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RELAX Reduce Lead time at company X ISE 250 Course Project

RELAX Reduce Lead time at company X ISE 250 Course Project. Sponsor: Executive Director, Diesel Fuel Injection pumps Dept Owner: Assistant Manager, Plunger Dept Coach: Dr. Baruch I. Saeed Team Members: Nazia Farooqi, Karpaga Sundari Revathy, Neelima Maganti, Sweta V Chegu. Background.

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RELAX Reduce Lead time at company X ISE 250 Course Project

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  1. RELAXReduce Lead time at company XISE 250 Course Project Sponsor:Executive Director, Diesel Fuel Injection pumps Dept Owner: Assistant Manager, Plunger Dept Coach: Dr. Baruch I. Saeed Team Members:Nazia Farooqi, Karpaga Sundari Revathy, Neelima Maganti, Sweta V Chegu

  2. Background Company X produces various automobile parts: • Fuel Injection Pumps • Spark Plugs • Auto Electricals Fuel Injection pump -- 81% of the market share Plunger is an important part of the fuel injection pump Plunger & Barrel - Element Different types of Plungers: Type A, B, K & Q Type A plungers – 85% of total production. Project concentration – Type A Plungers

  3. DEFINE

  4. Charter

  5. Charter

  6. Is & Is-Not Analysis

  7. Involvement Matrix

  8. Involvement Matrix (Cont’d)

  9. CAP Chart

  10. CAP CHART (CONTD.....

  11. Gantt Chart of Project schedule

  12. Steps in Plunger Production Plunger Production Soft Stage Heat Treatment Stage Hard Stage

  13. Process Steps for Hard Stage Pre-Dia Grinding Brushing Top Surface Grinding Alkedox cleaning Final Dia grinding Inspection Throttle groove grinding Repair Vanegrinding Stop Groove grinding

  14. Process Flow Diagram

  15. CTQ Tree

  16. Kano Model

  17. MEASURE

  18. Balance Score Card Internal Business perspective Customer Perspective Financial Perspective Innovation & Learning

  19. Data collection summary

  20. PARETO CHART(CONT)

  21. ANALYZE

  22. Cause and Effect Diagram

  23. Cause and Effect ( contd..)

  24. IMPROVE

  25. FMEA ChartProject: RELAX Team: Karpaga, Nazia, Neelima, Sweta Date:3/7/2006 (original)

  26. FMEA Chart (Cont’d) Stop Groove

  27. FMEA Chart (Cont’d)

  28. Affinity Diagram

  29. Affinity Diagram (cont’d)

  30. CONTROL

  31. Prioritization Matrix

  32. Prioritization Matrix (Cont’d)

  33. Prioritization Matrix (Cont’d)

  34. Plan –Do-????

  35. Implementation Gantt Chart

  36. Program and Project Success factors

  37. Program and Project Success factors

  38. Line balancing

  39. Line Balancing (Cont’d)

  40. Summary

  41. Summary (Cont’d)

  42. Summary Total output per day = 14500

  43. Conclusion A thorough investigation of the problem indicates that some of the important factors that contribute to a high lead time are: • Imbalanced Line • Improper binning & storage • Bad maintenance programs • High set up times • Workers – being casual labor/regular labor Our recommendations include: • Balance the line identify four separate lines • Employ kanban systems • Schedule maintenance programs • Reduce setup times by planning the production schedule • Increase the number of regular employees • Use control charts to ensure the manufacturing process is in control

  44. Appendix

  45. PARETO CHART

  46. Time Study chart

  47. Calculation Of Lead time:

  48. Benchmarking & Inventory Turns Benchmarking is the process of determining who is the best? How good are they? And how do we get that good? Since Plunger is not a FINAL product, we cannot do benchmarking. We cannot get data for intermediate stages of production costs. However, we can benchmark the Final product (Fuel injection pump). This is beyond the scope of the project. We do not have access to data from other departments. Inventory Turns: Similarly, we cannot calculate inventory turns since, Plunger is not the final product. We cannot calculate the cost of goods sold for Plunger. The selling price of Fuel injection pump may be obtained, but is beyond the scope of our project. We do not have access to this data.

  49. House of Quality The team tried to implement House of Quality, but the tool was not really applicable to the project.

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