Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Short Pipe Connector Fitting 08/11/19
Date

Before After Effect

 Issue  Improvement Idea  Defect Reduction
- Due to connector id loose, Connector were loose Adding a pneumatic cylinder in short pipe
with fitting tube connector cup fitting machine which will make an (unit;- PPM.)
impression mark near tube insertion area of 10%
 Improvement Point connector.

- Caulking process added at connector tube joint to 1200

remove loose fitment issue 1090

Jan ~Oct 19 Mar’20

Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model MA Supplier Star Sintered

Implementation
Process Final Fitment 15/11/19
Date

Before After Effect

 Issue  Improvement Idea  Defect Reduction
Dealing with the spring back force, a new
- New Fitment die with no tapping after verification at LG machine at final inspection stage comprising a
(unit;- PPM.)
set of pneumatic cylinders has been added for
100% auto fitment to counter attack the manual 5%
 Improvement Point tapping on die
547
Final fitment machine- Die Being used 523
with tapping as per spring back action of tube
Jan ~Oct 19 Mar’20
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Both Cup Fit 06/11/19
Date

Before After Effect

 Issue  Improvement Idea  Less Breakdown
Both Cup Fit Machine - Bolt Breaking Double bolting instead of 1 bold with taper
(2 times in a month) support has been assembled at both cup fit (unit;- hr.)
machine for better support and avoiding bolt
2%
breaking breakdown
 Improvement Point
1.12
- Improving machine Breakdown 1.1

Jan ~Oct 19 Mar’20

Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model CMA Supplier Star Sintered

Implementation
Process 2ND Bending 18/11/19
Date

Before After Effect

 Issue  Improvement Idea  Less Breakdown
2ND
ND Bending M/c – U shape bend Not

straight (in radius form at bottom of U) – Roller Wear 2nd Bending machine roller has been replaced (unit;- hr.)
Out too quick and Pinching Part with double roller support instead of single roller 10%
 Improvement Point at bottom
0.69
- single roller at bottom roller replaced 0.62
with double roller support
Jan ~Oct 19 Mar’20
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model MA Supplier Star Sintered

Implementation
Process 1st Bending 15/11/19
Date

Before After Effect

 Issue  Improvement Idea  Less Breakdown
1 bending- Decon side Bolt Break
st
st

( Every Month due to continue friction) Threaded Bolt guided and pain in moving area
(unit;- hr.)
instead of Plain with easy movement against
friction of cylinder rotation. 5%
 Improvement Point
1.2
- Improving machine Breakdown 1.12

Jan ~Oct 19 Mar’20

Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Short Pipe Bending 15/11/19
Date

Before After Effect

 Issue  Improvement Idea  Less Breakdown
Manual Short Pipe Bend - Lever valve
Free – no pre identification Changed Lever valve with new one and life cycle (unit;- hr.)
monitoring of valve to change it before break.
5%
 Improvement Point
- Improving machine Breakdown 0.79
0.75

Jan ~Oct 19 Mar’20

Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model CMN Supplier Star Sintered

Implementation
Process Air Compressor 25/11/19
Date

Before After Effect

 Issue  Improvement Idea  Less Breakdown
Line Stoppage due to air leakage from
All leakage area identified and correction on
machines (unit;- hr.)
going, change of corrupted solenoid valve and
control of moisture in air by providing heaters at 20%
 Improvement Point air compressor storage line
3.04
- Improving machine Breakdown due to Air Leak 2.42

Jan ~Oct 19 Mar’20

Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Packing and inspection 08/11/19
Date

Before After Effect

 Issue  Improvement Idea

Separate Manpower for Visual inspection and packing - Merging of Manpower through Line balancing  Manpower↓
in Bin - Combined Process time is less than Neck process
time ( 6.18 Sec) 50% ↓
 Improvement Point unit - MP

- Merging of Manpower through Line balancing 2

1

Before After
(Jan~Sep’19) ( Nov’19)
Inspection Time : 5 Sec Packing Time : 2.20 Sec
Packing & Inspection Time : 6.03 Sec

Cycle Time ↓
Unit : Sec

7.20 6.03

2.20 6.03

Before After
(Jan~Dec’19) ( Jan’20)
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Ring Insertion 15/01/2020
Date

Before After Effect

 Issue  Improvement Idea

Long pipe Ring Insertion – 2 Manpower used Jig Kept in one hand and pushed by other  Manpower↓
Cycle Time 1 st Stage - 3.96 Sec
50% ↓
Cycle Time 1 st Stage - 3.96 Sec
unit - MP

