COMPARISON TABLE

Design Alternative Tribal LED Accendo Nippo Premier (Chinese)

Price 1200 1500 1000 350
Warranty 1 yr 1 yr 1 yr
Function (Primary) 360 light 120 light 360 160 degrees
Function (Secondary)
Part Count: 42 25 26 20
Metal 24 11 11 10
Plastic 16 8 8 6
Glass 2
Paper 2 1 1 1
Others 5 6 1
Purchased
Made (inhouse)
Processes
Moving Parts 2 0 1 1
Fasteners 12 10 11 9
Switches 1 1 1 1

Assembly Time: 30 3
Aseembly Steps:
Assembly Effort: Difficult Easy Moderate Easy
Easy:
Moderately Difficult:
Difficult:
Flips:

Different Tools Required for Assembly: 5 1 1 1

Dis-assembly Time:
Design Analysis of LED Lights
 TOAST KAIZEN (DVD)
Manufacturing Kitchen
1 Over Production Excess Food
2 Waiting Person
3 Transportaion Vessels, Person (Cook), Materials, Tools
4 Over Processing Using Bigger Stove, Cooker, Mixie etc
5 Inventory Rice, Vegetables, Oil, Bread, Butter, Ghee,
6 Excess Motion Excess Hand, Leg, Body Motions
7 Defects Food that cannot be consumed
8 Under-utilized People
 Outline Process Chart 25th Mar 2010
Example (Battery Manufacturing)
Seconds / Serial
Battery Number Symbol Description (Task) Remarks
3 1 O Resin Application

7200 2 O Drying
1 o Inspection

1.3 3 O Fix vent caps

7.4 4 O Remove formation process sticker

2.8 5 O Place top cover on battery

3.4 6 O Paste formation process sticker

3.6 7 O Weld side 1 (Ultrasonic)

4.6 8 O Weld side 2 (Ultrasonic)

4.2 2 o Check weld strength
1.0 3 o Check resin

1.1 9 O Apply petroleum Jelly

5.5 10 O Place hardwarer packet on the + Terminal

7.9 11 O Fix the flaps on + Terminal

3.3 12 O Fix flaps on _ve Terminal

4.0 13 O Clean battery on all sides

1.0 14 O Clean battery on Top side

4.1 15 O Feel and stick Q label

7.1 16 O Feel and stick brand label

4.2 17 O Feel and stick caution Label

5.1 18 O Feel and stick Type stickers

 Outline Process Chart 25th Mar 2010
Example (Battery Manufacturing)
Seconds / Serial
Battery Number Symbol Description (Task) Remarks
3.0 19 O Feel and stick bar code label

2.0 20 O Punch serial number

2.5 21 O Punch date

1.2 22 O Record in traceability register

7.0 23 O Remove formation process sticker

1.0 24 O Place warranty card on top

57.0 25 O Do web sealing

2.9 26 O Feel and stick Q+ Sticker

1.0 27 O Feel and stick MRP label

28 O Place wooden skid on scissor lift

29 O Place battery on skid (first layer)

30 O Place card board on batteries

31 O Place battery (Second layer)

32 O Place card board on batteries

33 O Place battery (Third layer)

34 O Place card board on batteries

35 O Place battery (fourth layer)

36 O Place edge boards

37 O Place honey comb on top

38 O Stretch wrapping
 Outline Process Chart 25th Mar 2010
Example (Battery Manufacturing)
Seconds / Serial
Battery Number Symbol Description (Task) Remarks
39 O Do baling
7352.2
 Flow Process Chart
Flow Process Chart / Material /Type
Chart No: Sheet No: Summary
Subject Charted: Activity Symbol Present Proposed Savings
Operation
Activity: Transport
Delay
Method: / Proposed: Inspection
Location: Storage

Operative(s): Clock Nos: Distance (m)

Time (man-min)
Charted by: Date: COST
Labour
Material
Approved by: Date:
Total

Distance Time Symbol

Description Qty Remarks
(m) (min)

Total
 FLOW PROCESS CHART
Company: SUMMARY
Department/Section: TASK Symbol Exisiting Proposed Savings
Location: Operation ¡
TYPE: Material OperatorEquipment Type Transportation ð
Subject Charted: Inspection o
Activity: Storage s
Operator: Delay D
Method: Exisiting Proposed Cost (Labor)
Charted By: Date: Cost (Material)
Approved By: Date: Cost (Mequipment)
TOTAL
Symbol Analysis ACTION
TASK DESCRIPTION ¡ ð o s D Time (Min or Sec) Distance (m) Quantity What? Where? When? Who? How? NOTES Eliminate Combine Change Sequence Simplify Other
 MAN-MACHINE CHART
Company:
Department/Section:
Location:
Man-Machine
TYPE: Chart
Subject Charted:
Activity:
Operator:
Method: Exisiting Proposed
Charted By: Date:
Approved By: Date:

