1.

Daily production data of unit 4(core machining area)

Table 1. unit 4 daily production data

Target/shift Achieve Remainin No of No of Average Total No Total production

d g workstation worker cycle time production of in one day
s shift Presen Revised
t
2. Daily 6500
Bush production
0 19 data
3 unit 2 (pickling
4sec/unit buffing
123500 3 and
370500 392730
inspection)
Peterman
(6500)
Pin 5800 0 27 5 4.3sec/uni 156600 3 469800 559062
Peterman t
(5800)
Tornos INS 18000 0 8 2 1.5sec/uni 144000 3 432000 440640
bush t
 Target Achieved Remainin No of work station No of Material Rejection
g Buffing Inspection packin workstation movement
g s
CV(70000) 96% 4% 7 12 3 7 - 1000
SV 96% 3% 10 17 5 10 - 2000
TR13(70000)
TR(150000)
TR218(12000
)
V1(20000)
Pickling 480000 - 5 1 - -
(480000)

Table 1. unit 2 daily production

 Revised production data unit 2

Target Achieve RemaininTable 3. No

Revised production
of work station data unit 2 No of Material Rejection
d g Buffing Inspectio packin workstation movement
n g s
CV(87000) 98% 2% 7 12 3 7 - 1000
SV(315000 98% 2% 10 17 5 10 - 2000
)
Pickling 550000 30000 5 1 - -
 3 Monthly Production Data Unit -1 Core Assembly

Types of Availa Targ Producti Achiev Balance in lakhs Achievable

compone ble et in on /day ed in after
nts machin lakhs lakhs implementat
e ion of lean
Remaini achieva In lakhs
ng ble
Regular 05 60.00 2.07 41.17 18.83 56.85 58.52
core Table 4. Monthly Production Data Unit 1 Core
Assembly
INS core 02 75.00 2.19 46.42 28.52 46.42 72.75

INS pin 02 75.00 2.28 42.71 32.29 58.98 72.75

CH pin for 02 10.00 0.25 3.76 6.24 5.192 9.7

p7
3.1 Assembly line balancing Blitz machine centre

Task Task time unit Proceeding

/minute task
A 65 B
B 63 -
C 63 -
D 66 -
E 68 -
F 62 C
G 61 H
H 64 -
I 66 -
J 67 B, A, C
K 66 C, F, E
L 62 G, H, J