Lean Manufacturing - Stores

SN
1
2
3
4
5
6

Elements
Workstudy for Material Feeder person
Current state data collection for Stores
& PPC
List of items data collection
Space utilized measurement
Makigama
Material/man movement path within
factory
3C/Triple C/ unpacking/2bin system
7
action plan
8 Distance travelled by feeder person

Lean Manufacturing - Stores

Method for collecting data
Target Date
Video shoot & process study
Gemba
As per actuals in system
Any distance measurement tool
Gemba
Spaghetti Chart
Gemba
Pedometer

Dadra

Wada

HP2

Ahmedab
HP1
ad

BLUE STAR LIMITED

Purpose: VSM and VSM Metrics cretion for stores.
CURRENT STATE MAPING OF STORES
Sr.No.

Parameter

1
1.1
1.2

Inventory
Raw Material
Finished Goods

2
2.1
2.2

Floor space used ( foot print - not

verticle )
Raw Material
Finished Goods

3
3.1
3.2

No of material handlers in a day

Feeders
Feeder Supporters

4
4.1
4.2

5
5.1
5.2
6
6.1
6.2
7

Unit

Sq Meter
Sq Meter

No.of parts handled in a day

( Variety of parts handled in the
entire day min & Max )
Feeder
Feeder Supporters

Value Rs.

5539
1867
Assembly line 1
2
1

Work content in a day

Feeder
Feeder Supporters

Stores

Minutes
Minutes

Operator
1(Name)
350
300
Operator
1(Name)

Nos.
Nos.

15
3
Operator
1(Name)

Distance travelled in a day

Feeder
Feeder Supporters

Kms
Kms

Different variety of bins in which

material is fed to assly lines

Nos.

25

50% standard /
50% non
standard
locations

nos

25%

No of non standard location

How many parts delivered without

3C
Constant container

Constant qty

nos

Costant locaiton

nos

What is the oldest material locked

& how long

No part
delivered with
constant qty
40%

Part code RCSL-BPV1706D-00

Value
No of days

22.74 Lacs.
4 Yrs

11

How many parts are ready to use

condition without unpack in stores

Nos

No parts are
ready to use
condition in
stores

12

No. of parts fed to Assly duly unpacked

Nos

ion for stores.

TORES
Stores
No.of days
Inv.

Inv. Turn.

Assembly
line 2
2
1
Operator
2(Name)
310
400

Operator
3(Name)
420
400

Operator
2(Name)

Operator
3(Name)

Operator
2(Name)

Operator
3(Name)

1706D-00

measure the work content of individual material handler, M

Material Feeder Name:
No of variety of components handled :
SN
Activity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Time Start Time End

37
38
39

erial handler, Measure the Value added and Non Value adde
Products: DSA661 IDU
Assembly line :
OPERATOR
Load

Unload

Transport

n Value added Time, Type of waste and analysis. Kindly draw

R
Search

Rework

Downtime

Kindly draw the Spagatti Diagram (Material handler Loop

Ideal

Distance
travlled in
meters (if
applicable)

Observer Name :
Date :
Notes
(observations/improvement
ideas during proces
study/Wastes identified)

Purpose : To understand the op

max. 2 Hour
inventory on
line

Two bin
System

Unpacked/rea
dy to use
material

Compress
or

Yes

Yes.
2 pallet on
Assembly line

No.

Fan Motor

No

No

Stage
No

Part

Base
Panel
Loading

Fan
motor
assembl
y

NO.

Control
box
assembl
y

Control
box

Fan
blade
Fan blade
assembl
y

NO

2 trolleys
available

NO

No

1 on assembly
line & 1 trolley
in stores

Yes

Others

Overall
actions
required

nd the operator irritations/Unspoken issues whic

3C

Triple C

Constant
Container

Constant
Quantity

Constant
Location

Count
free

Yes. Compressor
supplied on
pallet as
received from
supplier.

Yes

No

Yes

No

No

No

Yes

No

No

Marking to be
done

No

Yes

No

No

No

ken issues which cause Quality/working speed/S

Triple C

Contact
Free

Ergonomics
Distance from
operator
position (No
Contaminant
Weight of the
of Steps or
free
component
Meter) use
any one unit
of measure

No

Yes

No

Yes

No

No

Yes

Yes

rking speed/Safety issues.

omics
Operator
Bend/Arise
Required?

