ANALYSIS TO REDUCE SETUP TIME IN CE

ELEMENTAL DESCRIPTION
TIME IN SECONDS
S. No
CHA
BEFORE
PROPOSED
40
ACTIVITY
NGE
1 Removing t39 30
2

Loosening 78

50

Adjusting 76

76

4
5

Removing t31
Turning dr 29

12
29

6
7

Taking the 80
Changing th
28

20
28

Adjusting t265

Tightening109

80

10 Tightening109

80

TIME IN SECONDS (BEF

80 120 160 200

11 First good135 135

12 Adjusting 35
13 Inspection 72

Total time in secs

0
45

### ###

BEFORE

TOTAL TIME IN MTS 18 9.8

verted to Parallel activityConverted to Pre-planning activity

TIME IN CELL 2 U LINE 1 DRILLING MACHINE FROM A

CONDS (BEFORE)
240 280 320

360

40

PROPOSED TIME IN SECOND

80 120 160 200 240

AFTER

ng activity

Time reduction through Kaizen

NE FROM ALRF 5 TO ALRF 7

IN SECONDS
280 320

TAR
GET
IMPROVEMENT
360
To provide DAT
E
drift type for17/07/09
easy
removal 16/0
Ratchet
Spanner
7/09
Provide
pin
with
welded 20/0
chain link
7/09
Provide pin
20/0
with welded
7/09
chain link
Off line
setting of
adapter
Ratchet
Spanner
Ratchet
Spanner

18/0
7/09
16/0
7/09
16/0
7/09
18/0
To be studied
Off
line 7/09
setting
of 15/0
Drill bit
7/09

gh Kaizen

No change

Operation
Time (min:sec)

Ste
p
No. Changeover Element

Inter Exter Was

Elapse nal
nal
te
0:00:20
20
preparation
0:00:15
15
preparation
0:00:08
8
preparation
0:00:07
7
0:00:10
10

1
2
3
4
5

switch on the mains

chk binder pot level
connect binder hose
chk glass
start rotary

Start
0:00:00
0:00:20
0:00:35
0:00:43
0:00:50

takes 4 screen to be changed

0:01:00 0:01:20 0:00:20

7
8
9
10
11

starts binder point

removing old screen1
remove nuts"2nd"
remove main nuts
fix the new screen
change position remove old
screen
fix new
change position remove 3rd
old screen

0:01:20
0:01:39
0:02:30
0:02:54
0:03:11

12
13
14

15

16
17
18
19

fix the screen

keep the removed screen back
to rack
start mcb blower 1
change the plates of vaccume
cooled.
adjust
parameters(temp,press)
GO top chk fiber path
serching far 12"tool
change settting motar

Stop
0:00:20
0:00:35
0:00:43
0:00:50
0:01:00

Changeover
Categories

0:01:39
0:02:30
0:02:54
0:03:11
0:03:37

20

0:00:19
0:00:51
0:00:24
0:00:17
0:00:26

19
51
24
17
26

0:03:37 0:04:15 0:00:38

38

0:04:15 0:04:38 0:00:23

23

0:04:38 0:05:19 0:00:41

41

0:05:19 0:05:40 0:00:21

21

0:05:40 0:06:15 0:00:35

35

0:06:19 0:06:35 0:00:16

16
15
28

remove blade assembly

0:07:58 0:08:20 0:00:22

22

0:08:20 0:09:20 0:01:00

60
0:09:20 0:11:28 0:02:08 128
0:11:28 0:11:50 0:00:22
22

27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46

clean the blade assembly

replace old blade with new
fix blade assembly
release knob for binder
removal
collect old binder.
stop the knob
searching/ take a cloth
clean the gun with acetone
fix motar on position
adg gun angle
adg binder knob
tight matar assambly
fiber traping
connect binder hose
set pressure to 4bar
GO down
applying wax to screen1
change position
applying wax to screen2
change position
applying wax to screen3
change position
applying wax to screen4
change roller

