Stanzen Toyotetsu India Pvt., Ltd.

Study Report in WELD LINE

MSRIT
Muzammil Shadab
Minkul Tekwani
Shreyas KN
Md.Mushtaque Ahmed

Guided by,
Mr.Hiremath & Mr.Pradeep Kumar (PC Dept)

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Presentation Outline

Conveyance
Minomi
Problems faced
Counter measures
Acknowledgement
Conclusion

Objective : Detailed analysis of Conveyance

and Minomi routes of weld line.

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Conveyance
Conveyance is the transportation of stamped parts from the
storage area to the welding line
In STTI –

ROUTE A B C D

MAN POWER 1 1 1 1

A
ROUTE LENGTH 45m 75m 45m 75m

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Problems Faced
A BCD
Kanbans not used 40 45 41 38 164
Standard Route not followed 8 12 5 10 35

Non Availability of parts 1 14 12 10 37

Wrong Storage of Stamped parts 6 3 2 4 15

Traffic/Collision 7 5 12 5 29

Absenteeism 0 4 0 2 6

62 83 72 69
Number of samples – 50/course
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From the Problem Vs. Conveyance Route Chart,
• Course B is the most problematic & changes need to be made
• Kanbans not being used is the most commonly observed
problems

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Minomi
Minomi is a concept wherein parts are transported and
displayed at the assembly stations completely without
packages.

IN STTI:

ROUTE A B C

MAN POWER 1 1 1

ROUTE LENGH 75m 100m 75m

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Problems Faced
A B C
Kanbans not used 23 25 19 67

Standard Route not followed 28 25 18

71
Non Availability of parts 15 13 5 33

Traffic/Collision 9 9 0 18

Absenteeism 2 0 4 6

Mixing of parts 14 6 18 38

78 64
91
Number of samples – 30/course
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• Course A is the most problematic and changes need to

made
• Most commonly found issue – Standard Routes are not
being implemented whilst Minomi

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SWOT Analysis
Strengths
•STTI has employed Heijunka ie levelled production and
Just In Time (JIT)
•Visualization with help Kanbans and Poka-Yoke
•Efficient inventory Management is followed
•Safe working environment
Weakness
•Kanban System needs to be implemented perfectly
•Stock checklist should be regularly updated
Opportunities
•Cycle Time can be reduced to increase productivity
Threats

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ACTIVITY DIAGRAM : COUNTER MEASUR

ABSENCE OF KANBANS MIXING OF PARTS

RE-PRINTING OF ALL MISSING IMPLEMENT KANBAN USAGE TO

KANBANS TRY AND DISTINGUISH BETWEEN RH
AND LH

ROUTES NOT IMPLEMENTED CHECKLIST UPDATATION

EDUCATE THE WEEKLY UPDATING OF ALL

LABOURERS TO FOLLOW AVAILABLE KANBANS AND
STANDARDIZED ROUTES. PARTS
REGULAR MONITERING
TO FOLLOW ROUTES.

ABSENTEEISM NON AVAILABILITY OF PARTS

IN CASE OF ABSENTEEISM , ENSURE

BACKUP MANPOWER IS PRESENT. ENSURE IMPLEMENTATION OF
EXTRA WORKFORCE CAN BE KANBAN SYSTEM
ASSIGNED OTHER TASKS.

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INTER-RELATIONSHIP DIAGRAPH

ABSENCE OF KANBANS ROUTES NOT

IMPLEMENTED

NON AVAILABILITY OF
TRAFFIC/COLLISION
PARTS

ABSENTEEISM MIXING OF PARTS

CHECKSHEET NOT UPDATED

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PARETO CHART FOR % DEFECTS

IT IS FOUND THAT THE MAXIMUM MAGNITUDE OF PROBLEM DECREASING THE CYCLE

TIME IS MISSING KANBAN

% Defect

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Acknowledgement

We would like to thank the Management of STTI for providing us

with the opportunity for taking up the Training at STTI Plant.
Also would like to thank Mr Ravishankar,Mr Guruprasad and our
Guides, Mr Hiremath and Mr Pradeep Kumar of the PC Dept

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Conclusion

After a month of study we put into our assignment of studying

the weld line we would like to conclude that ,though STTI
has tremendously succeeded in delivering excellent service to
its customers ,there is still a lot of scope for improvement in
reducing the cycle time which can result in increased productivity
And also decreased man power .By doing so STTI can
substantially cut down on its expenditure and also increase its profit
to some extent .The Toyota Production System though in use has
to be implemented at every step and regular monitering has to
be done to keep it in place.

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