PROCESS

IMPROVEMENT

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 Bay-4 Current Layout

Shot Peening + Primer Line

Shearing Area

Tail gate Sliding

side sheet Channel Tail Gate Tail Gate
Tail Gate
LH/RH LH/RH Tacking Full Welding
Finishing
Assembly Assembly fixture Fixture

Gangway

Old Tailgate Old Tailgate

Fixture Full Welding
Assembly
Subassy
Bin Lift

Bin Lift

Assembly

Ejector Assy Ejector Assy

Bin Lift

8 Series 17 Series Tailgate

Hinge
Assy

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 Bay 4 Proposed Layout

Shot Peening + Primer

WIP B/C Class -WIP B/C Class -WIP B/C Class -WIP B/C Class -WIP

Tailgate
Shearing Area

Hinge Sliding Tail gate Tail Gate

Assy Tail Gate Full Tail Gate
Channel side sheet
Tacking

Line
Tailgate LH/RH LH/RH Welding Finishing
Hinge fixture Fixture
Assembly Assembly W
Assy I
P

A-Class A-Class A-Class

WIP WIP WIP

Gangway

A Class-WIP A Class-WIP A Class-WIP A Class-WIP

FG
Bin Lift Binlift
WIP

Assembly 6 Series
6 Series
Tailgate Tailgate Full
Assembly

Welding &
Bin Lift

Ejector Assy 8 Welding

(OLD)

Ejector Assy 17
Series Series Fixture Finishing
Bin Lift
WIP

Subassy

WIP WIP B/C Class -WIP B/C Class -WIP B/C Class -WIP B/C Class -WIP

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 BENEFITS

Benefits
1. Zigzag Material flow avoided
2. Single Piece flow of material
3. Less material handling
4. Space Optimization
5. Optimized space will be utilized for
a. Tipper Tailgate Welding (Proposed New fixture)
b. Tipper Headboard welding (Proposed New fixture)
c. Mahendra Sideboard Welding Station (Need to Check Space feasibility)

Need to confirm if this fixture is still

in use,
Further space can be optimized if
this fixture will be removed

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2022
 COSMETIC AREA IMPROVEMENT

Current Practice Proposed Action

1. Side guard painting should

be done along with the body
or separately with all side
mudguard.

2. 3M tape application to be
done after final touchup

1. Side Guard Painting done

during final touchup
2. 3M tape masking done to
avoid paint on tape

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 SHEARING ARE STORAGE SPACE OPTIMIZATION

Current Practice Proposed Solution

OR Existing available rack can be deployed

Benefits:-
1. WIP storage Space Optimization
2. Space can be utilized for processed
parts storage
3. 5’s improvement

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 TIPPER HEADBOARD AND TAILGATE FULL WELDING AT OFFLINE STATION

Current Practice Proposed Action

1. Tipper Headboard and tailgate 1. Assembly fixtures to be

only tack welding done on offline developed for Headboard and
station. tailgate welding
2. Full welding done in gangway on 2. Full welding station with
floor in tipper fabrication area. fixture/stand to be added on
3. Non-standard process. offline station
4. Unsafe working condition 3. Standardize work
4. 5’s and safety improvement

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 SCRAP AREA IMPROVEMENT

Current Practice Proposed Action

1. Stand for scrap material should

be modified as per largest sheet
size.
2. Safe working condition
3. 5’s improvement

Benefits:-
1. Unsafe area
2. 5’s NOK

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 LASER ENGRAVING PROGRAM MODIFICATION

Current Practice-Video After Improvement-Video

Benefits :- Engraving of 71
Engraving time reduced from 35sec to 6 parts in Nesting
sec-
29 sec reduction in cycle time /
engraving
Further- Pravin Chopade working to identify such parts and modifying nesting
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 Thank You..

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2022