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PHASE I

Sundaram Brake Linings Limited,


Padi.

12/07/09

ANALYSIS TO REDUCE SETUP TIME IN CELL 1 DRILLING MACHINE FOR TVS/COM/1 TO TVS/HM/4
ELEMENTAL DESCRIPTION

TIME IN SECONDS

Sl.No.
ACTIVITY

CHANGE

TIME IN SECONDS (BEFORE)

BEFORE

PROPOSED

CURRENT
STATUS

40 80 120 160 200 240

Releasing clamp of cradle

32.55

32.55

32.55

Walking to take SMED trolley

30.26

30.26

Moving of trolley to m/c

36.24

Loading of cradle in trolley

22.68

22.68

22.68

Releasing of two bolts of Drill head

77.92

77.92

77.92

Releasing of drill head

8.96

8.96

8.96

Moving cradle to its location

55.87

Walking near to m/c


Taking the released drill head and placed in its
position

8.11

23.95

23.95

10

Placing of cradle to its place

18.38

11

Loading of required cradle in trolley

17.19

17.19

C
C
C
C

C
C

12

Searching of drill bit and taken

10.04

10.04

13

Moving of required drill head to m/c

15.62

15.62

14

Walking back to move cradle

7.12

7.12

15

Moving of required cradle to m/c

65.63

65.63

16

Loading of drill head

14.86

14.86

14.86

17

Tightening of drill head using two bolts

88.52

88.52

88.52

18

Loading of cradle

16.1

16.1

16.1

19

Clamping of cradle and tighten

26.24

26.24

26.24

20

Connecting all pneumatic hoses

12.73

12.73

21

Adjusting cradle with respect to drill head

278.25

70

278.25

22

Spindle adjustment

135.57

55

135.57

23

Down the bed and adjusting crimp height

78.47

30

78.47

24

Loosening of drill bush

25

Adjusting drill bush with respect to jig

26

Tightening of drill bush

27

checking of drill bit through bush with jig

7.25

7.25

7.25

18.83

18.83

18.83

14.4

14.4

14.4

56.17

56.17

C
C
C
C
C
C

C
C

C
C
C

320

PROPOSED TIME IN SECONDS


360

40

80

120 160 200 240 280 320 360

28

Fixing front side tool box

29

Connecting dust control hose

30

Air line on

31
32

26.74

26.74

26.74

17.99

17.99

17.99

8.03

Trial indexing

15.68

15.68

15.68

Tighten drill bit

25.93

25.93

33

Applying of lub oil on bush

18.83

18.83

34

Placing folded paper for dust

15.14

15.14

35

First piece trial

8.24

8.24

8.24

36

Inspection

52.05

20

52.05

37

Adjusting adapter

90.49

25

90.49

38

Second piece trial

39

Inspection

40

Third piece trial

41

Inspection

Total time in secs


Converted to Parallel activity

8.27

8.27

8.27

64.98

20

64.98

9.49

9.49

9.49

49.69

20

49.69

1589.46 670.72

C
C

C
C
C
C

C
C
C

C
C
C

1466.83

Converted to Pre-planning activity

BEFORE

PROPOSED

Time reduction through Kaizen

IMPROVEMENT

Off line setting of SMED trolley


Off line setting of SMED trolley

Provide SMED Trolley Back side of


Drilling M/C

TARGET DATE

20/07/09
20/07/09

15/07/09

parallel Activity

Quick coupler to be provided


Standardizing cradle Position
Provide lock pin
Provide Crimp height setting
gauge/ off line setting of adapter

Offline Setting

STATUS

11/07/09
15/07/09
25/07/09
28/07/09

18/07/09

COMPLETED

Placing air line nearer to operator

Off line setting of Drill bit


Offline lubrication
Dust hood modification

Placing Inspection table nearer to


m/c
off line setting of adapter

16/07/09

18/07/09
19/07/09
15/07/09

20/07/09
19/07/09

Placing Inspection table nearer to


m/c

15/07/09

Placing Inspection table nearer to


m/c

16/07/09

NO CHANGE

COMPLETED

Sundaram Brake Linings Limited,


Padi.

