Applied Mechanics and Materials Vol. 591 (2014) pp 215-218 Online available since 2014/Jul/18 at www.scientific.net © (2014) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/AMM.591.215
EFFECTIVE PERFORMANCE OF AN USER FRIENDLY DYNAMIC TOOL DESIGN IN SMALL AND MEDIUM SCALE ENTERPRISES Mr.T.Varun Kumar1*, Dr.B.Ganesh Babu2, Dr.M.Saravanan3 1*
Research Scholar (PT), Dept. of Mech Engg. Roever College of Engg &Tech,Perambalur, INDIA 2
Principal, Roever College of Engg & Technology, Perambalur, INDIA
3
Principal, Sir Subramanya College of Engineering and Technology, palani, INDIA a
ercrazyvarun @ gmail.com,
[email protected],
[email protected]
Keywords: Agile Manufacturing (AM), Small Medium Enterprise (SME), pumps, Agility.
Abstract. This research addresses the implementations of agile philosophy in SME’s to increase the production flow rate. Every Small manufacturing industry has put in continuous efforts for its survival in the current volatile economy. In order to face the situation, industries are trying to implement new and efficient techniques in their manufacturing operations. In this research, a systematic approach of developing a user friendly dynamic tool for cycle time reduction and to improve the production flow rate. These effective tools mainly focus on reducing the non-value adding activities, queue time and delays. Here, we selected a medium scale pump industry for our research work and the various process times for manufacturing a mono block pump were obtained from a pump manufacturing industry. The result shows that the implementations of agile manufacturing concepts to the small scale pump manufacturing industry for increasing the production time and profit level. Introduction India is one of the fast developing countries in the world. SMEs are said to be the lifeblood of any vibrant economy[5]. They are known to be the silent drivers of a nation‘s economy. Due to competition, the market has become stiff and it had brought immense pressure on the business entrepreneurs to produce quality products at low costs and continuously improve the performance of their business [3].For the growing International Manufacturing competitiveness and the recent movement towards globalization, the Small and Medium Enterprises (SME) are also competing for the favor of the customers[1]. They face a huge challenge due to open economy. Higher productivity, good quality & flexibility to changing market needs are “The need of the hour” for SME’s. But usage of agile/lean manufacturing technique is not focused in SMEs. A value stream is all the actions (value-added and non-value added) required to take a product from raw material to the customer, the design flow from concept to completion[2]. “Agility” means it is a measure of a manufacturer’s ability to suddenly react the unpredictable changes in customer demand for its products and services and make a profit. “An enterprise that is engaged in providing/rendering of services and its investment is more than 10 lakhs but does not exceed 2 crores is a small enterprise”[4].Implementation of concepts like Agile/Lean Manufacturing in SME’s lack popularity due to the following reasons. • Lack of training. • Lack of resources. • Huge cost involvement as experts needs to be hired. • Time consuming activity. • An effort loses focus due to less ROI (Return on Investment). • More efforts needed for documentation & analysis.
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Our project mainly focuses on making the implementation of Agile/Lean Manufacturing easy in SMEs. This will play a major role in increasing the quality of the products and productivity of those enterprises. Designing An User Friendly Tool For Flow Analysis For designing a user friendly dynamic tool in SMEs we need to find a particular company a have thorough study then the further processes are given below: Selection of Pilot Company: The first step involves the selection of pilot company to implement the new tool designed for flow analysis. Another important process before this is to select the field in which the flow analysis has to be done. So we decided to choose pump manufacturing sector. As this project’s main aim is to implement the flow analysis tool in small and medium scale industries, we selected pump assembly in SMEs. Study of the Process: To know about the flow analysis, the assembly process of pump has to be studied. So we have to take a keen look on the assembly process undergone in the company. This will give us a brief idea about the flow process of the current state in the selected company. And also we have listed out the future state modification of the company layout to reduce the process time.
Fig.1 Current and Future State of Company layout Video Shoot of the Process: The main aim of video shooting of the process is to replace the traditional method of calculating the assembly process time by using stopwatch. This traditional approach is a time consuming method and also less accurate. To overcome this time consuming method instead of using stopwatch, video camera can be used. It required less skilled labour and also minimizes the time. This involves the video shooting of all the assembly process.
