Productivity Improvement Project

K15C Hot End Line -1

SKH M – Manesar
HIMALAYA
 Quality Circle

HIMALAYA
“Work Hard, Have Fun, And
Make History”

Welcomes You
Passion to Win 2
 SKH MARELLI EXHAUST SYSTEM PVT. LTD.

Manesar

Pune

 JOINT VENTURE : SKH & Marelli

 ESTABLISHED : 2008
 AREA : 2 Acres Chennai
 PRODUCTS : Exhaust Systems

(Mufflers & Catalytic

Converters)
 ADDRESS : Plot No. – 23 , Sec- 3A,

Maruti Supplier Park,

Passion to Win
 Product Matrix

Hot End (Exhaust Manifold)

Customer Product Vehicle

K10C (Gasoline
/ CNG)

K15C
(Gasoline /
CNG)

YG8 (Gasoline/
CNG)
Passion to Win 4/87
 Product Matrix
K15C Hot End (Catalaytic Converter)

Customer Product Vehicle

K15C G
Manifold Exh .

K15C CNG
Manifold Exh

Passion to Win
 Q C History

• Quality Circle Name : HIMALAYA

• Started On : 10 October 2023
• Project completed : 9
• Project Under taken : 2
• Meeting Time : 3:30 to 4:30PM
• Frequency : Weekly (Every Monday)
• Attendance : 96 %
• Punch line :
Work Hard, Have Fun, And Make History”

Passion to Win
 Facilitator Members

HIMALAYA

Mr. Yogesh Ahuja Mr. Pratap

Coordinator Team Leader

Mr. Sandeep

Mr. Akash
Mr. Narender Yadav

Mr. Ankit

Passion to Win
 Theme

K15C HE

Passion to win
 Justification for theme
selection

Productivity Improvement means

Profitability Improvement

STEP 1 STEP 2 STEP 3 Passion

STEP 4 to STEP
Win 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12
 Activity Plan

MONTHS Oct – 23 Nov - 23 Dec – 23

PD WEEKS 1 2 3 4 5 6 7 8 9 10 11 12
S. No.
CA
ACTIVITY
Problem Plan
1 identification Plan
Actual
Selection of Plan
Plan

2 problem Actual
Plan
3 Define Problem
Actual
Analysis of Plan
4 problem Actual
Identification Plan
5 of causes Do
Actual
Finding of Root Plan
Do

6 cause Actual
Plan
7 Data Analysis
Actual
Development Plan
8 of solution Actual
Trial Plan Check
9 implementation Actual
Check

Foreseeing Plan
10 Probable
Actual
Resistance
Regular Plan Act
11 implementation Actual
Act

Review of Plan
12
results Passion to Win
Actual
 Activity Plan

ACT 3 PLAN 3

12

CHECK 2 DO 4

ATTENDANCE
TOTAL : 52 PRESENT: 50 %AGE - 96
Passion to Win
 Background History of K15C Line 1 Hot End Line
Plan

 K15C HE SOP Sep 2021

 Installed Capacity – 120 / shift , PPH – 1.50 , Line Man Power

10/ Shift

Actual :

 Target Oct 23 – 210 / Shift , PPH 2.62, Line Man Power 10/ Shift

 Target Nov 23 – 220 / Shift , PPH 2.75, Line Man Power 10/ Shift

 Target Dec 23 – 230 / Shift , PPH 2.87, Line Man Power 10/ Shift

 Target : Productivity Improvement Target For Dec 23

8.69 % Improvement as compared to Previous Months

STEP 1 STEP 2
Passion
STEP 3 STEP 4
to Win
STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12
 Top Cost Factor of K15C Hot End
Profitability

Productivity Improvement means Profitability

Improvement
Sl No. Description Rs Category Effect ON
Factors
Productivity Improvement
1 Man Power 210 to 230 Nos 33020 B Profitability
(Present 14 Man Power)
Welding Wire
Consumption Reduction
2 Welding Wire 16000 A Profitability
per 1100 mm by 5 gm
(Present 0.09 Kg / Mt)

Welding Gas Reduction per

3 Welding Gas mm by 0.01 m3 12800 A Profitability
(Present 0.17m3)

General Per part Saving 0.50 per

4 A Profitability
Consumable Part 4000
(Present 5.55 / Part)

Passion to Win
 Categorization of Problems K15C Hot
End Line

Category

A B C

‘A’ Category problem: Problems can be solved by the team

‘B’ Category problem: Problems can be solved with the help of other department team
‘C’ Category problem: Problems requires management / customer

Passion to Win
 Our Target

Productivity
3.5 250
2.87 230
3 240
2.5 230
2.62
2
220
1.5 210
1 210
0.5 200
0 Current Target PPH
190 Production Production
PPH Qty.Sept- Qty.Nov-23
23
PPH

Improve Productivity Improve Profitability

Passion to Win
Selection of Problem

Productivity Improvement means Profitability

Annually
Manpower
Sl Manpower Cost
Month Production Qty. PPH Cost Per Effect ON
No. as per volume
Part (Rs)
(Rs.)

