Study on Improving Throughput

Time through

Value Stream Mapping

Alwin P ThomasCHRIST UNIVERSITY INSTITUTE OF

MANAGEMENT

L e a n O p e r a t i o n a n d S y s t e m s

Su

mm

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Inte

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ip

Pro

ject

Apollo Tyres Ltd

@

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3

Company Profile

Apollo Tyres Limited

World's 7th biggest tyre manufacturer, with annual consolidated revenues of Rs 121.5 billion (US$ 2.5 billion) in 2011.

Acquired US based Cooper Tyres & Tyre Company valued USD 2.5 billion

The unit at Kalamaserry produces more than 25 types of tyres. But the unit is turning out to a full fledge unit for producing OHT (Off-Highway Tyres) in next 5 years.

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Aim of Study

To improve the throughput time by studying the values stream mapping of tyre manufacturing.

Objective of Study

To map the value stream of tyre manufacturing

To identify factors affecting throughput time

To reduce throughput time

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L e a n O p e r a t i o n a n d S y s t e m s

Introduction

Value Stream Mapping is a tool that helps people to understand the flow of material and information, as a product makes it way through the value stream.

Summer Internship Project

This tool is used primarily to identify, demonstrate and decrease waste, as well as create flow in the manufacturing process.

Manufacturing throughput time is defined as the length of time between the release of an order to the factory floor and its receipt into finished goods inventory or its shipment to the customer.

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Manufacturing Throughput Time is the sum of Process Time, Move Time, Queue Time

VSM’s can be created using Microsoft Visio & Microsoft Excel

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ProjectStudy Approach

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1. Study the Manufacturing Process and Parts produced

Mixing & Extrusion

Tyre Building & Curing

Inspection & Final Finish

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ProjectStudy Approach

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L e a n O p e r a t i o n a n d S y s t e m s

Parts of Tyre

Identify problem areas & Create Future State VSM

Implement action plans with respect to the Future state VSM

Map the Process & Create Current State VSM

Define Product

Value Stream Mapping

(VSM)

12.4-28PR krishak premium tyre

2. Identify the steps to VSM

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ProjectStudy Approach

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ProjectStudy Approach

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3. Find the parameters required to map VSM

Parameters

Manpower

No. Of Shifts

Utilization %

Setup Time

Time Available

Cycle TimeData

box

Sign used in VSM

Factors Affecting Throughput TimeProcess time/cycle time

Handling TimeAgeing Time

Setup Time

Transportation Time

Summer Internship

ProjectData Analysis

Uti

liza

tion

%

8

Section

Time

Availab

le (hrs)

Schedul

ed (S)

Breakdo

wn (B)

Running

Time (R

= S-B)

Utilitisa

tion

(R/S)

Dual Extruder 672 496.67 55.6 441 89%

8" Extruder 672 208.83 10.33 198.5 95%

Fabric

Calendaring 672 486.92 26.17 460.75 95%

Recoat

Calendaring 630 547.92 15.25 532.67 97%

VBC 672 571.25 41.75 529.5 93%

HBC 1344 819.84 12.33 807.5 98%

Bead Winding 672 664 188 476 72%

Slitter 630 305.5 0 305.5 100%

Squeegee

Lamination Nil 87%

Bead Apexing 1260 576.5 98.25 478.25 83%

Band Building 3150 3148.33 0 3148.33 100%

Bead Flipping 1890 860.75 85.42 837.5 97%

Tyre Building 4032 2688 23.25 2664.75 99%

Curing 14112

10943.4

8 1911.23 9032.25 83%

Tyre Trimming

Based on requirementTyre Inspection

Tyre Repair

This represents what % of machine is utilized in each process with respect to schedule and breakdown hours..

Utilization Calculation

Retrieved from SAP Calculated

Time (Hrs) available to produce the demanded output part of tyre from each process section in a month.Time required to produce the parts of tyre from each process, after monthly holidays and break time(30min/shift) Time Available = 24hrs *

No. Of Days Scheduled Days Scheduled = 28

Time Available

Schedule Time

Cycl

e

Tim

eA

gein

g T

ime

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ProjectData Analysis 9

Time required to complete a task from start to finish. With the help of line speed obtained from the machine spec. We can find the cycle time.

Cycle Time (CT)

Process

Cycle

Time

(min)

Setup

Time

(min)

ManpowerUtilization

%

No. Of

Total

shift

Available

Total Shifts

worked

             

Dual Extrusion 0.361 0.15 14 85 84 55.125

8" Extrusion 0.138 0.2 8 95 84 24.8125

Fabric Calendaring 20.3 2.2 10 97 84 57.59375

Recoat Calendaring (per

roll) 1.5 1.6 3 97 78.75 66.58375

VBC 4.18 0.25

8

93 84 66.1875

HBC 1.16 0.25 98 168 100.9375

Bead Winding 0.34 0.1 2 72 84 59.5

Slitter 1.33 0.18 2 100 78.75 38.1875

Squeegee Lamination

(per roll) 5.23 0.25 2 87 nil nil

Bead Apexing 1.25 0.1 2 83 157.5 59.78125

Band Building 0.69 0.15 1 100 393.75 393.5413

Bead Flipping 0.43 0.12 1 97 236.25 104.6875

Tyre Building 9 0.55 5 99 504 333.0938

Curing 55 2.5 2 83 1764 1129.031

Tyre Trimming 1.08 0.12 1 nil nil nil

Tyre Inspection 0.9 0.2 2 nil nil nil

Tyre Repair 6.97 0.2 2 nil nil nil

Dual Extrusion Process Line Speed = 7.1metre/min Tread required for 1 tyre = 2.56m Cycle time = 2.56/7.1 = 0.361min 8 inch Extrusion Process Line Speed = 16m/min Sidewall required = 2.22m Cycle time = 2.22/16 = 0.138

CT ca

lcula

tion

Uti

liza

tion

%C

ycl

e

Tim

eA

gein

g T

ime

Time required to prepare the machine/process for the production. It is a part of cycle time.