PHASE I

12/7/2009

ANALYSIS TO REDUCE SETUP TIME IN CELL 2 U LINE 1 DRILLING MACHINE FROM ALRF 5 TO ALRF 7

ELEMENTAL DESCRIPTION

TIME IN SECONDS

TIME IN SECONDS (BEFORE)

PROPOSED TIME IN SECONDS

S. No
CHANGE

BEFORE

PROPOSED

Removing the 5 inch drill bit

39

30

Loosening the drill head bolt for adjustment

78

50

Adjusting the spindle

76

76

Removing the pin for turning drill head

31

12

Turning drill head

29

29

Taking the removed pin and Locating it in drill head

80

20

Changing the 7 inch drill bit into drill adapter

Adjusting the drill bit

TARGET
DATE

IMPROVEMENT

ACTIVITY

Tightening the drill head bolt

28

28

265

109

80

10

Tightening the spindle

109

80

11

First good piece

135

135

12

Adjusting crimp height

35

13

Inspection

72

45

1086

585

Total time in secs


Converted to Parallel activity

40 80 120 160 200 240 280 320 360

40

80

120 160 200 240 280 320 360

C1`

To provide drift type for


easy removal

17/07/09

Ratchet Spanner

16/07/09

Provide
pin
welded chain link

with
20/07/09

Provide pin with


welded chain link

20/07/09

Off line setting of


adapter

18/07/09

Ratchet Spanner

16/07/09

Ratchet Spanner

16/07/09

C
C

To be studied
18/07/09
Off line setting of Drill
bit
15/07/09

C
C

BEFORE

Converted to Pre-planning activity

AFTER
Time reduction through Kaizen

No change

SUNDARAM BRAKE LININGS LIMITED

Phase 1

Padi.

ANALYSIS TO REDUCE SETUP TIME IN CELL 2 U-LINE 4 DRILLING MACHINE FROM ALRF TO EICHER
ELEMENTAL DESCRIPTION

TIME IN SECONDS

TIME IN SECONDS (BEFORE)

PROPOSED TIME IN SECONDS

SL. No

ACTIVITY

CHANGE

BEFORE

PROPOSED

Removing Drill head assembly.

70

Walking to trolley

18

40 80 120 160 200 240 280 320 360

40

80

120 160 200 240 280 320 360

E/I

Moving trolley with drill head to the rack

49

Searching for drill adapter and spindle adjuster

51

Moving trolley to the machine

15

Moving cradle(off line set) to machine

26

Loading to the machine bed.

24

10

Adjusting the spindle

77

30

Checking spindle key way with spindle shaft top locater

41

1
2
3
4
5
6
7

10

Moving trolley to the machine for placing the drill head

C
C

Fitting and locating spindle key

50

Fixing cradle

87

30

Moving spindle up.

16

Raising the bed.

22

15

17

Spindle Up/Down Movement.

11

11

18

Lifting Drill Head

62

Adjusting and fixing drill head

57

Drill head rotating for alignment

31

Fixing with 10 mm bolt

37

19

Searching for tools.

17

251

40

Adjusting Drill head key.

18

15

25

rotating spindle.

25

12

26

Spindle adjusting.

12

Drill bit setting

33

12
13
14
15
16

19
20
21
22
23
24

27

Moving spindle down

Tightening using Allen key.

E
E

To use same drill head

To design a new improved SMED tro


which wil be able to take up remov
assembly and the assembly to b
mounted along with place for dri
adaptor and necessary tools for th
concern change over.

11

Searching for tool

IMPROVEMENT

E
I
E
I
E

C
C

To arrange rollers in SMED trolley


To arrange setting gauge in SME
trolley.

E
I

To arrange al necessary tools for C/


SMED trolley.
To standardize the Key pin
To arrange roller type trolley

I
I
I

To give location for keeping the le


fixed.

I
I

To use same drill head

To use same drill head

I
I
E
I

To use same drill head

Bolting will be done


To provide the tools near by the
machine
To use rachet spanner instead of al
key.

I
I
I
E

off line setting of drill bit

28

Adapter setting.

19

15

29

Adapter fixing.

19

15

Adjusting Drill bit.

24

112

Tightening drill using Allen key.

63

23

Adjusting cradle

32

24

Adjusting drill head bolt.

41

20

Drill head adjusting

19

36

Checking for hole position.

10

10

37

Cradle adjustment with hammer

23

Adjusting CED plate

40

12

Adjusting spindle for hole position.

30
31
32
33
34
35

38

Adjusting drill adapter.

17

17

Connecting Airline to cylinder

116

20

Trial checking drill movement.

35

19

Drill up down position checking

13

10

Drill hole position checking in reverse direction.

18

44

Adjusting top limit switch for drill hole depth.

33

26

45

Indexing limit switch adjusting.