2 Oct-23 210 2.62 22.89 6070428 Profitability

3 Nov-23 220 2.75 22.36 6069398 Profitability

4 Dec-23 Profitability
230 2.87 21.76 6069473

TOTAL MANPOWER COST PER YEAR RS. 6216288

PRODUCTION PER SHIFT- 210 NOS. ,PPH=2.62
PROBLEM CHOSEN BECAUSE OF LOW PRODUCTIVITY AND HIGH MANPOWER COST

STEP 1 STEP 2 STEP 3 Passion

STEP 4 to STEP
Win 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12
Line layout
K15C Hot End Assembly Line

K15C

Total Station Stations – 14 Stations

Man Power 13Nos.
Mig Robot Welding - 4 Station
ROBO DED Welding - 1 Station
T Manual Welding - 2 Station
CELL-3 Chipping - 1 Station
Manual TIG - 1 station
LTM & Engraving - 1 Station
ROBOT
LVDT - 1 Station
CELL-2 Re-tapping - 1 Station
TPG - 1 Station
Inspection - 1 Station

Passion to Win
PROCESS FLOW K10C HOT END SA9 = CANNING

Dual circular welding

SA-
3
Cannin
g
SA1 = MIG Welding SA2 = TIG Welding of Half SA3 = MIG Welding of
of Half Shell Assy Shell Assy & I/L Flange Sensor Boss with SA2

ROBO CELL -2 SPM-1 SA-

9

ROBO CELL -1

SPM-2
ROBO CELL 3

SA4 = Welding of Left SA5 = Welding of Right Half Full welding

SA6 = Welding O/L Flange SA7 = Welding Bolt with
Half Shell Assy & Shell Assy & O/L Pipe with on O/L Pipe & EGR Assy with SA5 SA6
Sensor Boss SA4 & Shell assy

Manual
Final Visual Final Inspection Leak Testing & batch Spatter T-Joint
Gauge code engraving Welding
Inspection Passion to Win Chipping
BRAIN STORMING
(Scenario 1)
To Achieve the Target of Nov-23
 Productivity 2.75 PPH
 220 Parts per Shift
 Target Cycle Time required 106 Sec
Cycle Time Study -K15C Hot End

Actual
Output / Target Current Current
Total Cycle Shift @ Output / Actual Actual
S.No. Operation description time in 210 per Shift @ Output/Shi Output/Shi Shortage
secs shift 220 per ft @ 100% ft @ 85% against 220
requireme shift Efficiency Efficiency Parts/Shift
nt requireme
nt

Cycle time operation wise(in

1. ROBOT CELL-1 102 210 220 270 230 +10 sec)
2. ROBOT CELL-2 111 210 220 248 211 9 111
105
102
96
3. ROBOT CELL-3 105 210 220 262 223 +3 85 89
72
4 DED-1 72 210 220 383 325 +105 59

5 T-JOINT 59 210 220 467 397 +177

6 CHIPPING 96 210 220 287 244 +24
-1 -2 -3 1 T E
7 PRE-LEAKAGE 85 210 220 324 276 +56 LL LL LL D- IN NG AG LT
M
CE CE CE DE JO PI
T T T T- HIP
E AK
C L
O O O E-
8 LTM 89 210 220 310 263 +43 R OB R OB R OB PR

STEP 1 STEP 2
Passion
STEP 3 STEP 4
to Win
STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12
 Fish Bone for K15C Hot End

Man Machine 11 Possible causes identified

Machine Cycle
Time
Operator
unawareness

Unwanted Error made by the

Welding
operator while operating the
Parameter
machine
Improvement
Operator changed
Frequently Robot Teaching
Improvement

Line
Production
Line layout not
improvement
okay
Child Parts
dimension not
Machine Part okay
Chuter Lay Out

