MAT Production System Update

Feb’ 2024
FBI-CV Shoe
 FBI – CV Shoe Plant
Capacity

Old Capacity AT 100% Current Capacity AT 80%

Operations No of machine
CV Shoe/Day CV Shoe/Year CV Shoe/Day CV Shoe/Year

Welding 9 14756 4.43 11805 3.54

Pre-Treatment 1 7147 2.14 5717 1.72

Powder Coating 1 9648 2.89 7718 2.32

Riveting 11 12507 3.75 10005 3.00

Plant Capacity 7147 2.14 5717 1.72

 FBI CV shoe
Updates

• Location for all Quality gauges has been fixed on 2 welding machine and rest will be

completed by Week 10.

• SFMTP for Cell leaders has been started in FBI plant and training is also completed for

same to all team members.

• Label verification process has been done on 1 machine and horizontal deployment on all
machines has been planned by week 9.

• Team is working on PT machine improvement

• Interlocking of induction and welding machine done on 1 machine in order to ensure

without induction material shouldn’t move to next process.
 FBI CV Shoe
Updates

L0-L4 Status Lean Audit Score

140 No audit due
100
to plant
120 90 75
shifting
17 80
100 70 64 61 63 64
22 60 61 53
80 22 17 17 50
9
22
40
60 24 18 22
30
11 8 47 19 18 20
40 10 23
16 16 10
25 8 37 34 6 0
20 6 Aug'23 Sep'23 Oct'23 Nov'23 Dec'23 Jan'24 Feb'24
14 26 12 11
11 5 4 8 4 8
0
Aug'23 Sep'23 Oct'23 Nov'23 Dec'23 Jan'24 Feb'24

L0 L1 L2 L3 L4 Lean Audit Score Target

Avg Output Rejection% Rework%

3.59%
6000 4.00% 8.00%
6000
5037

4000 3.50% 7.00%

7.59%

7.43%
5000
4200

3813

3.00% 6.00%

6.50%
6.43%
3304

3342

4000
2.50% 5.00%
1.74%

3000
2132

2.00% 4.00%
1732

1.24%

1.20%

2000

3.94%

3.80%
1.50% 3.00%
1.09%

3.44%
0.62%

1000
0.66%
1.00% 2.00%
0 0.50% 1.00%
23 23 t'2
3 23 c'2
3
'2
4 24
g' p' v' an b'
Au Se Oc No De J Fe 0.00% 0.00%
3 23 3 23 3 4 24 23 23 3 23 3 24 24
g '2 p' t'2 v' c'2 '2 b' g' p' t'2 v' c'2 n' b'
Au S e Oc
N o D e J an F e Au S e Oc
N o D e J a F e
Avg Output Target
 CV Shoe Rework
Trend

Welding Rework PC Rework

6.00% 5.65% 3.50%
3.12%

5.00% 3.00%

2.50% 2.28%
4.00%
3.37% 1.96%
3.06% 2.93% 2.00%
1.68%
3.00% 1.55%
1.50% 1.22%
2.00% 1.52% Plant not
1.00%
Operational Due to
1.03% 1.05%
1.00% Shifting
0.50%
0.00%
0.00% 0.00%
Aug'23 Sep'23 Oct'23 Nov'23 Dec'23 Jan'24 Feb'24 Aug'23 Sep'23 Oct'23 Nov'23 Dec'23 Jan'24 Feb'24

Riveting Rework
2.50%

1.94%
2.00%

1.51% 1.48%
1.50% 1.38%

1.07%
1.00%
0.63% 0.63%

0.50%

0.00%
Aug'23 Sep'23 Oct'23 Nov'23 Dec'23 Jan'24 Feb'24
 Improvements-FBI CV
Shoe

Master sample provided at forming machine so that changeover Dosing pump provided for chemical adding during
can do simultaneously of both blanking and forming machine Pre-treatment process which Operator was filling
which reduces changeover time from 85min to 45min. manually earlier.