 Improvement Point 2
1
Jig Used
Before After
(Jan~Sep’19) ( Jan’20)
Stage 2 Ring Stage 1Ring
Insertion : 7 Sec Insertion : 7 Sec

Cycle Time ↓
Unit : Sec

3.96 2.4
Stage After - Process Time
1.56
Pick Long Pipe 1.2
Ring Pick Long Pipe 1.2 Ring 1.2 1.20
Put Long pipe in Ring on
Insertion in
Insertion in
Pick Ring 1.2 long Pipe
Mat 1.2 1.2 1.20
long Pipe
Manual Fit both 1.56 Element
Before After
Removed
(Jan~Dec’19) ( Jan’20)
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model CMN Supplier Star Sintered

Implementation
Process Deburring 15/11/2020
Date

Before After Effect

 Issue  Improvement Idea
2 Manpower used for Cutting & Deburring
1 Manpower used for Deburring process  Manpower↓
Cycle Time tube Cutting - 3.96 Sec One M/P
Cycle Time Deburing - 5.66 Sec One M/P 50% ↓
These are separate stage unit - MP

 Improvement Point 2
1
- Cutting Machine ( Trob M/c modified & Deburring Process
added at time of cutting of pipe Before After
(Jan~Sep’19) ( Jan’20)

Cycle Time ↓
Unit : Sec

9.62 4.10

5.66 0

3.96 4.10
Cycle Time tube Cutting - 3.96 Sec Before After
Cycle Time Deburing - 5.66 Sec Cycle Time tube Cutting & Deburring - 4.10 (Jan~Dec’19) ( Jan’20)
Sec
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model CMN Supplier Star Sintered

Implementation
Process Deburring 15/11/2020
Date

Before After Effect

 Issue  Improvement Idea
Long Pipe Ring Setting Stage :
1 Manpower used for Ring Setting in long pipe One Manpower removed after die modification &  Manpower↓
location defined by Jig
Cycle Time Ring Setting- 3.98 Sec 50% ↓
unit - MP

 Improvement Point 1
0
- Die modified and location defined by Jig 0
Before After
(Jan~Sep’19) ( Jan’20)

Cycle Time ↓
Unit : Sec

7.92 1.92

3.96 0
Stage Before - Process Time Stage After - Process Time
Manual Insertion of ring on Long 3.96 1.92
Ring Location defined by Jig
pipe ( No location defined for
Ring Setting Ring Setting
during ring insertion
1.92 Before After
Ring in Long Pipe ) 3.96 ( Jan’20)
No Ring Setting Reqd ( Die (Jan~Dec’19)
Ring Setting after Fittment 3.98
modified for Auto Ring Set ) 0
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model CMN Supplier Star Sintered

Implementation
Process Loading/Unloading 15/11/2020
Date

Before After Effect

 Issue  Improvement Idea
Cycle Time ↓
2 Manpower used for loading FG in truck
Lifter made for Loading and unloading bin and Unit : Sec
cart ( 2M/P  1M/P ) 7.20 6.09
 Improvement Point 3 1.89
2 2
- Lifter is used for lifting bins to Trucks
2.20 2.20

Before After
(Jan~Dec’19) ( Jan’20)

 Man Power
Before
Reduction
(unit;- Nos)

Activity After - Process Time

Activity Before - Process Time Picking Bin from FG ( 20 Nos )
Making
2.20 2
Making Picking Bin from FG ( 20 Nos ) one
2.20 Strapping all bins in one base
one Pallet & 1
cart - done at loading area 2
Pallet &
Lifting on truck one by One loading in
( 2 MP require) 3 truck Lifting in truck by Lifter Before After
loading in 1.89
Strapping all bins in one base (Jan~Dec’19) ( Jan’20)
truck
cart -done at truck floor 2
Process Loss Improvement Sheet LGE Internal Use Only

Line LG Section Cover Silencer Model BSA Supplier Star Sintered

Implementation
Process Dispatch and Production Planner 06/11/2019
Date

Before After Effect

 Issue  Improvement Idea

Dispatch and Production Planner – Both Separate

M/P Production planners has been assigned
customer wise to reduce workload and dispatch
planner has been merged with production
 Improvement Point
- Merge the working of Dispatch and Production Planner
Planner

Before- After-
1.RM taken from the store 1.RM taken from machine
2.Dispatch Data From Mail 2.Dispatch Data From Scheduling Board
3. Planning with respect to Dispatch Schedule with 3. Self Planning according to customer wise
prod Supervisor schedule  Man Power
Reduction
(unit;- Nos)

Before After
•Dispatch Planner Working •Prod. Supervisor Working (Jan~Dec’19) ( Jan’20)
with 45% load with 60% load