NVA Activity
Fitment issue
between cone
and inlet flange

Method Material
Passion to win
 Fish Bone for K15C Hot End

Man Machine
Machine Cycle
Time 1 Valid cause identified
Operator
unawareness

Unwanted Error made by the

Welding
operator while operating the
Parameter
machine
Improvement
Operator changed
Frequently Robot Teaching
Improvement

Line
Production
Line layout not
improvement
okay
Child Parts
dimension not
Machine Part okay
Chuter Lay Out

NVA Activity
Fitment issue
between cone
and inlet flange

Method Material
Passion to win
 Validation of Assignable Causes

PROBLEM PROBABLE SKETCHES OF CHECKED

S.NO CATEGORY WHO WHERE HOW
CAUSES THE PROCESS RESULT

This may be a
On Merge of valid cause
both Operation

1 Machine Cycle Time CFT Robot Cell 2

Cycle Time
Study
Line Takt time
Increase 111
Sec against 106
Sec

Passion to win
Focus Area for Improvement

1. Robot Cell-2

Cycle Time more than required Time ,

Bottle neck Cycle Time to be reduced to
achieve the Target

Passion to Win
Brain storming : Machine Cycle Time Reduction

Machine cycle ti me
60
52
50 Machine Cycle Time (Sec)

40 Part loading 32
32 Part clamping 15
30
Curtain down 3
20
15 Welding time 52
10
3 3 4 Curtain Up 3
2
0 Auto Declamp 2
e ng n e up ng e
tim pi do
w tim i n pi tim
in
g la
m i n in
g rta la
m
in
g
ad rtc rta e ld Cu dec ad
l o Cu o
rt Pa W rt un
l
Pa Pa rt
Pa

 Part clamping manually with particular clamping sequence

Passion to win
 Activity Plan

Activity Plan for Machine Cycle Time Reduction

S.no. Problem Action Plan Responsibility Target Date

Clamping
Part clamping manually with should
particular clamping sequence in auto mode Dharmander / Lalit 15-Nov
be done

Passion to win
 Improvement Activity:

Improvement Activity Status

Before After Cycle

S.no. Photo Problem Action Responsi Target Paramete Paramet Time Status
Plan bility Date r er Saving
(Sec)

Part clamping
Clamping
manually
should be
with Part Part
done in Dharmand
1 particular 15-Nov clamping clamping 5 Done
auto er / Lalit
clamping manually in auto
mode
sequence

Passion to win
 After Implementation of all
solution

Passion to win 27
 Deployment of Solution :
S.NO. CAUSE SOLUTION TRIAL IMPL. STATUS OK\NOT OK

Robot Cycle
(Machine
Line Cycle time be Time) reduce
reduce by 5 Sec by 5 sec & Process
OK
Cycle Time
from 111 Sec to Cycle Time One Shift prod.
validate &
1. 106 Sec reduce from (220 Nos.) Done
target
111 sec to 106 achieved
Sec

Passion to win
 Improvement in Cycle Time
Before After
Cycle Time Study -K15C Hot End Cycle Time Study -K15C Hot End
Actual Current Current Actual Current Current
Output / Target Actual Actual Output / Target Actual Actual
Output / Shortage Total Shift @ Output / Output/ Output/ Shortage
Total Shift @ Output/S Output/S Cycle
S.No. Operation description Cycle time 210 per Shift @ hift @ hift @ against S.No. Operation description time in 210 per Shift @ Shift @ Shift @ against
in secs shift 220 per 100% 85% 220 shift 220 per 100% 85% 220
shift Parts/Shif secs shift Efficienc Parts/Shi
requirem Efficiency Efficiency require Efficienc
ent requirem t ment require y y ft
ent ment

1. ROBOT CELL-1 102 210 220 270 230 +10 1. ROBOT CELL-1 102 210 220 270 230 +10
2. ROBOT CELL-2 111 210 220 248 211 9 2. ROBOT CELL-2 106 210 220 260 221 +1
3. ROBOT CELL-3 105 210 220 262 223 +3 3. ROBOT CELL-3 105 210 220 262 223 +3
4 DED-1 72 210 220 383 325 +105 4 72
DED-1 210 220 383 325 +105
5 T-JOINT 59 210 220 467 397 +177 5 T-JOINT 59 210 220 467 397 +177
6 CHIPPING 96 210 220 287 244 +24 6 CHIPPING 96 210 220 287 244 +24
7 PRE-LEAKAGE 85 210 220 324 276 +56 7 PRE-LEAKAGE 85 210 220 324 276 +56
8 LTM 89 210 220 310 263 +43 8 LTM 89 210 220 310 263 +43