47

clean the old fiber waste

0:21:00 0:22:10 0:01:10

70

48
49

clean the screen1

2

0:22:10 0:22:22 0:00:12

0:22:22 0:23:48 0:01:26

12
86

50

normal check on top

0:23:48 0:24:00 0:00:12

12

51
52
53
54
55
56
57

clean the third screen

4th
top & down
arranging base
clean base
rotate
unload

0:24:00
0:24:16
0:25:10
0:25:22
0:25:35
0:25:47
0:26:09

16
54
12

23
24
25
26

35 operator has to walk /screen rack should be near work place

4

0:06:50 0:07:18 0:00:28

0:07:18 0:07:47 0:00:29
0:07:47 0:07:58 0:00:11

0:11:50 0:12:17 0:00:27

0:12:17
0:13:19
0:13:21
0:13:31
0:14:20
0:14:40
0:14:59
0:15:28
0:15:45
0:16:28
0:16:32
0:16:54
0:17:03
0:17:33
0:17:35
0:17:57
0:17:59
0:18:28
0:18:30
0:18:53

0:13:19
0:13:21
0:13:31
0:14:20
0:14:40
0:14:59
0:15:28
0:15:45
0:16:28
0:16:32
0:16:54
0:17:03
0:17:33
0:17:35
0:17:57
0:17:59
0:18:28
0:18:30
0:18:53
0:21:00

0:24:16
0:25:10
0:25:22
0:25:35
0:25:47
0:26:09
0:26:43

0:01:02
0:00:02
0:00:10
0:00:49
0:00:20
0:00:19
0:00:29
0:00:17
0:00:43
0:00:04
0:00:22
0:00:09
0:00:30
0:00:02
0:00:22
0:00:02
0:00:29
0:00:02
0:00:23
0:02:07

0:00:16
0:00:54
0:00:12
0:00:13
0:00:12
0:00:22
0:00:34

20 operator has to walk /screen rack should be near work place

preparation

0:06:15 0:06:19 0:00:04

0:06:35 0:06:50 0:00:15

20
21
22

Comments/ Future Improvement Plans

29

29 PEEP for tools

11

60 keep a spare blade assambly.

128 keep a spare blade assambly.

27

27
62

2
10

62
2
10 PEEP

49
20
19
29
17
43
4
22
9
30
2
22
2
29
2
23
127 127 keep a spare roller assembly assambly.
make a trey arrange ment for collecting fiber
70 waste./also set the angle of fiber gun in such a
way that there is min wastage.

if a mirror is placed on top such that operator

can check fiber on top ,standing down

13
12
22
34

13 operator has to walk / rack should be near work place

12

58
59
60
61

put on cooling (vaccume)

check the weight
check thickness
keep the base.

0:26:43
0:26:50
0:27:28
0:28:01

0:26:50
0:27:28
0:28:01
0:28:20

0:00:07
0:00:38
0:00:33
0:00:19
###

7
38
33
19
481 595

0:10:04

0:28:20 Total time

###

0 once in a shift/if required

Bar chart of Screen changeover in Rotary m achine

1800
1600
1400

Time(in Sec)

1200
1000
800
600
400
200
0

41
38
26
17
51
19
20
10
7
8
15
20

41
38
26
17
51

20
10
7

19
8
15
20

elemental time

Internal

External

Preperation

Operator

switch on the mains

chk binder pot level
connect binder hose
chk glass
start rotary
takes 4 screen to be changed
starts binder point
removing old screen1
remove nuts"2nd"
remove main nuts
fix the new screen
change position remove old screen
fix new
change position remove 3rd old screen
fix the screen
keep the removed screen back to rack
start mcb blower 1
change the plates of vaccume cooled.
adjust parameters(temp,press)
GO top chk fiber path
serching far 12"tool
change settting motar
remove blade assembly
clean the blade assembly
replace old blade with new
fix blade assembly
release knob for binder removal
collect old binder.
stop the knob
take a cloth
clean the gun with acetone
fix motar on position
adg gun angle
adg binder knob
tight matar assambly
fiber traping
connect binder hose
set pressure to 4bar
GO down
applying wax to screen1
change position
applying wax to screen2
change position
applying wax to screen3
change position
applying wax to screen4
change roller
clean the old fiber waste
clean the screen1
2
normal check on top
clean the third screen
4th
top & down
arranging base
clean base
rotate
unload
put on cooling (vaccume)
check the weight
check thickness
keep the base.