Setup Time

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ProjectData Analysis 10

Uti

liza

tion

%C

ycl

e

Tim

eA

gein

g T

ime

Section

Handling

Time

(min)

Transportatio

n time (min)

Ageing Time

Dual Extrusion 1.2 1.3 4hrs

8" Extrusion 1.2 1.1 6hrs

Fabric Calendaring 2.3 1.35 Nil

Recoat Calendaring

(per roll)1.2 0.55 Nil

VBC 0.55 0.5 Nil

HBC 0.5 1 Nil

Bead Winding 0.5 0.55 Nil

Slitter 1 1.2 Nil

Squeegee

Lamination (per roll)1.1 1.5 Nil

Bead Apexing 0.45 0.5 Nil

Band Building 1.2 1.2 Nil

Bead Flipping 0.55 1.1 Nil

Tyre Building 1.3 3.2 Nil

Curing 2.3 2.2 5 min

Tyre Inspection 1.1 1.1 Nil

Tyre Trimming 0.55 1.1 Nil

Tyre Repair 1.3 1.3 Nil

Time required to heal the raw material produced from the specific machine. Eg: After curing process, the treated tyre cannot be used suddenly after the process, a healing time is required.

Ageing Time

Time required to handle the raw material before and after a process. Eg; time is required to handle the nylon roll from storage to the setup place.

Handling TimeFie

ld

Stu

dy

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ProjectData Interpretation

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Current State VSM

From the data analysis, we can map the current state VSM and assess the throughput time.Throughput time = VA time + non-VA time = 1hr 44.55min + 14 hr 30.10min = 15hr 74.65min

Cycle Time Setup timeTransportation timeHandling timeAgeing time

Value Added Time

Non-Value Added Time

Keywords

VA time – Value Added TimeTTC – Current Throughput TimeTTF – Future Throughput Time

It was found out that the cycle time of fabric calendaring was high. The non-VA time was also high for the same, which delayed the following processes.

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ProjectRecommendation

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Increase the line speed of Fabric Calendaring machine. The speed can be increased from 40 metre/min to 46 metre/min. This will reduce the cycle time. Modify the 3-rolled calendaring machine to 4-rolled calendaring machine. The cycle time will be reduced by more than 50%. It was analysed that time taken to calendar one dipped roll is 86 min through a 3-rolled calendaring process. If the machine is changed to a 4-rolled machine, the time taken for the process will be reduced to 75min. Modify the tyre building machine to turret type tyre building machine. By installing the machine, the process like band building, 50% of squeegee lamination process, and the breaker lay-up can be discarded. Thus reduces the overall lead time, as well as the manpower. By proper planning, the PPC can forecast the electrical and mechanical breakdowns by understanding the machine use and its nature. By doing such, the process can be continued without making the band building section to delay.

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ProjectImplementation of Action Plan

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Future State VSM

After the recommendation that can be suggested , we can map the future state VSM and assess the throughput time. Also we can find the time saved in each process.Throughput time = VA time + non-VA time = 1hr 28.96min + 14hr 17.65min = 15hr 46.61min

Cycle Time Setup timeTransportation timeHandling timeAgeing time

Value Added Time

Non-Value Added Time

Reduced throughput time

= TTC - TTF

= 15hr 74.65min – 15hr 46.61min = 28.04min

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ProjectCurrent State Value Strea Map

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ProjectFuture State Value Stream Map

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ProjectConclusion

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The value stream map thus helped to identify the factors affecting the throughput time and helped to reduce the same through proper action plan.

The various factors that affected the throughput time were studied through VSM and necessary recommendations were suggested to improve the throughput time.

It can be concluded that the company strives for improved performance and effectiveness, and by analysing the throughput time the company can forecast the necessary action plans.

Company profile retrieved from http://www.apollotyres.com/india/aboutus-overview.aspx

Hines, P., and Rich, N., (1997), "The Seven Value Stream Mapping Tools.

Houtzeel, A. (1982). “Computer integrated manufacturing.” Proc. Of 1982 Academic-Practitioners Liaison Operations Mgmt. Workshop, American Production and Inventory Control Society, pp23-37.

Jazar, Reza N. (2008). Vehicle dynamics: theory and applications. Springer. p. 11. ISBN 978-0-387-74243-4. Retrieved 2011-03-16. "Inner layers are made of different fabrics, called plies”.

Suri, R.; Wemmerlöv, U.; Rath, F.; Gadh, R.; and Veeramani, R. (1996). “Practical issues in implementing quick response manufacturing: insights from 14 projects with industry.” Proc. of Mfg. and Service Operations Mgmt. (MSOM) Conf., Dartmouth College.

Tyre manufacturing retrieved from http://www.maxxis.com/AutomobileLight-Truck/How-a-Tire-is-Made.aspx

Werner Obrecht, Jean-Pierre Lambert, Michael Happ, Christiane Oppenheimer-Stix, John Dunn and Ralf Krüger (2012), "Emulsion Rubbers" in Ullmann's Encyclopedia of Industrial Chemistry

Reference

A bad system will defeat a good person every timeEdwards

Deming

Thank You

2013

Lean Operation and Systems CUIM

Alwin P Thomas1220206