-Fit (IUFF), Rank and Assign (RA) Heuristic, Hoffmann algorithm. From this book and paper, I got idea about line balancing.

The Methodology proposed revolves around determination of the values for various variables in the System study. To achieve this, the following methodology is proposed: 1) Physical observation 2) Data for Idleness is collected from PPC system. 3) Line Balance study 4) Pareto Analysis of Rejection Data 5) Pareto Analysis of Idleness

At the end of this Study we intend to achieve the following: 1) 2) 3) 4) Idle time Reduction Increased utilization of the line Reduction of XXXXX rejection (28% to 10%) Line efficiency increases