3. INTERNAL ADVISOR EXTERNAL ADVISOR

4. OVERVIEW
INTRODUCTION
DATA COLLECTION AND METHDOLOGY
RESULTS & DISCUSSIONS
CONCLUSION

5. OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
 Company Profile:
Alsons AutoParts (Pvt.) Ltd. Is an ISO 9001 and ISO-14001-2004 Certified
company which was established in 1988, and has become a leading name in
the Pakistan Automotive Industry.

6.  Major Products:
Alsons AutoParts Pvt. Ltd. consists of three main products in their manufacturing
plant, which are given below;
 Plastic Injection Moulding Products
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

7.  Sheet Metal Products:
 Automotive assembly products:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

8.  Existing Situation:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
The existing situation of press shop is that they have a targeted schedule
of the production of 1200 plates daily for Suzuki with a Takt time of
0.375 min/pcs which is difficult to achieve so in order to meet the
customer demand they go for over time.
The company experiences the following issues in the manufacturing of
backing plate at press shop.
 Lack of Traceability of product.
 Greater lead-time.
 Unnecessary stoppages
 Greater Takt time
 Issues:

9. INTRODUCTION:
Industries are in the favor to get more capital and resources to improve their
productivity.
It is necessary to optimize their capital, time and working environment. Industries
needed improvement tools to optimize its processes to attain more capable results.
Many improvement techniques and tools were developed and adapted to work in the
different types of business.
Now day’s industries focused on more production with higher efficiency in less lead
time. The companies focused mainly on customer satisfaction. In an increasingly
competitive environment, many manufacturing firms are looking for a winning card
over their competitor. Manufacturers have to understand that the conventional
production system has to connect with the lean tools and techniques.
Lean manufacturing system was developed by Toyota, Japan.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

10. Project Background:
A shorter lead time results into better utilization of manufacturing resources,
quick adaptation to customer’s demand, reduced cost and better products.
Today companies are intensively indulging in activities to reduce their
production lead times.
Our Team, keeping in mind, the importance of a short lead time, therefore we
worked in Alsons AutoParts with the intention to reduce Production Lead time.
Technique that the team adopted was Value Stream Mapping .
Value stream mapping is the technique of Lean Manufacturing.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

11. VALUE STREAM MAPPING:
Value Stream Mapping (VSM) tool shows all the activities, from supply to
final product through the different processing steps.In other words it is a
sketch of a production line.
Value stream map is the technique that bring the all processing steps at one
place. It shows the big picture of shop floor rather than individual processes
and improving the each area at the production line. It is used to draw
attention to different wastes and eliminating them in Future State Map.
It is necessary that every process as closely as possible produces only what
its customers need. The existing processes have some types the waste in a
production line which is the result of product design and machinery.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

12. Lead Time:
• A lead time is the time interval between the initiation and
execution of a process.
• In industry, lead time reduction is an important part of lean manufacturing
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

13. Critical inputs for the VSM:
The following data are considered to be important in a value stream
mapping project.
• Cycle time
• Number of operators
• Waiting time
• Process time per shift
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

14. Methodology:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

15. 1.Selection of the Product:
The selection of the product is very important step in Value Stream Mapping.
Baking plate is the critical product of the Alsons AutoParts due to its
requirement and demand by the Suzuki Automobiles.
There is the lack of traceability, scheduling, greater lead time, unnecessary
stoppages, etc. Due to these problems the completion of the customer
demand on time will be difficult.
After observing all these major issues which will directly effects the whole
production system .BAKING PLATE is our critical product for working for
the improvement
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

16. 2.Collection of Relevant Data:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
I. Product flow within press shop.
II. Cycle time of each process.
III. Identification of bottlenecks.
IV. Transportation of product within press shop.

17. OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
I. Product Flow within Press Shop:

18. Process Cycle time
Shearing 13sec
Blanking 23sec
Forming 12sec
Collar Bending 11sec
Flattening 8sec
Piercing 1 10sec
Piercing 2 10sec
Chamfering 11sec
CO2 Welding 20sec
Remering 10sec
Spot Welding 28sec
Debeurring 12sec

19.  Flattening
It has the capacity of 960 pieces per shift which is a bottleneck for press
shop.
Reason:
Lack of trollies at the workstation, which stops the production after 100
pieces which creates bottleneck for production system.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

20.  Spot Welding:
It has the capacity of 450pieces/shift by each machine. Press
shop has 2 spot welding machines which produces 900 pieces
per shift.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

21. IV. Transportation Method:
1-With the help of trollies.
2-Fork lifter.
3-Manual lifter
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

22. OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
3.Current State Map:

23. Description:
• The current state map shows that the backing plate has the
production lead time of 12.6 hours.
• It clearly shows the unwanted Waiting Time between each
workstation .
• It shows the big picture about the real time process &
performance of the production process.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

24. 4.Identification the nature of wastes in the process:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
Wastage of time:
• Un necessary usage of lifter between the process shearing &
blanking which causes delays in production up to 1 hour due to un
availability of lifter at the press shop.
• Lack of availability of trollies at each work station which causes
the process to stop & wait for the raw material inventory .

25. OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
5.Future State Map

26. Future Product Flow Layout:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

27. Description:
• Lead time reduced about 2.25 hours i.e. 20% reduction
which reduces the companies overtime cost.
• Reduced the transportation between the processes.
• Kaizen burst:
1)Machine Relocation
2)Material handling equipments
3)New machine.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

28. 6.Suggestion for Improvements:
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION
Ergonomic trollies should be used
which provides effective
transportation within press shop.
I. Material Handling Equipments

29. II.Machine Relocation:
Relocation of blanking machine near to shearing machine so that the
operation of lifter will be eliminate which reduces:
1- Transportation time.
2- Transportation cost.
3- Process waiting due to un availability of lifter.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

30. III. New Machine
 Another Spot Welding Machine should be install to fulfill the requirements.
 Cooling system must be maintained properly for effective working.
Good quality electrodes will help to increase productivity & on time
delivery of products.
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION

31. Conclusion:
The project was to reduce the production lead time, for this purpose the team
selected lean manufacturing tool Value Stream Mapping.
In addition to reduction of lead time, following benefits were expected after
the completion of the project.
 Improved productivity
 Determination of Value stream
 Better understanding of Wastes and their causes
 A roadmap towards an efficient, lean production line
OVERVIEW INTRODUCTION
DATA
COLLECTION &
METHODOLOGY
RESULTS &
DISCUSSIONS
CONCLUSION