TIME UNIT
MAN MACHINE
TASK DESCRIPTION TIME TIME TASK DESCRIPTION
 SUMMARY
TASK Symbol Exisiting Proposed Savings
Man:

Working
Idle
Machine:
Working
Idle
Utilization:
Man:
Machine:
Cycle Time:
 Multiple Activity Chart
Flow Process Chart / Material /Type
Chart No: Sheet No: Summary
Activity Symbol Present Proposed Savings
Project:
Cycle Time

Man

Machine

Working
Process:
Man

Machine

IDLE
Machine (S):
Man

Machine
Operative(s): Clock Nos: UTILISATION
Charted by: Date: Man

Machine

TIME(min) Man Machine Time(min)

 Multiple activity chart

An operator at Goodyear Rubber Company is expected to take 2 minutes to load and

1 minute to unload a molding machine. There are several machines of this type, alll
doing the same thing, and the automatic run-time on each is 4 minutes. Respective
costs are Rs. 400 per hour for the operator, and Rs.1000 per hour for each machine.

One operator, Two molding machines Man-Machine chart

Time scale Operator M/C 1 M/C 2

1
Loading M/C 1
2
3
Loading M/C 2
4
Run time
5
6
Runtime
7 Unload M/C1
8
Loading M/C 1
9
10 Unload M/C2
11 60 2400
Loading M/C 2 Run time
12 7 280
13
14 Unload M/C1
Runtime
15 man mc
Loading M/C 1
16 1 6
17 Unload M/C2
18
Loading M/C 2 Run time
19 6.666667 166.6667
20
21 Unload M/C1
Runtime
22 7 173.33
Loading M/C 1
23 60 1485.686
24 Unload M/C2
25
Loading M/C 2 Run time
26
27
28 Unload M/C1
Runtime
29
Loading M/C 1
30
31 Unload M/C2
32
Loading M/C 2 Run time
33
34
35 Unload M/C1
Runtime
36
Loading M/C 1
37
38 Unload M/C2
39
Loading M/C 2 Run time
40
41
42 Unload M/C1
Runtime
43
Loading M/C 1
44
45 Unload M/C2
46
Loading M/C 2 Run time
47
48
49 Unload M/C1
Runtime
50
Loading M/C 1
 Runtime
Time scale Operator M/C 1 M/C 2
Loading M/C 1
51
52 Unload M/C2
53
Loading M/C 2 Run time
54
55
56 Unload M/C1
Runtime
57
Loading M/C 1
58
59 Unload M/C2
Run time
60 Loading M/C 2

1 Construct an operator-machine chart for the "one operator-two machine" situation.

Ans Side diagram
2 What is the cycle time?
Ans 7 minutes
3 What is the operators idle time per cycle
Ans 1 minute
4 What is the total idle time per cycle for both machines
Ans 6 minutes
5 What is the total cost per hour?
Ans Rs.2400
6 What is the total cost per cycle?
Ans Rs.280
7 What is the idle time cost cost per hour?
Ans Rs.1485.686
 Two-hands Process Chart
Part Name: S. No Description Symbol
Drawing/Part Picture: 1 Select SL
Production Line: 2 Search SR
Workstation: 3 Find FD
Operation: 4 Transport Empty TE
5 Grasp G
6 Regrasp RG
Operator: 7 Transport Loaded TL
Date of Study: 8 Preposition PP
Shift: 9 Position P
10 Use U
Analyst: 11 Assemble AS
Charted By: 12 Disassemble DS
13 Apply Pressure AP
14 Turn T
15 Crank C
16 Eye Travel and Eye Focus ET & EF
17 Release RL
18 Hold H
19 Inspect IN
20 Plan PL
21 Avoidable Delay AD
22 Unavoidable Delay UD
23 Rest R
24 Body Motions BM
 Two-hands Process Chart
Part Name:
Drawing/Part Picture:
Production Line:
Workstation:
Operation:

Operator:
Date of Study:
Shift:

Analyst:
Charted By:

Element# LEFT HAND

1 SL SR FD TE G RG TL PP P U AS DS AP T C ET & EF RL H
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
 RIGHT HAND
IN PL AD UD R BM SL SR FD TE G RG TL PP P U AS DS AP T C ET & EF RL H
IN PL AD UD R BM
Machine Name Sheet Yard