PT trolley design changed from horizontal to vertical Cleaning table modified providing supporting tools
part placing, eliminating brown patches from shoe location
after PT operation
 Repeated Issues-FBI

• Team running welding machine without FPA procedure completion.

• Accountability issues at welding machine and rework area.

FBI Kami – Kitset
 Kitset Plant Capacity-FBI

Capacity/Day AT 100% Capacity/Year AT 80%

Operations No of machine
Kitset/Day Kitset/Year Kitset/Day Kitset/Year

Bar Cutting 1 2513 0.75 2010 0.60

CNC Turning 6 1723 0.52 1378 0.41
Surface Grinding 1 2871 0.86 2297 0.69
Knurling 1 5025 1.51 4020 1.21
Induction 1 2513 0.75 2010 0.60
F – Stamping 1 8040 2.41 6432 1.93
Batch Oven 1 8040 2.41 6432 1.93
CNC Roller 1 3350 1.01 2680 0.80
CNC Forming A 1 5025 1.51 4020 1.21
CNC Forming B 1 6700 2.01 5360 1.61
Crimping 4 2680 0.80 2144 0.64
Tempering 1 6700 2.01 5360 1.61
Plant Capacity 1723 0.52 1378 0.41
 Material & Information
Flow using SAP-Kit set
Customer order & Transferred
Forecast to MST/ WH

Production order
RM Availability release Cell planned
Check order BOM-Availability
RM Availability
Check Check
Separate orders for each Child Parts
component
Heijunka Separate order Final FG Order FG Storage
Board Bar Cutting
Knurled & Roller Pin Heijunka Board Area

Child Parts
Heijunka CNC Turning
Forming Forming Forming Board QST – Good parts Order
Roller Return Return confirmation confirmation
Retainer Spring B Spring A RST – Rej. Book in SAP
Surface
Grinding
1 Day Plan & Material
Hook Press Hook Press on Flow rack
Re-striking Child Components/
Fit Fit Packaging
Packaging Material
F – Mark 1. Child Part Issuance
Knurling 2. Packaging Material
Stamping
Issuance
3. BOP Part Issuance
Tempering
Induction
Hardening

PDI
Tempering
Child Part
Order
Store
Confirmation
PDI
QST – Good parts
confirmation
QST – Good parts RST – Rej. Book in SAP
confirmation Powder Order
RST – Rej. Book in SAP Coating Platening IQC
Confirmation
 Kit-Set Update

• Scrap conveyor installed on one CNC turning machine and other machines has been

planned to be done by week 9.

• All packed material 18168 sets has been rechecked and found 1% Approx. (rework & scrap

material) because of quality issues like paint peel off , Anchor pin nub dia. NG and Wiggle

pin flange broken.

 Kitset Updates

L0-L4 Status Lean Audit Score

2 0
75 75 75 75 75
2 0 57 60
49 51 53 56
34 Audit
2 0 47
2 2 2 2 2 start from
0 0 0 0 0 0 18 34
16 week 3
19 19 16 16 18

26 31
17 17 19 20 21 19 20 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9

L0 L1 L2 L3 L4 Lean Audit Score Target

Avg Output Avg. Rej at packing stage Avg. Rej. at process

Packing
not done
5%
680

0.5% 3.6%
589
535

1%
511
465

4.9% 3.6% 0.60%

352

4.6% 0.45% 0.28%

273

3.9%
2.5% 1.8% 2%2.8% 0.36% 0.49% 0.22%
0.14%
0.48% 0.22% 0.30%
0.15%
0.26%
0.20%
0.16% 0.09% 0.11% 0.16% 0.06%
150

2.3%
0.8% 0.9% 0.0% 1.3% WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK
0.3% 0.2% 0.0% 1 2 3 4 5 6 7 8 9
0

Week Week Week Week Week week week week week WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK WEEK
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9