Fig.2 Videos Imported to Software Extract Information from Video by Using Subtitle Edit Software: After shooting the flow process, it should be arranged according to process flow. To calculate the process time, software called “subtitle edit” is used. By using the process flow as input to the software, videos are subtitled according to the flow process. After the sub-title edit process, exporting of the subtitle text with time to notepad. Then this should be transferred to an excel sheet. By using the basic formulas,
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the process time of the process can be found in the excel sheet. This will help us to find the time taken for any process that is video shot. Design and analysis of template for calculation using statistical software: A template is created to calculate the value and non-value added processes. This sheet is created by using the statistical software namely Microsoft Excel. Then another template is created to find non-value and value added processes. This can be done by importing the cycle time from the first template. The below figure shows the comparison of current and future state cycle time with the help of kaizen identification tool.
Fig.3 Cycle time Calculation Using Kaizen Identification Tool Process and Cycle Time: Here we have listed the process cycle time for the production of parts for current and future state operations and they are: Table: 1 Current and future state values Current State Future State Operations Cycle Time (sec) Cycle Time (sec) Coil forming 86 67 Stator winding 269 246 Coil forming 85 66 Stator winding 213 172 winding insulation lead out and binding 315 272 Winding final testing 69 58 Stator core pressing into body 64 52 Stator final assembly 261 224 Pump pre-assembly with stator and rotor 268 230 Pump final inspection 99 67 Pump final assembly 168 152 Labeling 21 19 Name plate fixing 47 38 Plastic wrapping 30 27 Final packing 119 110 Future State Calculation Scheduled time/Shift : 8 Hrs Scheduled time/Month : 240 Hrs Time waste/Shift : 0.75 Hrs Time waste/Month : 22.5 Hrs Planned Downtime/Shift : 0.5 Hrs SET: 1 Availability = (Scheduled time – Down time) / Scheduled time = (30 x 8 – 22.5) / (30 x8) = (217.5/ 240) A = 91 %
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Performance = (No. of Component x Time per Component) / (Working hours per shift x Hours per shift) = (1 x 35) / (6 x 8) = 35 / 48 P =
73.00 %
As per world class manufacturing, (If 100% Quality) = 99.99 % Q OEE
= = =
OEE =
99.99 % AxPxQ 0.91 x 0.73 x 0.9999 66.36%
Presentation to Management: After finding the solution to the problem, all the non-value added process is reduced. Then it should be presented to the management of that company to get their approval. This includes the explanation of all the procedures done by us to reduce the non-value added time. Training to Their Employees: After getting the approval, the proposed method is to be implemented with the help of employees. This can be done by conducting training sessions to the employees for making them to understand the new techniques and use it. IMPLEMENTATON OF AGILE IN SME In small medium enterprise level many of the workers are lack about agility and following agile manufacturing is costlier and no owners come forward to practice the system. SME is one of the backbones to our nation and most of Indian owners have practicing the SME. If we providing a simple tool in an easier way, many of SME will come forward and follow the system which leads to the drastic change in the quality and production environment. Thus considering this factor we have created an effective and dynamic tool for the lead time reduction in the pump industry. CONCLUSION Here a tool is created and the cycle time is reduced and production is increased. This tool can majorly used in small and medium scale enterprises only. This won’t require any expert guidance and can be easily implemented in SMEs without any much investment. As this tool is designed mainly focusing the SME environment, it is easily affordable for SME owner who needs to increase productivity without much investment. This project will bring a great improvement in the SME economy which ultimately helps the country’s economy grow. This also helps in popularizing the field of Lean techniques which brings a major increase in productivity.This project can be extended by trying to formulate a Value Stream Mapping (VSM) for each sections present in a particular SME. References [1]. K.jeyakumar, D.Jebakani, A.Krishnaveni (2012), Focusing Agility towards small and medium Scale, International Journal of Engineering Research & Technology (IJERT) Vol. 1 Issue 5, July – 2012. [2]. Fawaz A. Abdulmalek & JayantRajgopal, Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A Process Sector case study, International journal of Production economics (2007) 107:pp223-226. [3]. Murlidharan Nebhwani, Hussain Bux Marri, & Riyaz Ahmed Sohag, An Assessment of entrepreneurs business strategies towards SME is success, Mehran University Research Journal of Engineering & Technology, Vol 30.Issue 3. [4]. Science & Technology for small & medium scale enterprises for Eleventh Five year plan [200712]. [5]. M Sharma, A Mehra, H Jola, A Kumar, Scope of cloud computing for SMEs in India, Journal of Computing, Vol 2. Issue 5, May 2010., ISSN 2151-9617.
Advanced Manufacturing Research and Intelligent Applications 10.4028/www.scientific.net/AMM.591
Effective Performance of an User Friendly Dynamic Tool Design in Small and Medium Scale Enterprises 10.4028/www.scientific.net/AMM.591.215