Sheet Yard
RM Stores
TPP1 (pega)
TPP2 (Emnew)
TPP3 (Emold)
TPP4 (AE)
PH
Drilling
Shearing 1 (old)
Shearing 2 (new)
110T(new)
110T(old)
63T
AIDA 1
AIDA 2
ISGEC 163T
RG50
RG35
RG35(New)
RG100(old)
RG100(New)
RG-125
HDS50 - 1
HDS50 - 2
Trays Fab1
Trays Fab2
Others
Cab fab
Small parts
Pretreatment
Auto Powder coating
Manual Powder coating
Trays Final Fitting
AREL final Fitting
ARPSL Final Fitting
External Final Fitting
Loading Area
Total

METRICS
Description UOM
MH Load forward Ton-m/year
MH Load back tracking Ton-m/year
MH cost/year Rs.mn/year
Number of 90 deg. Turns No's
 Mate
RM TPP1 TPP2 TPP3 TPP4 PH
Stores (Pega) (EmNew) (Emold) (AE)

204 250 360 335 20

 204 250 360 335 20

AREA in sqm
Quantity Description Quantity
2217798 Machines 2015
300708 Tooling 126
4.2 Maintenance 50
171 Stores 912
Utilities 150
Amenities 122
Displays 68
Office 145
WIP 962
FG 609
Aisles area 970
Approx. surface area 6129
Material handling load for exis
Shearin Shearin 110T
Drilling g 1 g2 110T(old) 63T AIDA 1
(new)
(old) (New)

40 180 93 27.5

1 5

21 13
2
2
1 40 180 114 27 30
sqm.
d for existing layout (850 MT/Mo
AIDA 2 ISGEC RG35 RG100 RG100
RG50 RG35
163T (New) (old) (New)

105 80
23
10 34 13
150

8
28 50

2 2
1.5
30 50 115 25 44 93 150
50 MT/Month)
RG-125 HDS50 - HDS50 - Trays Trays Others Cab fab
1 2 Fab1 Fab2 Fab

34.5 38
72 164
6.5 23 27
33 29

7 2
8 5 4.3
7.5 9
3 4 8 4
9 4
65 77

31 19
 38 28
40.5
27.75
28 17 3
29 17 2

40 83 177 279 237 5 102

Small Pretreat Auto Manual Trays AREL ARPSL
parts Powder Powder Final final Final
ment
(fab) coating coating Fitting Fitting Fitting

6 6.4

61
25

33

81
28

42
14
14
456
473
106
71
14
549.7 357.5
16 355 144
200

77 1358 550 364 362 144 200

Externa Loading
l Final Area Total
Fitting

1510
0 12
258
259
121
212
67
25
0
42
79
11
21
18
52
13
142
81
50
 93
41
70
61
62
456
473
106
71
14
907
515
120 320
0
0
0
0
0
120 0 6161 Ton-m/Day

184817 Ton-m/Month
2217798 Ton-m/Year
TIME STUDY
Date: 4-Aug-15
Area/Department/Section:
Machine/Workcenter:
Operator:
Time:
Time Study Analyst:

S. No Machine Element Manual Element Total Cycle Time

Comments
 TIME STUDY FORM-B
Company: Layout/Photograph:
Department/Section:
Location:
Subject Charted:
Activity:
Operation:
Machine:
Tools and Gages:
Operator:
Study By: Date:
Approved By: Date:

Observed Time
S. No Element Description 1 2 3 4 5 6 7
e
8 9 10 Average Rating BT Allwnc Std Time

TOTAL:
 TIME STUDY FORM-A
Company: Layout:
Department/Section:
Location:
Subject Charted:
Activity:
Operation:
Machine:
Tools and Gages:
Operator:
Study By: Date:
Approved By: Date:

S. No Element Description Observed Time Rating Basic Time Relaxation Allownace

ORM-A

Contingency Allowance Standard Time

Rating Exercise (Pinboard)
12-Nov-10

Trail Time Actual Rating Observed Rating (Sudarshan)

1 38.87 63 80
2 31.67 78 83
3 30.34 81 85
4 31.61 78 90
5 30.87 80 95
6 25.22 98 100
7 26.19 94 102
8 26.72 92 110
9 24.27 101 120
10 29.55 83 120
140

