Continuous Improvement Day DOWNTIME: The Eight Types of Waste Case Study

DOWNTIME: The Eight Types of Waste

Air-Cooled Chiller Assembly Process
Case Study
An Air-Cooled Chiller

Refrigeration Cycle of Air-Cooled Chiller

BY: MOHAMMED K. BARAKAT 1

Continuous Improvement Day DOWNTIME: The Eight Types of Waste Case Study

Assembly Flow Process

1. Assembly Foreman brings the chiller design paper drawings from the Design section [30m, 10min]
2. Move chiller base from the Blacksmithing section to the Assembly section using roller jacks [20m, 15min]
3. Assembly operators search for chiller metal parts the Metal Forming section [15min]
4. Move metal parts (columns and panels) from the Metal Forming section using trolleys [25m, 30min]
5. Move coils from Coiling section to Assembly section [15m, 10 min]
6. Move chiller fans and fixtures from warehouse using trolleys [50m, 30 min]
7. Assembly Foreman studies design drawings [15 min]
8. Foreman visits Design engineer for errors or unclear drawings [30m, 30min]
9. Design engineer correct drawings [15min]
10. Foreman meets with operators to explain assembly process
11. Operators assemble columns on base using screwdrivers and wrenches [60min]
12. Operators assemble coils in v-shape on ground [30min]
13. Foreman and Operators assemble coils on columns using cranes. (Operators need Foreman help to show
coils direction during assembly) [20min]
14. Operators assemble fans on top using cranes [30min]
15. Assembly operators wait for Mechanical section to install the mechanical parts.
16. Mech operators move mechanical parts in the assembly area [30m, 15min]
17. Mech operators install mech parts (Evaporator, Compressor, Filter, Expansion Device, and Gas cylinder)
on chiller [180m]
18. Assembly operators wait for Electrical section to install electrical parts.
19. Elec operators move parts to the assembly area [20m, 15min]
20. Elec operators install electrical panel and connect wiring [120min]
21. Assembly operators re-paint areas of scratches after mechanical and electrical works [25m, 20min]
22. Assembly operators comb coils fins after mechanical and electrical works [15m, 10min]
23. Assembly operators assemble coils side panels [15min]
24. Assembly foreman perform panel balancing after assembly [15min]
25. Assembly foreman fills out chiller information in a copy of QC checklist [15min]
26. Foreman and Assembly Engineer approve checklist [15min]
27. Foreman searches for QC Inspector to inspect and sign off checklist [15min]
28. QC inspector inspects the chiller [30m, 20min]
29. Foreman corrects defects through NCR (loose nuts) [10min]
30. QC inspector re-inspects and approves the checklist [30m, 20min]
31. Commissioning operators move the chiller to commissioning area [15m, 15min]
32. Commissioning operators test chiller performance [180min]
33. Packaging workers move and pack the chiller outside the production hall [50m, 120min]
34. Shipping officer measures final volume of the chiller and acquires a suitable truck to ship it [60min]
35. Chiller waits for the truck to arrive [24 hours]
36. Load and ship the chiller to the customer site.

What is required?
a) Study and understand the process.
b) Process-map the process
c) Identify the wastes in the process
d) Measure the waste
e) Identify the root cause of each waste type
f) Propose a preventive action to the root cause

BY: MOHAMMED K. BARAKAT 2

Continuous Improvement Day DOWNTIME: The Eight Types of Waste Case Study

Process Analysis-Wastes
Activity Waste Type Measure Cause Root Cause Preventive Action

BY: MOHAMMED K. BARAKAT 3

Continuous Improvement Day DOWNTIME: The Eight Types of Waste Case Study

Activity Waste Type Measure Cause Root Cause Preventive Action

BY: MOHAMMED K. BARAKAT 4