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Introduction
DEFINE
MEASURE
ANALYZE
IMPROVE
CONTROL
DEFINE
Problem Definition
DEFINE
Problem Definition
DEFINE
Problem Definition
Rework in components
Majority of the time is spent in non value added process such as personnel movement, Photostat copying, etc.
Data Collection
MEASURE
Rework in components
In the month of June, 1695 components were inspected Of the 1695 components, 98 components were reworked. Time Management A value stream map revealed that on an average, a component requires 135 min for inspection of which 25 minutes is the value added time required while the remaining non-value added time was spent on movement of inspection personnel, arranging the component, cleaning the component etc If an error is made in measurement, the entire time is wasted.
Rework in components
Error in reading the value on the micrometer scale
IMPROVE
An ideal mistake-proofing method is to cross check the reading with a Vernier caliper to ensure that a reading error was not made It is not time consuming and avoids any repeatability of inspecting the component once again
CONTROL
To prevent recurrence of errors, a separate column in the inspection report is made where the Vernier caliper/pie-tape readings can be noted adjacent to the micrometer reading. To Manage time, during any process, say for example dismantling of any equipment, the assembly section can offer the equipment for inspection so that inspection and dismantling can be carried out parallel rather than in series. Using formats (with drawing readings/tolerances)for commonly dismantled assemblies and keeping instruments ready can reduce time by 25%
Cost Analysis
Cost of inspection/ hr (average)
Previously , cost incurred is Rs. 157 per hour (considering a M10 employee earning Rs.450000 PA) i.e Rs 354 for Inspecting (for 135 min) After Poka-yoke, a 25% of cost is reduced i.e, Rs 265 per hour