87

18

46

Setting of first piece

20

13

Trial piece check

16

16

Inspection of crimp height

15

15

Moving to hole position gauge

17

Hole position checking

35

22

Plug gauge checking

20

20

Counter Bore Dia Checking

15

15

53

Moving back to machine

14

54

Checking CED

20

Fine tuning the Adapter

33

Setting of second piece

20

13

Trial piece check

16

16

Inspection of crimp height

15

15

2097

590

39
40
41
42
43

47
48
49
50
51
52

55
56
57
58

E
I
E
E

To arrange setting gauge in SMED


trolley.
To arrange setting gauge in SME
trolley.

I
I
I
I

To use same drill head

I
I
I

To provide easy locator

I
I

Common airline connecting junctio

I
I
I
I
I

Standardizing the limit switch for e


product

I
I
I
I

To place the hole position gauge


SMED trolley based on the produc

I
I
I
I
I

standardizing CED plate

off linesetting of adapter

I
I
I
BEFORE

AFTER

34.95

9.833333

Converted to Pre-planning activity

Time reduction through Kaizen

No change

UP TIME IN CELL 2 U-LINE 4 DRILLING MACHINE FROM ALRF TO EICHER

Date :12/07/09

IMPROVEMENT

Target Date

To use same drill head

15/07/09

To design a new improved SMED trolley


which wil be able to take up removing
assembly and the assembly to be
mounted along with place for drill
adaptor and necessary tools for the
concern change over.

To arrange rollers in SMED trolley.


To arrange setting gauge in SMED
trolley.
To arrange al necessary tools for C/O in
SMED trolley.
To standardize the Key pin

17/07/2009

18/07/2009
21/07/2009

18/07/2009
20/07/09

To arrange roller type trolley


20/07/09
To give location for keeping the lever
fixed.

20/07/09

To use same drill head

18/07/09

To use same drill head

18/07/09

To use same drill head

18/07/09

Bolting will be done


To provide the tools near by the
machine
To use rachet spanner instead of allen
key.

18/07/09
completed

off line setting of drill bit

18/07/09

17/07/09

To arrange setting gauge in SMED


trolley.
To arrange setting gauge in SMED
trolley.

To use same drill head

To provide easy locator

19/07/09
19/07/09

24/07/09

22/07/09

Common airline connecting junction.

18/07/09

Standardizing the limit switch for each


product

26/07/09

To place the hole position gauge in


SMED trolley based on the product.

20/07/09

standardizing CED plate

24/07/09

off linesetting of adapter

24/07/09

No change

Sundaram Brake Linings Limited,


Padi.

ANALYSIS TO REDUCE SETUP TIME IN CELL -5 IN DRILL 08 FROM 280DIA to 10/MB/1A


ELEMENTAL DESCRIPTION

S.No.
ACTIVITY

TIME IN SECONDS
CHAN BEFORE
PROPOSED
GE

TIME IN SECONDS (BEFORE)

PROPOSED TIME IN SECONDS


IMPROVEMENTS

50

100

150

200

250

300

50

100

150

200

250

300

Cleaning the machine

32

32

Taking the spanner

16

60

60

Fixing the tools with in the machine

Searching and taking cotton waste

26

59

59

Off-line arrangement

58

Cleaning the machine

58

Removing the Jig clamp bolts(2 Nos)

57

57

15

56

56

Reducing the no of turns

55

55

Fixing c-washer within the machine

54

54

Provision done for keeping the guide rod with


in the head itself

53

53

52

52

51

51

50

50

49

49

48

48

47

47

46

46

6
7
8
9

Removing the jig bolts(3 Nos)


Loosening guide rod bolts and taking CWasher

29
16

10

Removing the guide rod


Removing jig from m/c and keeping in offline
trolley

30

10

20

20

10

Moving to the drill head c/o trolley

16

11

Moving the trolley to machine

29

12
13

Adjusting the trolley to position


Moving the inner trolley to m/c and climping
to top

14

Taking tool

15

10

10

Off-line arrangement/trolley to be serviced


Off-line arrangement

64

40

55

15

45

45

44

44

44

18

Loosening bolts and c-washer


Lowering drill head and moving the inner
trolley back
Moving the trolley back and bringing the new
trolley
Moving the inner trolley to m/c and climping
to top