120

100

80
Column E

60 Column F

40

20

0
1 2 3 4 5 6 7 8 9 10
 Station station -10 station -7 station -8 station -9 station -5
Operation Time 54 53 57 29.47
1 32 51 0 32 15.4
2 42 53 54 59 30.5
3 38 55 52 31 15.6
4 39 53 0 65 32.9
5 49 52 58 31 15.8
6 40 60 68 61 30.5
7 63 50 0 48 14.9
8 29 50 0 62 30.5
9 63 51 0 52 15.1
10 30 53 52 67 30.5
11 40 55 54 35 15.8
12 35 54 0 60 29.9
13 64 57 0 38 15.9
14 32 60 58 58 30.4
15 51 50 68 32 15.8
16 46 58 0 53 30.8
17 42 52 0 33 14.8
18 57 53 52 52 31.1
19 72 57 56 35 16.1
20 54 53 54 54 31.2
21 52 54 0 32 16.2
22 40 54 0 57 32.1
23 63 61 57 36 16.1
24 29 62 54 58 29.48
25 63 55 60 32 14.8
26 30 57 0 55 29.65
27 32 56 0 30 14.7
28 51 57 53 55 30.2
29 46 52 54 32 15.9
30 42 53 0 60 30.5
31 57 53 0 38 15.6
32 54 54 0 62 29.9
33 52 58 54 34 15.1
34 40 57 55 65 29.5
35 63 59 0 36 14.8
36 51 60 0 63 29.5
37 46 55 52 35 16.1
38 42 50 54 62 29.5
39 52 53 58 35 15.2
40 67 52 53 50 30.5
Avg 47.25 54.73 30.75 47.13 22.97
Min 29 50 0 30 14.7
Max 72.00 62.00 68.00 67.00 32.90
Talk Time 67.5 67.5 67.5 67.5 67.5
PCT 57.4 57.4 57.4 57.4 57.4

Chart Title
80
72.00
70 68.00 67.00
62.00
60
57.4 57.4 57.4 57.4 57.4 57.4 57
50
 Chart Title
80
72.00
70 68.00 67.00
62.00
60
57.4 57.4 57.4 57.4 57.4 57.4 57
50

40
32.90
30 27.00

20

10

0
station -10 station -7 station -8 station -9 station -5 station -4 station0.-
Avg Min Max Tal k Ti me
 station -4 station -10 station -10 station -10 station -10 station -10
27.71
2.35
26.53
2.1
27

14.50 #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

2.1 0 0 0 0 0
27.00 0.00 0.00 0.00 0.00 0.00
67.5 67.5 67.5 67.5 67.5 67.5
57.4 57.4 57.4 57.4 57.4 57.4

Chart Title

7.4 57.4 57.4 57.4 57.4 57.4 57.4

 Chart Title

7.4 57.4 57.4 57.4 57.4 57.4 57.4

2.90
27.00

-5 station -4 station0.00
-10 station0.00
-10 station0.00
-10 station0.00
-10 station0.00
-10
n Max Tal k Ti me PCT
 Station station -01 station -02 station -03 station -04 station -05
Operation Time
1 24
2 32
3 25
4 25
5 24
6 26
7 23
8 35
9 30
10 30 39
11 29 24
12 29 21 45
13 33 31 41
14 34 28 42
15 33 26 40
16 25 30 54
17 33 15 56
18 28 30 56
19 27 32 56
20 35 19 56
21 27 39 55
22 32 34 55
23 26 34 57
24 26 19 46
25 34 28 47
26 30 31 50
27 33 21 47
28 33 36 43 70.00
29 32 29 46
30 33 30 53 60.00
31
32 50.00
33
34 40.00
35
36 30.00
37
38
20.00
39
40
#DIV/0! 29.53 28.38 49.74 10.00
#DIV/0!
Avg
Min 0 23 15 40 0
Max 0.00 35.00 39.00 57.00 0.00
0.00
Talk Time 67.5 67.5 67.5 67.5 67.5 1
PCT 57.4 57.4 57.4 57.4 57.4

Chart Title
80

70

60 57.00
57.4 57.4 57.4 57.4 57.4
50
 Chart Title
80

70

60 57.00
57.4 57.4 57.4 57.4 57.4
50
39.00
40 35.00
30

20

10

0
station 0.00
-01 station -02 station -03 station -04 station 0.00
-05
Avg Min Max Ta lk Ti me PCT
70.00
Takt time
60.00 PCT

