Академический Документы
Профессиональный Документы
Культура Документы
A CASE STUDY
IMPLEMENTATION OF THEORY OF
CONSTRAINTS (TOC) IN PRODUCTION
Deals in
• SHEET METAL
• ALUMINIUM EXTRUSIONS
Vendors/ Partners
• Valco India ltd, Indo alusys, Bhushan steels,BALCO, Jindal Steels, Tata
Steels
HEAT INDULGENCE?!
Machines used :-
6 SPINDLE 6 SPINDLE
SPM DRILLING TAPPING
6 SPINDLE
4 SPINDLE
2 SPINDLE
Manual
4 SPINDLE 4 SPINDLE
DRILLING TAPPING
2 SPINDLE 2 SPINDLE
DRILLING TAPPING
For manufacturing 851-153403450010
2- 6 spindles drilling
2- 2 spindles drilling
1- 6 spindle tapping
Single manual machine –
Chamfering
Manpower- 6 operators
851-153403450010
For manufacturing 851-0001
1- 6 spindle drilling
1- 2 spindle drilling
1- 6 spindle tapping
5-manual machines are
required
◦ For m4 holes
◦ For m3 hole
◦ For chamfering
◦ For tapping m4 holes
◦ For tapping m3 holes
Manpower- 8 operators
851-0001
For manufacturing 851-0002
October
73880 18.61 1374906.80
November
46060 18.25 840600.60
December
58880 17.91 1054540.80
The CHALLENGES we face.
Slow throughput
Less productive
High non-operating expenses
Incomplete purchase order
Inventories deposition near 6-
spindle tapping machine of
851-153403450010 line.
Slow productive rate due to
poor synchronization between
manual machines and
automatic SPM machines.
What is Theory of constraint(TOC) ?
Identify - the system constraint(s)
Exploit - the system constraint(s)
Subordinate - the system constraint(s)
Elevate – the system constraint(s)
Go back to step 1 if bottleneck fails
Main causes of slow throughput:
The center distance between 3 holes in front portion is 13mm. but our existing spindles
are not able to adjust lesser than 14mm, that’s why we do 1st and 3rd hole of front portion
and two holes of bottom portion at a time. For the 2nd hole we need extra machine and
labor.
(Note-1:- All three parts are having same front and bottom operations.)
(Note-2:- We use compounded fixtures in which we can perform two operations at a time one
is at front and another one is at bottom).
First we place unprocessed part in first block, then after the completion of operation we
take it out and place in second block like this we can perform two operations at time.
working of compounded fixtures given below:-
Elimination
The problem can be eliminated only when we can adjust our spindles at
the center distance of 13mm.
Grind our spindles 0.3mm from both the sides
Remove the capping ring placed over the bearing.
PRODUCTION LINE:-
In both 851-0001 and 851-0002 heat sinks
Before:-
6-spindle 2-spindle 6-spindle manual M4 manual M3 manual M4 manual M3
chamfering
drilling drilling tapping drilling drilling tapping tapping
After:-
2-spindle 2-spindle
6-spindle 6-spindle manual M3
drilling-M4 tapping-M4 chamfering
drilling tapping drilling
holes holes
In 851-0002
Before:-
After:-
2-spindle 2-spindle
6-spindle 6-spindle
drilling- tapping-M4
drilling tapping
M4holes holes
Line 2
6-spindle 2-spindle
drilling drilling
6-spindle 6-spindle
chamfering
drilling tapping
Line 2
we used our vacant operator for running one extra 6-spindle tapping
machine for converting all WIP inventories into FG’s.
Figures after the implementation of TOC
No.of 851-0001 heatsinks produced
No.of 851-0001 heatsinks produced
50000
32750 26880 28480
35040
26240 27840
October
73880 18.61 1374906.80
November
46060 18.25 840600.60
December
58880 17.91 1054540.80
Expected
100000 17.91 1791000.00
Rate of production : A comparison
Manual SPM
Total 2842700
Rate of production per shift. (After)
Mothlty Operator's/
No.of parts/ No. of operators No.of Price Total Total wage
Part code WIP production month Net value
shift required working days rate/Part value value given
capacity wages
Manual SPM
851-
5000 0 5 1 4 20 100000
153403450010
17.91 1791000 7045 35225 1755775
Total 3623825