12

12

43

43

19

Adjusting for bolt position

25

10

42

42

20

Tightening the bolts

79

40

41

41

21

Coming down and taking inner trolley back

10

10

40

40

22

Moving the trolley back to its position

16

39

39

Off-line arrangement

23

Bringing the offline trolley to machine

23

38

38

Off-line arrangement

24

Taking the jig from trolley and keeping in m/c

14

14

37

37

25

Connecting the pneumatic hoses

25

10

36

36

35

35

34

34

33

33

32

32

31

31

30

30

16
17

26

Putting jig bolts and tightening(3 Nos)

38

20

27

Keeping spacer in jig

15

Fixing the tools with in the machine


C-Washer to be changed
Problems in drill head to be corrected
Off-line arrangement

Stopper to be provided
C-Washer to be changed

Quick coupler provided


Reducing the no of turns
Provision to be done in bush holder to locate
without using spacer

28

Bed up and taking C-washer and loading the


bush holder in Off trolley from machine

33

33

29

Loosening drill adaptor bolts and taking out

58

30

30

Keeping spacer

10

31

Keeping the bush holder from trolley to m/c

32

Taking guide rod and putting it (2 sides)

47

10

37

37

36

36

35

35

34

34

33

33

32

32

31

31

30

30

29

29

28

28

27

27

26

26

25

25

24

24

Lever type arrangement provided instead of


using hand tolls
Bed movement rod to be serviced and
provision to be done for reducing hand tools
Lever type arrangement provided instead of
using hand tolls
Seperate sensors provided for each cylinder

33

Putting stopper for guide rod

11

34

Loosening bed movement lock bolts

32

10

35

Adjusting bed for guide rod free movement

90

40

36

Tightening bed movement bolts

28

10

38

Changing indexing cylinder sensors


Checking spindle for hole position in bush
holder
Loosening universal joint bolts and replacing
joints

66

23

23

68

20

22

22

280

21

21

31

20

20

39
40
41

43

Putting bolts
Checking drill bit free movement in the bush
holder and placing the drill bit(6 Nos)
Adjusting spindle for drill bit position and
insertig the drill bit in to the spindle

103

18

44

Tighteneing drill bits with spindle

86

86

17

17

45

Putting bush holder c-washer

17

17

16

16

46

Adjusting spindle

150

15

15

47

Putting jig clamp

33

33

14

14

48

Searching for Jig clamp stud

18

13

13

12

12

11

11

42

74

20

19

19

103

18

49

Tightening the clamp bolts

14

14

50

Putting guide rod c-washer

22

10

Checking indexing and cycle start

26

52

Checking crimp height

43

53

Adjusting bed up and down travel

27

10

54

Checking crimp height

30

10

24

10

57

1st trial

37

37

58

Adjusting crimp height limit switch

22

59

2nd trial

15

15

60

Checking crimp height

17

17

Off-line arrangement

To be done in Offline
Bed height to be standardised for each
product

To be done in Offline
Bed height to be standardised for each
product
Lock nut to be provided for using the 2nd limit
switch

Adjusting crimp height limit switch

Offline crimp height adjustment to be done

Adjusting bed up and down travel

Off-line arrangement

56

Off-line arrangement
It should be standardized instructed to fix
atleast 10 joints in the head
Lever type arrangement for loosening the
bolts instead of hand tools

Fixing c-washer within the machine

55

Provision done for keeping the guide rod with


in the head itself

10

10

51

Drill adaptors to be serviced for free


movement
Provision to be done in bush holder to locate
without using spacer

Bed height to be standardised for each


product

50

100

150

200

250

300

50

100

150

200

250

300

19

19

18

18

17

17

16

16

15

15

14

14

13

13

12

12

11

11

10

10

1
0

61

First off approval

Total time in secs


Converted to Parallel activity

20

20

2216

833

50

100

150

200

BEFORE

Converted to Pre-planning activity

250

300

50

100

150

200

250

300

Proposed
Time reduction through Kaizen

No change

12/7/2009

UP TIME IN CELL -5 IN DRILL 08 FROM 280DIA to 10/MB/1A

TARGET DATE

25/07/2009
20/07/09

Completed
30/07/09
Completed

Completed
10/07/09

25/07/2009
20/07/2009
Completed
20/07/09

15/07/2009
20/07/09

20/07/2009
20/07/2009

Completed
Completed
25/07/2009

30/07/2009
25/07/2009

Completed

Completed
Completed
Completed
Completed
20/07/09
20/07/2009
Completed
20/07/09

20/07/2009

20/07/09

20/07/09

20/07/09
25/07/2009
20/07/09
25/07/2009
Completed

25/07/2009

No change