Avg Output Spring roller Target Spring roller Target

 Roller retainer Quality
improvement- KITSET

BEFORE AFTER

Issues Improvements
Part NG At Machine due to corner stuck with quill . Groove cut in quill to enable free movement of part.
Results Results
• Per shift 2 manpower was employed in the process • No Manpower required.
• Leads to open orders for part. • Zero open order for part
• Time consumed :- 1280 Pcs completed in 2 days • Per shift 2000 production
• Per shift 700 Pcs production • Saving/Part = Rs. 0.94 ( only wages)
• Cost per part was 1.14 rupees ( only wages) • Saving/Month Rs.47K, Saving/ Annum 5.64 lacs
 Improvements-FBI KITSET

GO and NO-GO gauge for checking GO and NO-GO gauge for checking
Spring A to reduce inspection process. knurled pin to reduce inspection process.

Shadow box has been made for ensuring All component location has been freeze
all parts picked by operator for reducing part miss at Kit set line
Improvements– KIT Set line
PV Bonding MBSI-KAMI
 MBSI Update

• Material & Information flow has been defined along with required infrastructure for
streamlining the process.

• All MAT production system best practices visual boards has been implemented on shop
floor.

• Conveyor material is received in plant for transferring material from store racking
arrangement and will be installed by 10 Feb’2024.

• Team has achieved 28 K sets output against 30 K plan in January’2024 month with average
plant running in 1 shift.

• Team is start hiring second shift operators for training purpose and has been planned to
run 2nd shift by mid Feb’2024.

• Repeated issue of first part approval bypassed has been observed on linner cutting
machine and training provided to team for follow FPA SOP.
 MBSI Updates

L0-L4 Status Lean Audit Score

50 100
45 2 2 90
2 2 2 2
40 2 0 2 02 2
0 2
0 2
0 2
0 80
2 2 2 0
2 70 75 75 75 75 75
35
2 0 2 0
2 20 20 60 49 51 54 56 57 60
30 2 50 51
25 40 Audit start from
32 32
36 36 30 week 3
20
35 20
15 29 30
21 21 10
10
0
5 8 8 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9
4 4
0
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9

L0 L1 L2 L3 L4 Lean Audit Score Target

Avg Output Rejection%

1464

1424

2.30%
1294
1272

1260

2.50%
1236

1400
1117

1200

1.80%
990

2.00%
1000

1.42%
1.35%

1.31%
800
660

1.19%
1.18%
1.50%

1.13%
1.11%
600
400 1.00%
200
0.50%
0
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9
0.00%
Avg Output Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9
 Activity Timeline
Brake Shoe Bonding MBSI
Month November’23 December’23 Jan'24 Feb’24
S. Responsi
Activities Remarks
No. bility Week 45 46 47 48 49 50 51 52 1 2 3 4 5 6 7 8 9

Layout for Plant Plan

1 capacity Team/Le Done
ramp up 1.5 an Team Actual
MN

Receiving of Project/ Plan

2 required Done
machines Purchase Actual

Installation Project & Plan

3 of Mainten
machines ance Done
Actual

Trial for Plan

4 production Plant Done
run Team
Actual

Store Plan Material has been

Racking received and its
5 arrangement Project under installation
installation Actual T.D. is 20/01/24
10/02/24

Trollies/ Plan
bins/
6 unbalance Project Done
rack for
material Actual
movement

Plan Area identification

Standard Producti
7 visual board will be
boards on received by WK6
Actual

Plan
8 Y-Clamps Project/ Done
(1100 nos.) Purchase
Actual
PLAN ONGOING DONE NOT STARTED
 Improvements-MBSI

Weighing scale added at glue tank, alarm will ring Fixture provide at radius plate, no need to locate H
when glue becomes less than minimum level mark on shoe for lining pasting

Andon light implemented at drying oven which will Acrylic cover provided at shoe dipping to control
turn red when oven temp. goes out of spec foreign particles
Thanks