Application of Lean Manufacturing Principles for ...

5th National Conference on “Recent Advances in Manufacturing (RAM-2015)”, 15-17 May, 2015

Application of Lean Manufacturing Principles for Process Time Reduction- A Case of Conveyor Pulley Manufacturing Purvi Chauhan1, Shyam Rangrej2, Kaustubh Samvatsar2, Saurin Sheth3 1Assistant

Professor, Production Engineering Department Birla Vishvakarma Mahavidyalaya, V.V.Nagar-388120 E-mail: [email protected]

2UG

Students, Production Engineering Department, Birla Vishvakarma Mahavidyalaya, V.V.Nagar-388120 E-mail: [email protected]

3Associate

Professor Mechatronics Engineering Department, GCET, V.V.NAGAR-388120 E-mail: [email protected]

Abstract: An exploratory study for the production system must be conducted to identify pertinent issues of wastes existing within an organization which may give an impetus for application of lean principles. This may lead to synthesis of data and development of divergent scope of improvement which thereby effectively contributes to accelerate the productivity by reduction in waste without addition of resources. Such a methodology has been implemented to minimize the motion and time losses occurring during the conveyor pulley manufacturing by making appropriate modifications in the existing plant layout. Keywords: Conveyor Pulley, Existing Layout, Proposed layout, Productivity, Lean manufacturing

1.0 INTRODUCTION Lean manufacturing is a systematic method for the elimination of waste ("Muda"), wastes created through overburden ("Muri") and wastes created through unevenness in workloads ("Mura") within a manufacturing process. Lean Manufacturing process has three key stages. (Purvi Chauhan et al., 2015) The initial stage is to identify waste. According to the Lean philosophy, waste always exists and it can always be attempted to reduce it. One of the vital tools used to find this waste is a Value Stream Map (VSM). This shows how materials and processes flow through the organization for complete manufacturing of the product. It looks at how actions and departments are inter-connected and it highlights the waste. The intermediate stage is to analyze the waste and find its root cause and then Root Cause Analysis can be performed. Other effective tools for finding a root cause include Fish-bone Diagrams and Brainstorming. The final stage is to resolve the root cause and repeat the cycle. Using an appropriate problem-solving process, finalising the decision must that be done to fix the issue for increasing efficiency. Continuous improvement by eliminating seven types of wastes mainly waste from overproduction, waiting time, transportation, processing, inventory, motion and defective production. It has even supported that the implementation structure reduces the setup time, overall cycle time and reduces manufacturing system divergence. (R.Sundar et al., 2014) Abbreviations: KM: Keyway Milling Machine NCL: Numerical Control Lathe VB: Vertical Boring Machine PGC: Plasma Gas Cutting Machine

BM: Bending Machine HT: Heat Treatment SAW: Submerged Arc Welding Machine SKL: SK Series Lathe

2.0 PROBLEM DESCRIPTION & METHODOLOGY Time for every operation for conveyor pulley manufacturing was monitored. Fig 1 shows motion of conveyor pulley in the plant. Table 1 shows cycle time in marking, handling, machining, welding of the shell and turbo machining of the conveyor pulley in existing layout of the company. The crane speed is kept constant throughout (0.667 m/s). 423 SVNIT, Surat - 395007


2.1 Existing Layout

Fig 1.Existing Layout Table 1. Motion loss in existing layout Operation on Shell Turbo Shell + Turbo Shaft Bearing Block Total

Distance travelled by crane(m) 930 305 630 270 40 2175

Total Time = 2175/0.667 = 3263 s The machines required during the operation conveyor pulley are spread in different sheds. The production system includes more material movement from one shed to the other. Thus, a need arises for reduction in total time required for manufacturing of conveyor pulley. By proposing a new layout, the motion losses can be reduced and optimization in the process time of conveyor pulley manufacturing becomes possible. 2.2 Proposed Layout-1 The initial proposed layout is based on minor changes to be made in the existing layout of the company. An attempt has been made to reduce the motion loss by shifting easily movable machines and keeping the heavy duty and grounded machines intact as shown in fig 2.

