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Analysis
OBJECTIVE
Dynamic staggering
Alert systems
Flexible group of
staggerers
are
used
replacing
current 3:1 ratio
Workforce
alert
systems are installed
Involves
the
need
based solutions in the
process
OEE improvement
Preventive maintenance
Design improvement
Areas of design
improvement in the
system is taken care
by the process
Defining the
standard work
pattern of the worker
IT Solutions
as well
Operations flow
Current
Manning
Standard time L4
Standard time L4
Boxing
optimization
Operation
Standard time
11 seconds
1 minute 7 seconds
17 seconds
10 seconds
22 seconds
5 seconds
1 min 25 seconds
TOTAL
3.6 minutes
Operations
L3
L2
Units per box
216
120
Minutes taken to fill
2.057143 1.142857
Boxes in a pallet
48
40
Pallet turnaround time (mins)
98.74
45.71
Time taken to fill a pallet
9.4
8.33
Rearrangement time 3 minutes
For every two hours the 2 GT/YIT are utilized only for 27
minutes which can be optimized by man force reduction
Current practice
Functions: i) To check th
availability of the boxes
In L2,L3 as well as bottles
in L4 ii) movement of loa
lifter to boxing location
Functions: i) Arrangement of
incoming boxes ii) movement
of boxes to slit
Proposed practice
Pallet Manning
optimization
ime analysis Palleting process
Alert systems
Alert systems
Current practice
L3 packaging line
Proposed practice
Position
Findings
analysis
d every position of manning in the line is analyzed and effective working percentage in the system is ident
ent system: i) Position of a YIT near the orienter is a NVA activity caused due to design
the current system the worker has 12% of value added activity to the system and improving it
he workers within the loop are capable of handling the defects can be done
orienter
efects are happening as the effect of machine process - Orienter
orienter
sed system: i) Employee in the machine loop can take care of this process as it is a lowly
NVA
hine must be shifted other side so that the person in the system can work on it
L4 line
nt system: i) YIT at packaging area of large boxes has a idle time of around 35% and he packs
s/10 minutes
Bundling
mal packing capacity would be around 9 boxes/10 minutes of packing
Packaging YIT
sed system: i) YIT can take care of the taping as well as arrangement of the boxes in the pallet
idle time is reduced from 35% to 21% and labor on that part is reduced and can be focused
ll box packaging
ngs from L4 line:
e line as observed is not constrained by labor effectiveness but by the machine breakdowns decreasing OE
petitive failure of few critical machines are observed and effective preventive maintenance should be done
w positions of labor are not VA labor but they are due to machine defects which can be improved and shifte