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"KAIZEN" Event On Establishing 1S & 2S in Logistics Area For Accomodating Super ACE & Venture Parts
"KAIZEN" Event On Establishing 1S & 2S in Logistics Area For Accomodating Super ACE & Venture Parts
“KAIZEN” Event
On
Establishing 1S & 2S In Logistics Area For
Accomodating Super ACE & Venture Parts
Confidential
For discussion only 1
Team List: TCF 1C TCF 1C SHOP
TEAM MEMBERS
1. Rajal Guhe
2. Kanwarinder Singh Kochhar
3. Peter Chethalan
4. Faizi Raza
5. Nitish Rayal
6. Ashu Mawa
7. Kuldeep Cheema
Confidential
For discussion only 2
Team Members Participation: TCF 1C SHOP
AVG
ATTENDANCE =
98.9%
Confidential
For discussion only 3
TEAM MEMBERS PARTICIPATION TCF 1C SHOP
Confidential
For discussion only 4
TCF 1C SHOP
REARRANGEMENT OF MATERIALS
FASTNERS
GANGWAY A/C
Plastic
Membrane
Heat Pipe
Shield
Cables
Door
Actuator
GALLERY
RGC
Seat Belt
Snorkel
Felt
Battery
Snorkel
Felt
Snorkel
Felt
29 28 27 26 25 24 23
GANGWAY
Confidential
For discussion only 5
Objective, Scope & Target TCF 1C SHOP
OBJECTIVE
- To Provide Proper Place for Venture & Super ACE Parts
- To Establish FIFO in Store
- To Establish 2 Bin System For Venture & Super ACE
-To Establish 1S & 2S Status
SCOPE :
- TCF 1C LOGISTICS AREA (C 27-29)
TARGET :
- 1s & 2s Audit Score Above 80%
-100% FIFO for all parts
--Minimise Material Movement
Confidential
For discussion only 6
Problem Definition:- Team 1 TCF 1C SHOP
Confidential
For discussion only 7
Activity Schedule: TCF 1C TCF 1C SHOP
Confidential
For discussion only 8
Kaizen for Second Row Seat Fitment TCF 1C SHOP
Excess
Material 2S
Implemented
Confidential
For discussion only 9
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
GANGWAY GANGWAY
NOT MARKED MARKED
Confidential
For discussion only 10
Kaizen for Heat Insulation Hole Mismatch TCF 1C SHOP
Empty boxes
Empty boxes removed to red
placed tag area
Confidential
For discussion only 11
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Battery There was no proper Place was defined for battery Reduced movement of
location defined for the closer to the station material and 2S
battery hence implemented
unnecessary movement
of material
Accessible
Battery was not and closer to
easily accessible
the station
and not in proper
location
Confidential
For discussion only 12
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Pillar 29-28 No place defined for .Buffer area defined Excess material not
keeping excess material kept in the gang way
hence are placed in the
gang way
Confidential
For discussion only 13
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Cables Cables are not properly .Trolleys used to Keep the Proper storage of
stored in the cables cables and better
supermarket area hence quality
compromising the
quality
Improper
storage of Trolleys used
cables to store
without any
damage
Confidential
For discussion only 14
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Primary seal Difficulty in access of Trolley was used to store the Better accessibility
parts and improper parts in the super market
storage of parts
Better
accessibility
Part difficult
to access and
improper
storage
Confidential
For discussion only 15
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Cables Cables are not properly . .Trolleys used to Keep the Proper storage of
stored in the cables cables and better
supermarket area hence quality
compromising the
quality
Improper
storage of Trolleys used
cables to store
without any
damage
Confidential
For discussion only 16
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Pillar 29-28 No system to sort parts .Place defined for each part 1S & 2S implemented
or their arrangement
1S & 2S
implemented
1S & 2S not
followed
Confidential
For discussion only 17
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Confidential
For discussion only 18
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
.
Pillar 29-28 No 1S & 2S System .Part identification & 1S & 2S Implemented
maintained Arrangement is done
Confidential
For discussion only 19
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Unorganised Sorted
Part Storage Parts
Confidential
For discussion only 20
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Wire Harness Improper Storage and Boxes are replaced by bins 1S & 2S Implemented
more time wasted for leading to better quality of
part identification parts & better part
identification
Confidential
For discussion only 21
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
.
Pillar - 28 Improper Storage and Boxes are replaced by bins 1S & 2S Implemented
more time wasted for leading to better quality of
part identification parts & better part
identification
Confidential
For discussion only 22
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
FELT Improper Storage For 3 FIFO racks modified for 1S & 2S implemented
Felts. Was Kept At Storage of all types of Felt
Pillar 25-24
Confidential
For discussion only 23
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Snorkel Was
1S & 2S
Kept in
improper way
implemented
Confidential
For discussion only 24
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Pillar 29-28 Excess material and no .Place defined for each part 1S & 2S implemented
system to maintain 1s and excess material removed
or 2s
Confidential
For discussion only 25
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
1S & 2S
Unorganized implemented
Part Storage
Confidential
For discussion only 26
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP
Confidential
For discussion only 27
TCF 1C SHOP
RESULTS
Confidential
For discussion only 28
TCF 1C SHOP
BEFORE AFTER
25-24 25-24
26-25 26-25
27-26 27-26
28-27 28-27
29-28 29-28
3 3
Proper Location
Improper Location
Confidential
For discussion only 29
TCF 1C SHOP
BEFORE AFTER
24-23 24-23
25-24 25-24
26-25 26-25
27-26 27-26
28-27 28-27
29-28 29-28
5 5
Proper Location
Improper Location
Confidential
For discussion only 30
TCF 1C SHOP
TRIM - 3 TRIM - 5
120 160
140
100
120
Meters
Meters
80
100
60 S eries 1 80 S eries
60
40
40
20 20
0 0
BEFORE AFTER BEFORE
1 AFTER
2
1 2
Confidential
For discussion only 31
TCF 1C SHOP
Thank You
Confidential
For discussion only 32