Cycle time operation wise(in sec) Cycle time operation wise(in sec)
111 105 102 106 105
102 96 96
85 89 85 89
72 72
59 59

-1 -2 -3 1 T G E -1 -2 -3 1 T G E
LL LL LL D- IN IN AG LT
M
LL LL LL D- IN IN AG LT
M
CE CE CE DE JO PP AK CE CE CE DE JO PP AK
T- I E T- I E 29
B OT B OT B OT CH
E-
L
B OT B OT B OT CH
E-
L
RO RO RO PR RO RO RO PR
 Target Achieved :

3.5 Productivity 220/shift

2.75
3 210/shift
2.5
2.62
2
1.5
1
0.5
0 Current PPH Target PPH

PPH

Productivity Improve Production Increase

Passion to win
BRAIN STORMING
(Scenario 2)
To Achieve the Target of Dec-23
 Productivity 2.82 PPH
 230 Parts per Shift
 Target Cycle Time required 102 Sec
Cycle Time Study -K15C Hot End

Actual
Output / Target Current Current
Total Cycle Shift @ Output / Actual Actual
S.No. Operation description time in 220 per Shift @ Output/Shi Output/Shi Shortage
secs shift 230 per ft @ 100% ft @ 85% against 230
requireme shift Efficiency Efficiency Parts/Shift
nt requireme
nt

Cycle time operation wise(in

1. ROBOT CELL-1 102 220 230 270 230 0
sec)
2. ROBOT CELL-2 106 220 230 248 221 9 106 105
102
96
3. ROBOT CELL-3 105 220 230 262 223 7 85 89
72
4 DED-1 72 220 230 383 325 +95 59

5 T-JOINT 59 220 230 467 397 +167

6 CHIPPING 96 220 230 287 244 +14
-1 -2 -3 1 T G E
D- M
7 PRE-LEAKAGE 85 220 230 324 276 +46 CE
LL
CE
LL
CE
LL
DE
T-
JO
IN
HIPP
IN
E AK
AG LT

B OT B OT B OT C E-
L
8 LTM 89 220 230 310 263 +33 RO RO RO PR

STEP 1 STEP 2
Passion
STEP 3 STEP 4
to Win
STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 STEP 10 STEP 11 STEP 12
 Fish Bone for K15C Hot End

Man Machine
Machine Cycle 12 Possible causes identified
Time
Operator
unawareness

Unwanted Error made by the

Welding
operator while operating the
Parameter
machine
Improvement
Operator changed
Frequently Robot Teaching
Improvement

Line
Production
Line layout not
improvement
okay
Machine Part Child Parts
Chuter Lay Out dimension not
okay
Extra process
available at station

NVA Activity
Fitment issue
between cone
and inlet flange

Method Material
Passion to win
 Fish Bone for K15C Hot End

Man Machine
Machine Cycle
Time 1 Valid cause identified
Operator
unawareness

Unwanted Error made by the

Welding
operator while operating the
Parameter
machine
Improvement
Operator changed
Frequently Robot Teaching
Improvement

Line
Production
Line layout not
improvement
okay
Machine Part Child Parts
Chuter Lay Out dimension not
okay
Extra process
available at station

NVA Activity
Fitment issue
between cone
and inlet flange

Method Material
Passion to win
 Validation of Assignable Causes

PROBLEM PROBABLE SKETCHES OF CHECKED

S.NO CATEGORY WHO WHERE HOW
CAUSES THE PROCESS RESULT

This may be a
valid cause
Extra
Tacking should
1 Method
process
available at
CFT
Robot Cell 2
&3
Operation
sequence study
be done at T
joint station
station

Passion to win
Focus Area for Improvement

1. Robot Cell-2
2. Robot Cell-3

Tacking at inlet and outlet joint should

be done at T joint station

Passion to Win
 Activity Plan

Activity Plan for operation sequence change

S.no. Problem Action Plan Responsibility Target Date

Inlet and outlet joint tacking Tacking should

be done at T Dharmender 15-Dec
done in the robot station itself joint station
1

Passion to win
 Improvement Activity:

Improvement Activity Status

Before After Cycle

S.no. Photo Problem Action Responsi Target Paramete Paramet Time Status
Plan bility Date r er Saving
(Sec)

Inlet and Tacking

Tacking
outlet joint operation Tacking
done at
tacking done done at T Dharmand done at T
1 15-Dec robot 4 Done
in the robot joint er joint
station
station itself station station
itself