Intern
element
al
al 20
time
15
8
7
10
20
19
51
51
24
24
17
17
26
26
38
38
23
23
41
41
21
21
35
35
4
16
15
15
28
28
29
29
11
11
22
22
60
60
128
128
22
22
27
27
62
62
2
2
10
10
49
49
20
20
19
19
29
29
17
17
43
43
4
4
22
22
9
9
30
30
2
2
22
22
2
2
29
29
2
2
23
23
127
127
70
70
12
12
86
2
12
12
16
16
54
54
12
12
13
12
22
34
34
7
38
33
19
1700

Exter per
nal atio
20
n
15
8
7
10
20
19

4
16

13
12
22
7
38
33
19

1353 201 62

Op 6

1800
1600
1400
1200
Time(in min)

Op 5

1000
800
600
400
200
0

41
38
26
17
51
19
20
10
7
8
15
20
elemental time

41
38
26
17
51
19
20
10
7
8
15
20
elemental time

Bar chart scenario for 2472

41
38
26
17
51
Internal

20
10
7
External
Operator

keep the base.

check thickness
check the weight
put on cooling
(vaccume)
unload
rotate
clean base
arranging base
top & down
4th
clean the third
screen
normal check on
top
2
clean the screen1
clean the old fiber
waste
change roller
applying wax to
screen4
change position
applying wax to
screen3
change position
applying wax to
screen2

19
8
15
20
Preperation

Time(in Sec)
1

1800
1600
1400
1200

Time(in Sec)

1200
1000
800
600

600
400
200
0

element

Bar c

Bar c

mental time

ar chart of Screen

ar chart of Screen

Internal

Operat

Operat

reen changeover i

reen changeover i

perator

External

perator

ver in Rotary mach

ver in Rotary mach

rnal

Prep

machine

machine
keep the base.

rotate

clean the third scree

change roller

applying wax to scre

connect binder hose

fix motar on position

release knob for bin

change settting mot

Preperation

change settting mot

start mcb blower 1

change position rem

starts binder point

chk binder pot level

chk binder pot level

keep the base.

check thickness

check the weight

put on c

rotate

clean base

arranging base

top & d

clean the third screen

normal check on top

clean th

change roller

applying wax to screen4

change position

applying

applying wax to screen2

change position

applying wax to screen1

GO dow

connect binder hose

fiber traping

tight matar assambly

adg bin

fix motar on position

clean the gun with acetone

take a cloth

stop the

release knob for binder removal

fix blade assembly

replace old blade with new

clean th

change settting motar

serching far 12"tool

GO top chk fiber path

adjust p

change settting motar

serching far 12"tool

GO top chk fiber path

adjust p

start mcb blower 1

keep the removed screen back to rack

fix the screen

change

change position remove old screen

fix the new screen

remove main nuts

remove

starts binder point

takes 4 screen to be changed

start rotary

chk glas

chk binder pot level

switch on the mains

chk binder pot level

switch on the mains

ght

put on cooling (vaccume)

unload

top & down

4th

clean the screen1

clean the old fiber waste

applying wax to screen3

change position

screen1

GO down

set pressure to 4bar

adg binder knob

adg gun angle

stop the knob

collect old binder.

de with new

clean the blade assembly

remove blade assembly

er path

adjust parameters(temp,press)

change the plates of vaccume cooled.

ambly

er path

uts

adjust parameters(temp,press)

change the plates of vaccume cooled.

change position remove 3rd old screen

fix new

remove nuts"2nd"

removing old screen1

chk glass

connect binder hose