Proposed Agenda

• Explination of timestudies.
• Line capacity calculation.
• Manpower planning.
• World class manufacturing cell (Video).
• Line balancing.
 Time Study & Line Balancing

1. Conducting a timestudy:
• Identify all the activities of an operation (Welding operation):
• load part in jig, clamp and start cycle (operator).
• robot welding the part (machine auto cycle).
• unload part from welding jig (operator).
• Record the time utilised to perform each activity:
• load the part 10 seconds (operator)
• Welding 40 seconds (robot)
• Unloading 5 seconds (operator)
• Operator allowance 9% of total time: 5 seconds
Total time to produce a part: 60 seconds (60 parts per hour).
• Operations such as leak testing and final checking have no machine time all the time is
operator time.
 Line Capacity / Hourly Target

Available time
Available time per shift:(8hours x 60 minutes) 480
Less: Lunch time 30
Less: Meeting 10
Less: Houskeeping 5
Net available time: 435
Less :Planned down time:
Robotic Consumable changes: 10%
Machine availabilty (100% - 10%) 90%
Total available time:(435 x 90%) 392

Shift Target = (392 minutes / 1minute per part) 392 parts

Hourly Target = (392 parts / 7.35 hours) 53 parts per hour
 Current Layout: Line 1D

Heatshield welding Spot H/shiel

weld Leak test
clinching

Dr.
Wiesner
S/ boss
Embos Leak test
rolling
Final Final
Exit check Round
weld

Teamleader Cal. Tackweld

Entry
Cone / inlet Cone / inlet Cone round
pipe tackweld pipe tackweld weld
 Current Layout Line 1D & Output
Current Process Flow & Cycle Times

Operation No operators Parts / cycle FTF (min.) Operator Min. Parts / hour
Inlet cone tackweld Included in first tackweld
1 2 0.57 105
Inlet cone tackweld cycle

Calibration 1 1 0.15 Operator dependant 400

Sensor boss rolling 1 1 0.5 120

Cone round weld 1 2 1.35 0.25 89
Outlet cone sub assy tack 1 1 0.37 0.1 162
Final round weld 2 2 1.34 0.9 90
Leak Tester 1 1 0.83 Operator dependant 72
Leak Tester 1 1 0.83 Operator dependant 72
Heat shield clinching 1 1 0.66 91
Heat shield embossing
1 1 0.52 Operator dependant 115
Heat shield spot weld
Heat shield welding
2 2 0.55 109
Heat shield welding
Dr. Wiesner 1 1 0.69 Operator dependant 87
Final check 1 1 0.8 Operator dependant 75
Total Operators: 15
 Revised Cycle Times & Output
Revised Process Flow: 6-Jun-07

Assumptions:
1. Line availability = 80%
2. Current bottleneck = 72 / hour at 100%. At 80% availability the revised hourly target = 58 parts / hour.
3. Based on current demand the tact time = 51 parts / hour (demand can be achieved in 2 shifts, any increase will require a 3rd shift)

1. Remove one water leak tester from the line.

2. Relocate calibrator to sensor boss rolling.
3. Swing outlet cone tack station 180 degrees.
4. Re-position spot weld closer to clinching.

Operation No operators Parts / cycle FTF (min.) Operator Min. Parts / hour
Inlet cone tackweld Included in first tackweld
1 2 0.57 105
Inlet cone tackweld cycle
Calibration 1 Operator dependant
1 0.65 92
Sensor boss rolling 1
Cone round weld 2 1.35 0.25 89
1
Outlet cone sub assy tack 1 0.37 0.1 162
Final round weld 1 2 1.34 0.9 90
Leak Tester 1 1 0.83 Operator dependant 72
Heat shield clinching 1 1 0.66 91
Heat shield spot weld 1
1 0.52 115
Heat shield embossing 1 Operator dependant
Heat shield welding
1 2 0.55 109
Heat shield welding
Dr. Wiesner 1 1 0.69 Operator dependant 87
Final check 1 1 0.82 Operator dependant 73
Total Operators: 10
 Revised Layout: Line 1D

Heatshield welding Spot H/shiel

weld clinching

Dr.
Wiesner

Leak test
S/ boss
Embos
rolling
Final
check Final
Exit
Round
weld
Cal.
Tackweld
Teamleader

Entry
Cone / inlet Cone / inlet Cone round
pipe tackweld pipe tackweld weld