Sr.

No Issues Observed Action Proposed Benefits Remarks

Warcon laser machine engraving
1. Update nesting program for engraving
1 program- Laser head goes up & down 2. Take help from laser experts Cycle time reduction
100mm for each letter engraving
increasing cycle time

1. Increase the batch size by identifying

2 Bending Machine Frequent setup common components for each variants Lesser setup change will save setup change
change 2. super market to buid safety stock for time and productivity will improve
common components of Tipper

Bend observed in sheets in laser and

3 plasma may damage laser head and Rolling of sheets to be done befor cutting 1. Breakdowns can be avoided
2. Quality will improve
Mirror

Visual Display for SOP, Machine start Proper documents display to be done New Operators training can be done and
4 up, Parameter sheets not available (Pictorial view) Operator dependencies will be reduced

Racks are not labled for material Master list on rack to be displayed with
5 material number Material traceability and ease for storage FIFO needs to be maintained
storage Eg- Rack1.1- XXX material(with Photo)

Incoming sheets found rusty & Shed for R/m storage area 1. Pneummatic lifter cylinder may get damaged
6 if external particle get inside gripper cylinder
Unclean FIFO to be maintained 2. Quality will improve with material safety

Tipper line Tailgate and Head body

assembly offline station
- Only tacking done full welding done Full welding to be done in additional station 1. Standardize work
7 2. Hurdle in internal material flow
on floor in front area of tipper. offline 3. Reduce waiting time
-Other operators waiting till
Headbody full welding done

1. Standardize work
Side body LH/RH plate welding on
8 floor for head body fitment Dedicated work station to be provided 2. Hurdle in internal material flow
3. Reduce waiting time

1. Standardise work
9 Variant wise Job card with drawings 2. To avoid wrong part/welding on variant

Unnecessary rails to be removed

10 causing hurdles for internal material
and man movement
Eg- In tipper welding area

compactor all fixture available for

11 welding ok

Dedicated work station with kitting Dedicated work station with kitting trolley Kitting trolly available but to
13 Standardise work be identified labled and
trolley for compactor assembly for compactor assembly to be provided modified as per veh set

Compactor assembly line nut

12 runners / SOP / Drawings to be
provided for hydrolic fitting

Compactor Hyd assy done on floor

14 Stand for compactor at assembly line New stand to be provided Standardise work

Alternate solution for welding stands

15
of tipper line
 Ajay Sir's Shopfloor observation Points

Sr. No Issues Observed Action Proposed Responsibility Remarks

1 Material R/m sheet lying in Gangway Anand B Find Alternate solution
Discipline isue

2 Jib crane provision for Bending line Sagar Pawar

3 Machine shop super market Sagar Pawar

Rack reduction in front of Shearing
4 Anand B
line
Trolley provision for internal material
5 Ganesh Patare
movement
Tail door and Hear board full welding Dran engineering and other
6 Fixture and work station provision Anand B
offline welding station suppliers

Step and iges file for all types tailgate

7 Amol Shinde
and Head board

8 WIP storage fo RCB Ganesh Patare

Study for RCB floor assembly wave

9 Anand B Eliminate waviness
coming after welding

808 RCB side board design feasibility Check for 4mm thickness
10 Anand B
3mm thickness wall not OK. impact

11 Tipper Tailgate sq tube cutting with Anand B

standard plasma

12 RCB No welding after painting. Anand B

Check for fouling in assembly shop
 Assembly Area / Mahendra Material Storage Area
Tipper Parking / Chassis AS1 AS2 AS3 AS4 AS5
Rework Area mtg

Side Body LH/RH welding station

BAY-2

Gangway

WS1 WS2 WS3 WS4 WS5 WS6 WS7 WS8

Fabrication Area
U-Body welding

Welding M/c Welding M/c Welding M/c Welding M/c Welding M/c Welding M/c Welding M/c Welding M/c
Welding
M/c

Manpower Allocation
Machine Mp / Shift No of
shifts
Laser 2 3
Plasma 2 3
Bending 600 4 3
Bending 160 1 3
Drilling 1 1
Shearing 3 1
Shot Blasting 4 3
Primer 3 3
Tipper Line 6 3 8 Stations
U-Body As Reqd
 Assembly Area / Mahendra Tack Welding Floor Rock WIP Storage
Tipper Parking / Chassis AS1 WS5 WS6 WS7 WS8 Fixture Rock Breaker
Rework Area mtg Body Welding

Shot Blasting + Primer Line

Gangway
BAY-2

Tack Welding Floor Rock

Fabrication Area WS1 WS2 WS3 WS4 Fixture BOX Breaker
Body Welding
U-Body welding WIP Storage

Manpower Allocation
Machine Mp / Shift No of
shifts
Laser 2 3
Plasma 2 3
Bending 600 4 3
Bending 160 1 3
Drilling 1 1
Shearing 3 1
Shot Blasting 4 3
Primer 3 3
Tipper Line 6 3 8 Stations
U-Body As Reqd
Observations
All fixtures available for Compactor line