Best Practice :TPS Visualisation

Prashant Mahindrakar- Knorr Bremse India Pune, September 7th, 2007

Knorr-Bremse Group

Best Practice : TPS - Visualization

Team : KB,India Industrial Engineering Team.
Department : Operations Industrial Engg.

Team Members (starting from left)

1. Vinayak Ganachari. 2. Shripad Hambir. 3. Prashant Mahindrakar. 4. Jyoti Dahatonde.

Knorr-Bremse Group

TPS : TRUCK PRODUCTION SYSTEM.

Visualization
Goal : Establishment of Corporate identity and effective communication of product and production relevant data, so that corrective action and quality awareness will be improved across the organization.

Knorr-Bremse Group

Best Practice : TPS - Visualization

The information displayed are, Team Info, Assembly Info and Cell Info, with the following details: (a) Team Info Board :- Displays the information related to daily production, current issues, product quality, team working on the cell and the internal audit reports. (b) Assembly Info Board :- Displays the exploded view of the product, with the individual part identification. (c) Cell Info Board :- Cell info board gives details about the salient features of the Product and the Cell, the type of layout used for the cell with the location on the shop floor. This also displays the flow of process on the product cell. The use of product on the vehicle and location on the vehicle is also displayed.

Knorr-Bremse Group

TPS : TRUCK PRODUCTION SYSTEM.

Team Info Board

Assembly Info Board

Cell Info Board

Investment: The total investment per product is Rs. 22,450 /- for 3 boards.
Knorr-Bremse Group

Team Info Board

Production Plan V/A Actual

Team Members

Daily Production Reports

Operator Skill Matrix

Internal Line Audit Report

Daily Cell Checklist

Customer PPM
Knorr-Bremse Group

Projects Review

FTFA-Report
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Team Info Board

Production

Production Performance Plan Vs Actual : 1. 2. Production numbers on y-axis. Three months data on the x-axis. Last two months achieved and the present months target. Blue color for plan and brown for achieved. Updating frequency- monthly Responsibility: Industrial Engg.

3. 4. 5.

Knorr-Bremse Group

Team Info Board

Production

Daily Production Performance : 1. 2. 3. 4. 5. 6. 7. 8.

Knorr-Bremse Group

Production numbers on y-axis. One y-axis for daily production and other for monthly production. Days of month on the x-axis. Tabulated data for cumulative production, O.K. and rejection Green line for daily production target. Blue line for monthly production target. Blue curve to show cumulative data. Updating frequency- daily Responsibility: Industrial Engg.
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Team Info Board

Audit

KBI- Internal Audit Results : 1. 2. 3. 4. 5. All products are audited once in six months as per VDA 6 Part 3. The process audit rating in terms of degree of fulfillment is displayed. The summary also encloses the planned actions for the audit observations. Updating frequency- six months Responsibility- Quality Assurance

Knorr-Bremse Group

Team Info Board

Quality

Quality- Functional Test Failure Analysis Report : 1. 2. Tabulated daily FTF quantity against the daily production, PPM and cumulative PPM Graph on the left side gives weekly rejection PPM trend with Week no.s on x-axis and PPM on the yaxis. Graph on the right gives PPM monthly PPM trend for the current calendar year. Corrective action plan with responsibility, target date and Status tabulated at the bottom. Updating frequency- weekly Responsibility- Quality Assurance
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3. 4. 5. 6.
Knorr-Bremse Group

Team Info Board

Quality

Quality- Customer PPM 1. 2. 3. 4. Month on x-axis and PPM on the y-axis. Gives monthly PPM trend for the present calendar year. Updating frequency- monthly Responsibility- Quality Assurance

Knorr-Bremse Group

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Team Info Board

Continuous Improvement

Continuous Improvement- Project Review 1. 2. All the Continuous Improvement projects for the particular product are enlisted. Projects categorized under. For eg: CI: Capacity Increase, IQ: Improvement in Quality , IP: improvement in Productivity, Safety and Environment (SE), Improvements in Systems (IS) 3. 4. 5. 6.
Knorr-Bremse Group

Responsibility- main and co-operation with target dates shown. Present status traffic light signals- Green: as per schedule, Yellow: Delay under control, Red: delayed. Updating Frequency weekly Responsibility Industrial Engg.
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Team Info Board

Team Information

Team Information: 1. 2. 3. Photographs and name of the operators working in the particular cell are displayed. Updating Frequency whenever a team member changes. Responsibility Manufacturing.

Knorr-Bremse Group

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Team Info Board

Skill Matrix: 1. 2. 3. 4. 5. 6. Shows the present level of competency of the operator for all the products. Three levels of skill based on defined criteria B: Basic, I: Intermediate and C: Competent. Green color shows the operators current skill level. Updating Frequency monthly. Responsibility Manufacturing.

Knorr-Bremse Group

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Team Info Board

Daily Checklist: 1. 2. Part of TPM- Autonomous Maintenance by the Operator. All the check points enlisted for machine aspects Pneumatic, Electrical, Mechanical and general and checked and then ticked on the checklist. One of the operator identified as TPM member from the team signs the checklist on daily basis. Updating Frequency daily. Responsibility TPM Member

3. 4. 5.

Knorr-Bremse Group

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Cell Info Board

Product

Product Features

Application Location in Truck

Cell Features

Cell Layout

Process Flow

Location On Shop Floor

Knorr-Bremse Group

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Assembly Info Board

Displays the Exploded View of the Product

Knorr-Bremse Group

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Best Practice : TPS - Visualization Benefits :

A. Customer/ Visitors:
Tansperancy Confidence building Visualisation of internal parts

B. Team/ People:
Tranining/ Awareness Pride and ownership Awareness of Key Performance Parameters of the cell.

C. Processes:
Improvement projects actions planend and status. Functional Test Faulire Analysis Daily checks to be performed on the line as part of autonomous maintence by Operators.

...Thank you
Knorr-Bremse Group

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