Reducing Changeover Time using SMED Automobile Battery Manufacturing unit
Discrete Process
Before
Analysis of tool change activities 1200
T/C Duration ( Secs)
1200
After Prepared Instruction for Operator 1 & 2 after work balancing
No written Instruction for operator 1 & 2
1000
QUICK CHANGE OVER STANDARD MOLD CHANGE INTERNAL ACTIVITIES MAJOR SUB
800
600 400
Assembly
360
300
200
240
240
0
40
1
• 40
30
Mold Change
A
Crates pushed in the pack-house
5
After
40
Table Unloader Table Unloader Table
120
C
Mold Fitting Cables & Pipes Conection Select Battery Type on the Screen
180 40 30
F
Dummy strap casting
120
G
Mold Positioning
300
• No Quick Wrongly Placed brooms C/O standard
Before
STANDARD TIME (SEC)
Use of trolleys Unloader
Mold Removal
E
PICTORIAL
Operator A ( Loader) Cables & Pipes Disconection
B
D
Tool Change Activities
TOOLS
Correctly Quick C/O placed standardbrooms prepared
Results : Reduction of C/O time after Kaizen Month
Jan’2012
April’2012
No. of Tool changes
15
18
Average time taken
42
19
Total time taken (minutes)
630
342 Workings
Difference in Time (minutes)
630-342=288
No. of Batteries saved ( Cumulative)
288*2.9=835
Potential Savings ( Cumulative)
Mould station Rail Grove worn out
Mould station Rail Grove Reconditioned
835*7000=5.846 M
Monthly Savings of 5.8 M’ Kash 5