A Study on Effective Space Optimization

& Time Reduction in Part Feeding

System
-Deecan Sanyo Chillachi A.,
MBA 2013-2015, Operations.

Objectives of the project

To reduce the overall delay time (DT) in the part feeding system.
To design the layout models for storing cases in warehouse and in assembly
stores.
To reduce labor's walking time during unpacking cases.
To reduce the materials replenishment time in frame assembly .

Process flow diagram of part feeding activities

Process flow diagram includes various processes from moving cases from 40 shipping
containers to replenishing materials in assembly line.
Identification of the overall problem
The first two process
accounts for approx. 64%
of delay time (DT)

The rest of the processes

accounts for approx. 36%
of the delay time(DT)
Majority of the problem is
caused by the first two
process
*Graph 1 Pareto chart

Analysis of the problem

Process C Rearranging, Sorting & Transferring D-MAX Cases before Unpacking

Problem Identification

Reasons for the problem

Process time (PT) approx. 91 Mins

Prevent the problem

Process time (PT) after proposing layout model

Results

for storing cases approx.

Time Reduced by 76%

23 Mins

- 68 Mins

Process C Rearranging, Sorting & Transferring Pajero Sport -CR45 Cases before Unpacking
Problem Identification
Process time (PT) approx.

Prevent the problem

Reasons for the problem

200 Mins

Process time (PT) after proposing layout model

Results

for storing cases approx.

Time Reduced by 74%

51 Mins

- 149 Mins

Process A Moving D-MAX & CR-45 Cases from Shipping Containers to Warehouse & Assembly stores
Problem Identification

Reasons for the problem

Process time (PT) approx. 58 Mins

Prevent the problem

Results

Process time (PT) after proposing layout model for

storing cases approx. 42 Mins
Time Reduced by 30%

Process -D Unpacking D-MAX Cases in Assembly Store

Problem Identification

Reasons for the problem

Process time (PT) approx. 221 Mins

Prevent the problem

Results

Process time (PT) after proposing layout model for

storing cases approx. 169 Mins
Time Saved by 23% - 51 Mins

Process -D Unpacking Pajero Sport CR-45 Cases in Assembly Store

Problem Identification

Reasons for the problem

Process time (PT) approx. 225 Mins

Prevent the problem

Results

Process time (PT) after proposing layout model for

storing cases approx. 154 Mins
Time Saved by 39% - 100 Mins

Process E & F Parts Feeding to Assembly line & Remodeling Material Storing Shelf s
Problem Identification

Reasons for the problem

CT 394, PT 343, DT - 51 Mins

Prevent the problem

Results

Walking time (WT) before proposing shelf design

47Mins, Walking time (WT) after approx.25 Mins
Time Saved by 48% - 22 Mins

Overall Improvement Results

Process A
Moving cases from container
to warehouse
Cycle time = 58.14 MIN
Process time = 41 MIN
Time saved in
rearranging cases
after proposing
30%
storage layout
model =

Process A
Moving cases from container
to assembly store

17.14 MIN
Delay time

process time = 95.95 MIN

Improved PT = 23.07 MIN
Time reduced after
proposing the
76%
storage layout
model =

Process B
Moving cases from warehouse
to assembly store
By implementing proposed
layout rearranging & sorting
time can be reduced

Rearranging time

28.2 MIN
Delay time

72.88 MIN

45.34

cycle time = 305.15 MIN

Process time = 221.31 MIN
Improved PT = 169.9 MIN
Time saved = 51.4 MIN
Time saved after
using trolly's &
23%
other vehicles =

144.35

cycle time = 347.20 MIN

Process time = 255.10 MIN
Improved PT = 154.99 MIN
Time saved = 100.11 MIN
Time saved after
using trolly's &
40%
other vehicles =

217.23
No cases moved

296.4

83.83 MIN

Process E
Material feeding activity in
frame line
Process time = 324.46 MIN
Improved PT = 192.4MIN

Process F
Storage pallets increasing &
reducing replenishing time in
frame assembly
140.6 Min
Process time = 47.49 MIN
Improved PT = 25.11 MIN
Time saved after
increasing storage
48%
pallets in frame
assembly

Unpacking CR-45 cases in

assembly store and seperating
acc. to stage wise

Sorting, rearranging,
transfering cases before
unpacking for CR-45 model
Process time= 200.45 MIN
Improved PT = 56.1 MIN
Time reduced after
proposing the
74%
storage layout
model =

Cycle time = 156 MIN

Process time = 127.87 MIN

214.1

Process D
Unpacking D-MAX cases in
assembly store and seperating
acc. to stage wise

Process c
Sorting, rearranging,
transfering cases before
unpacking for D-MAX model

92.09 MIN

175.92
652.3

140.6
324.46

22.3
47.49

Total DT =

601 MIN

Total CT= 1487 MIN

Before proposing the overall improvement techniques

168.87

No cases moved

296.4

476.41

324.46

47.49

Total PT= 1314 MIN

79.17

324.89

192.4

25.11

Total PT=

After proposing the overall improvement techniques

123.53

No cases moved

Process Time(PT) before implementing proposed models approx. 1314 Mins

Forecasted Process Time (PT) after implementing proposed models approx. 745 Mins

Total Time Saved by approx. 43% - 569 Mins

745 MIN