Action Reqd on
Responsi
points with non
bility
compliance
Compressor
storage area
marking to be
done on
assembly line
Compressors
need to come
unpacked from
Fan
motor trolley
stores
#02 (32nos)
1 on assembly
line & 1 trolley in
stores

Avinash
J/N M Rao

Target
Date

9-Apr-16

N M Rao

30-Apr-16

N M Rao

8-Apr-16

Trolley parking
location to be
defined when not
in use
N M Rao

8-Apr-16

Unpacking to be
done before it is
supplied to
assembly line
* Extra lug
cutting & new
lug crimping
activity to be
studied

N M Rao

22-Apr-16

Toda
y
Statu
s

Unpacking
location to be
defined

N M Rao

13-Apr-16

Unpacking
responsibility to
be defined

N M Rao

22-Apr-16

Area for packing

waste storage to
be defined
N M Rao

22-Apr-16

marking for fan

motor trolley
storage area on
assembly line to Avinash
be
donebox PPH J/N
M Rao
8-Apr-16
Control
Nilesh
bins with
Patel/ N M
partition from
Rao/
Implemen
supplier (36#)
Avinash J ted
marking for
control box
storage on
assembly line to Avinash
be done
J/N M Rao
8-Apr-16
Process of
Nilesh
returning empty Patel/ N M
boxes to be
Rao
8-Apr-16
defined
Trolley storage
location to be
defined on
Avinash
assembly line
J/N M Rao
8-Apr-16
Unpacking
location to be
defined

N M Rao

22-Apr-16

Unpacking
responsibility to
be defined

N M Rao

22-Apr-16

Area for packing

waste storage to
be defined.
Proposal to be
prepared for
management
Training to
operators for
2hrs inventory/
3c & triple C to
be given

N M Rao

22-Apr-16

Wasif
Sayed/N M
Rao
13-Apr-16

Training to
PPC/Stores for
Wasif
VSM to be given Sayed
skilled manpower
required for
better planning
of material
feeding on
assembly line
Frequent change
in production
plans to be
prevented, to
smoothen
material supply
on assembly line

13-Apr-16

To be
decided

To be
decided

Sr
Name
no.
1 Alok jha
2 Krupesh Patel

3 Krupesh Patel

4 Vijay Varali

Purpose: Backup for Before after comparison and Work Balancing

No. of
Distance
Height
Date
steps
(km)
177 inch
12.04.2016
5175
3.91
168 inch
13.04.2016
9015
5.95

168 inch

14.04.2016

10559

7.025

15.04.2016

13103

9.67

on and Work Balancing

Model
DPAP661R1-O
DSW361R2-O
DSW 361R1-OA
DSW 661 R2-OA
DSW 661 R1-O
DSW 1052 R1DSW 1322 R1DSW 1322 R2-O
DSA661R1-OA
DSA661-K
DSA361R1-IA
DSA361R2-I
RUAHOP0614
RUAHOP1014
RUAHOP1514
RUAHOS2014

Assly line
G -0
G -3
G -3
G -3
G -3
G -3
G -3
G -3
G -3
G-2
G-2
G-2
G-2
G-2
G-2
G-2
G-2

No of
variety of
component
11

VALUE STREAM MAPPING : (PART Name:

Deleted

PRESENT PROCESS MAPPING

Activity

04/22/2016

VA NVA (waste)

NVA but
necessary

Where

Who

Qty./ Batch
size

Remark 1

TIME FOR
ACTIVITY
(sec.)

DISTANCE
TRAVELLED
IN MTRS.

WIP

NO.OF
M/CS /
EQUIPMENT
S / BW

Total
Total mins.
Total hrs.

0
0
0

Activity

Process
change
P
r
o
c
e
s
s
NVA but
VA NVA (waste)
necessary
c
h
a
n
g
e

Location change

Aiming for deletion

Value added

PROPOSED PROCESS MAPPING

Where

Who

Qty.

Remark 1

TIME FOR DISTANCE

ACTIVITY TRAVELLED
(sec.)
IN MTRS.

Total
Total mins.
Total hrs.

0
0
0

34/40

0
1.6 KM

NO.OF
M/CS /
WIP EQUIPM Remarks
ENTS /
BW

hcl263/c/Lean Manufacturing/315441112.xls

Purpose: To understand the curreent inventory condition ,Ho

Level 1 exercise: Start with A & B Class Parts. (ABC & Runner/Rep

SN

Item Code

Descripti
Inventory
Category
on
in nos

MOTOR
1 MOAC-F001014-002
GE
DC403T

Motor

764

Total
value

899992

d the curreent inventory condition ,How we can reduce,where to start and identify the low hanging fruits
& B Class Parts. (ABC & Runner/Repeater/Stranger Classification and Clearity is required before collecting data)

Vendor
Marathon
electric India
pvt ltd,
Faridabad

Lead Time
without
Forecast

% of Supply
Adherence
against
leadtime

Vendor
Distance
from
factory
(km)

Supplier
standard
packagin
g

1278

80

MOQ

ruits
ollecting data)
For how Many
runner models
this part (item
code) is
applicable

Min
Required
quantity
per model

Min
Required
quantity
per model