Passion to win
 After Implementation of all
solution

Passion to win 38
 Deployment of Solution :
S.NO. CAUSE SOLUTION TRIAL IMPL. STATUS OK\NOT OK

Robot Cycle
(Machine
Line Cycle time be Time) reduce
reduce by 4 Sec by 4 sec & Process
OK
Cycle Time
from 106 Sec to Cycle Time One Shift prod.
validate &
1. 102 Sec reduce from (230 Nos.) Done
target
106 sec to 102 achieved
Sec

Passion to win
 Improvement in Cycle Time
Before After
Cycle Time Study -K15C Hot End Cycle Time Study -K15C Hot End
Actual Current Current Actual Current Current
Output / Target Actual Actual Output / Target Actual Actual
Total
Total Shift @ Output / Output/S Output/S Shortage Shift @ Output / Output/ Output/ Shortage
Cycle
S.No. Operation description Cycle time 220 per Shift @ hift @ hift @ against S.No. Operation description time in 220 per Shift @ Shift @ Shift @ against
in secs shift 230 per 100% 85% 230 shift 230 per 100% 85% 230
secs
requirem shift Efficiency Efficiency Parts/Shif requirem shift Efficienc Efficienc Parts/Shi
ent requirem t ent requirem y y ft
ent ent

1. ROBOT CELL-1 102 220 230 270 230 0 1. ROBOT CELL-1 102 220 230 270 230 0
2. ROBOT CELL-2 106 220 230 248 221 9 2. ROBOT CELL-2 102 220 230 248 230 0
3. ROBOT CELL-3 105 220 230 262 223 7 3. ROBOT CELL-3 102 220 230 262 230 0
4 DED-1 72 220 230 383 325 +95 4 DED-1 72 220 230 383 325 +95
5 T-JOINT 59 220 230 467 397 +167 5 T-JOINT 59 220 230 467 397 +167
6 CHIPPING 96 220 230 287 244 +14 6 CHIPPING 96 220 230 287 244 +14
7 PRE-LEAKAGE 85 220 230 324 276 +46 7 PRE-LEAKAGE 85 220 230 324 276 +46
8 LTM 89 220 230 310 263 +33 8 LTM 89 220 230 310 263 +33

Cycle time operation wise(in sec) Cycle time operation wise(in sec)
102 106 105 102 102 102
96 89 96
85 85 89
72 72
59 59

-1 -2 -3 1 T E
LL LL LL D- IN NG AG LT
M -1 -2 -3 D-
1 T G GE M
CE CE CE DE JO PI LL LL LL IN IN KA LT
T- IP AK CE CE CE DE JO PP
OT OT OT CH -L
E T- CH
I
LE
A
40
B B B E B OT B OT B OT E-
RO RO RO PR RO RO RO PR
 Target Achieved :

Productivity
230/shift
3.5
2.82
3 220/shift
2.5
2.75
2
1.5
1
0.5
0 Current PPH
PPH Target PPH

Productivity Improve Production Increase

Passion to win
 Activity Plan Vs Actual
PD MONTHS Oct-23 Nov-23 Dec-23
S. No. CA WEEKS 1 2 3 4 5 6 7 8 9 10 11 12
ACTIVITY

Plan
1 Problem identification
Actual
Plan
Plan

2 Selection of problem
Actual
Plan
3 Define Problem
Actual
Plan
4 Analysis of problem
Actual
Plan
5 Identification of causes
Actual
Plan
Do

6 Finding of Root cause

Actual
Plan
7 Data Analysis
Actual
Plan
8 Development of solution
Actual
Plan
9 Trial implementation
Actual
Check

Foreseeing Probable Plan

10
Resistance Actual
Plan
11 Regular implementation
Actual
Act

Plan
12 Review of results
Actual

Passion to win
 Result

Tangible Benefits:-
 Production Target achieved 230 / Shift.

 Productivity achieved 2.75 to 2.85 (PPH).

Cost Benefits:-

Annual Net Saving Rs 3.55 Lakh

Passion to win
 Intangible Benefits

Lean Manufacturing –
Line Balancing
Process Capability Improved
Confidence –
Presentation skills improved

Motivation –
Solve the problem at down level

Skill Level –
Uses of quality of tools

Team work –
Team spirit increased by
working together

Passion to win
Quality Tools Used in this Project

PDCA Cycle Pie Chart Flow Chart

Cause & Effect Diagram Bar Graph Brain storming

Passion to win
Passion For People