Fig 2. Proposed Layout-1 Table 2 Motion loss in proposed layout-1 424 SVNIT, Surat - 395007


Operation on

Distance travelled by crane(m)

Shell Turbo Shell + Turbo Shaft Bearing Block Total

570 80 435 230 45 1360

Total Time = 1360/0.66 = 2039 s 2.3 Proposed Layout-2

Fig 3. Proposed Layout-2 This layout has been constructed by shifting all the machines in a single shed. This further reduces motion loss of material. Table 3 Motion loss in proposed layout-2 Operation on

Distance travelled by crane(m)

Shell Turbo Shell + Turbo Shaft Bearing Block Total

310 110 250 160 60 890

Total Time = 890/0.66 = 1334 s 2.4 Proposed Layout-3 This layout has been constructed using lean principles. All the arrangements have been done depending upon the operation sequence. Hence, the material will follow in U shaped path.

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Assembly

DIS PA

Fi nis

K M

N C L

Inve ntor y Are

Bal anc ing

V B

S K L

S K L

Cas Beari ng

Ra w Mat eria l

PGC

BM

S h el l

T ur b o

S A W

Fabric ation

Sh ell + Tu rb o

Area

S et ti n

S A W

H T

S h af t

Fig 4. Proposed Layout-3 Table-4 Motion loss in proposed layout-3 Operation on Shell Turbo Shell + Turbo Shaft Bearing Block Total

Distance travelled by crane(m) 180 90 120 70 50 510

Total Time = 510/0.667 = 765 s 426 SVNIT, Surat - 395007


3.0 RESULTS & DISCUSSIONS Table 5 Comparison of Crane Travel Distance & Time In Different Layouts

Operation on Shell Turbo Shell+Turbo Shaft Bearing Block Total Distance Total Time(s)

Crane Travel Distance (m)

Existin g Layout 930 305 630 270 40 2175 3263

Proposed Layout 1

Proposed Layout 2

Proposed Layout 3

570 80 435 230 45 1360 2039

310 110 250 160 60 890 1334

180 90 120 70 50 510 765

Table 6 Percentage Reduction in Crane Travel Distance & Total Time in Different Layouts % Reduction in Crane Travel Distance

Layouts

2175−1360

Proposed Layout-1

2175−890

Proposed Layout-2

2175 2175−510

Proposed Layout-3

2175

3263−2039

= 37.47%

2175

% Reduction in Total Time

3263 3263−1334

= 59.08%

3263 3263−765

= 76.55%

3263

= 37.51% = 59.11% = 76.55%

Table 7 Labour requirement in Layouts Layouts

Labour Requirement

Existing Layout

20

Proposed Layout-3

13

Proposed Layout-1 is easily feasible for company. As CNC machines in shed can be easily transfer to other place and we need not have to transfer heavy and grounded machines. Company can easily apply layout-1 in HMBS. In Proposed Layout-2, all machines required for conveyor pulley manufacturing are merged in one shed (H4). So Productivity increases as compared to layout-1. Proposed layout-3 is prepared on lean manufacturing concept. The Travel distance and time is reduced by high amount. So it is the best optimum layout for higher productivity for conveyor pulley manufacturing. Labour requirement has reduced from 20 to 13 by adopting lean principles (as shown in table 7). 4.0 CONCLUSION The present modifications done by following the Lean Principles results in 76.55% reduction of idle time as well as material movement distance. Also, noteworthy reduction in labour requirement can reduce labour cost and thus reduces overall cost. Hence, effective implementation can considerably optimize overall cycle time, increase labour productivity, and eliminate unnecessary idle time and movements. 5.0 ACKNOWLEDGEMENT The authors would like to acknowledge the ELECON EPC PROJECTS LTD., Vallabh Vidyanagar, Anand for sharing valuable information. 427 SVNIT, Surat - 395007


6.0 REFERENCES 1.

2. 3. 4. 5. 6. 7. 8. 9.

10.

11. 12.

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