50.00

40.00

30.00

20.00

10.00

0.00
1 2 3

57.4
 57.4

tion 0.00
-05
 Station station -01 station -02 station -03 station -04 station -05
Operation Time
1 57 44 60 35 66
2 60 44 62 40 71
3 63 44 57 47 63
4 61 67 60 44 60
5 66 51 58 38 63
6 84 56 45 38 59
7 65 47 60 41 68
8 87 53 56 43 62
9 63 52 60 48 66
10 62 53 57 33 68
11 66 46 58 37 64
12 65 50 59 39 59
13 74 54 49 35 54
14 58 50 53 37 57
15 61 45 56 40 56
16 60 61 58 41 60
17 83 47 50 37 54
18 74 53 57 38 56
19 68 45 56 41 54
20 76 68 59 34 49
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Avg 67.65 51.50 56.50 39.30 60.45
Min 57 44 45 33 49
Max 87.00 68.00 62.00 48.00 71.00
Talk Time 67.5 67.5 67.5 67.5 67.5
PCT 57.4 57.4 57.4 57.4 57.4

Chart Title
100
90 87.00

80
71.00
70 68.00
62.00
60 57.4 57.4 57.4 57.4 57.4
 Chart Title
100
90 87.00

80
71.00
70 68.00
62.00
60 57.4 57.4 57.4 57.4 57.4
50 48.00

40
30
20
10
0
station -01 station -02 station -03 station -04 station -05
Avg Mi n Max Ta l k Ti me PCT
 station -06 station -7 station -8 station -9 station -10

51 51 0 32 42
67 53 54 59 38
53 55 52 31 39
58 53 0 65 49
56 52 58 31 40
61 60 68 61 63
58 50 0 48 29
56 50 0 62 63
53 51 0 52 30
58 53 52 67 40
56 55 54 35 35
61 54 0 60 64
62 57 0 38 32
54 60 58 58 51
50 50 68 32 46
50 58 0 53 42
49 52 0 33 57
53 53 52 52 72
49 57 56 35 54
52 53 54 54 52

90.00

80.00

70.00

60.00

50.00

40.00

30.00
55.35 53.85 31.30 47.90 46.90
49 50 0 31 29
20.00
67.00 60.00 68.00 67.00 72.00
67.5 10.00 68.00 36.00 43.00
10.00
57.4 67.5 67.5 67.5 67.5
57.4 57.4 57.4 57.4
0.00
1 2 3

71.00

57.4
 71.00

57.4

tion -05

62 68
 PCT

1 2 3 4 5 6 7 8 9 10
 Takt time -67.5

PCT-57.5

9 10
 Station station -7 station -8 station -9 station -10
Operation 54 53 57 32
1 51 0 32 42
2 53 54 59 38
3 55 52 31 39
4 53 0 65 49
5 52 58 31 40
6 60 68 61 63
7 50 0 48 29
8 50 0 62 63
9 51 0 52 30
10 53 52 67 40
11 55 54 35 35
12 54 0 60 64
13 57 0 38 32
14 60 58 58 51
15 50 68 32 46
16 58 0 53 42
17 52 0 33 57
18 53 52 52 72
19 57 56 35 54
20 53 54 54 52
21 54 0 32 40
22 54 0 57 63
23 61 57 36 29
24 62 54 58 63
25 55 60 32 30
26 57 0 55 32
27 56 0 30 51
28 57 53 55 46
29 52 54 32 42
30 53 0 60 57
31 53 0 38 54
32 54 0 62 52
33 58 54 34 40
34 57 55 65 63
35 59 0 36 51
36 60 0 63 46
37 55 52 35 42
38 50 54 62 52
39 53 58 35 42
40 52 53 50 52
Avg 54.73 30.75 47.13 47.13 #DIV/0!
Min 50 0 30 29 0
Max 62.00 68.00 67.00 72.00 0.00
Range 12.00 68.00 37.00 43.00 0.00
Talk Time 67.5 67.5 67.5 67.5 67.5
PCT 57.4 57.4 57.4 57.4 57.4

Chart Title
80

70 68.00
67.5 67.5 67.5

60
54.73 57.4 57.4 57.4
50
50 47.13
 Chart Title
80

70 68.00
67.5 67.5 67.5

60
54.73 57.4 57.4 57.4
50
50 47.13

40 37.00
30.75 30
30

20
12.00
10

0
station -7 station
0 -8 station -9
Avg Mi n Ra nge Ta l k Ti me

62 68 67
 #DIV/0! #DIV/0! #DIV/0! #DIV/0!
0 0 0 0
0.00 0.00 0.00 0.00

67.5 67.5 67.5 67.5

57.4 57.4 57.4 57.4

Chart Title

67.5 67.5 67.5

57.4 57.4 57.4

47.13 47.13
Chart Title

67.5 67.5 67.5

57.4 57.4 57.4

47.13 47.13
43.00
37.00

30 29

station -9 station -10 0 0.00

Ra nge Ta l k Ti me PCT

72