Lean Project-improvements -Fiber Patch Cord
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Cost Optimization - Fiber Patch Cord Problem Statement : • High Product Cost Project Leader Rahul Vazurkar Team Rahul Vazurkar Sushant Desai Saish Pal Kedar Borkar Shivani Prabhu Siddhesh Dessai Sponsor Rajkumar Timmarayan Project Timing Start Date End Date Goal statement : • Reduce Product Cost Business Impact : • Product Std Cost Reduction by 20% Risk Assessment : •Machine breakdowns leading to increased down times
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Transcript of Lean Project-improvements -Fiber Patch Cord
Cost Optimization - Fiber Patch Cord
Problem Statement : • High Product Cost
Project LeaderRahul Vazurkar
TeamRahul Vazurkar Sushant DesaiSaish PalKedar BorkarShivani PrabhuSiddhesh Dessai
SponsorRajkumar Timmarayan
Project Timing Start Date End Date
Goal statement :• Reduce Product Cost
Business Impact : • Product Std Cost Reduction by 20%
Risk Assessment :•Machine breakdowns leading to increased down times
Go to Gamba (Process walk through)
USEFUL TIME : 1932 DMHDESIGN TIME : 2407 DMHINDUSTRIAL EFFICIENCY : 35 %
Cord preparation Connectorizing Crimping PolishingVisual Inspection
Heat Shrinking Testing Winding
Define
PackingFiber Patch Cord
Man Material Useful/Design Time
Measure Fiber Patch Cord
Assembling Cost
High man power deployed for assembling
High Material Cost involved at testing & packing stage
High Useful time and Design time
Man-Power Measure
•Man-Power required for assembling of Fiber Patch Cord is 9•High DT•Capacity Per Hour is 30
MeasureRaw Material Cost
Blister For Patch Cord
Test Certificate Plastic Bag 3*4
Glaze Card
SC Connector LC Connector
SM Duplex
MeasureTime study
Fiber Patch Cord Line Analyze
•UT= 215 DMH•DT = 261 DMH•KD = 82 %•Involves Glaze Card Preparation
Testing Packing
•UT= 273 DMH•DT = 341 DMH•KD = 80%•Involves test report preparation
•UT= 322.5 DMH•DT = 417 DMH•KD = 77 %•Offline activity•High DT as the operator moves out of the main line
Polishing
ImprovePolishing -Offline Polishing –Inside the U-line
Results
•Offline Activity•Operator wastes time (20 dmh) for polishing activity
•Wash basin provided inside the line•Time saved thus improving KD
Test report
Printed label
Improve Test report eliminated and replaced with auto test report label machine
Results•Test report preparation eliminated after Auto-test- printing machine •Testing involved Test Report Preparation
Blister
Glaze Card
Poly bag
Improve
Winding Fixture
Results•Packing involved glaze card preparation and blister packing
•New Fixture Provided for winding •Blisters eliminated and replaced with poly bag
Fiber Patch Cord Packing- Blister replaced with poly bags
11SPS-0159EN V01 Kaizen Report Template
RESULTSTime study
12SPS-0159EN V01 Kaizen Report Template
RESULTSLine Architecture
13SPS-0159EN V01 Kaizen Report Template
Raw Material
RESULTS
Blister For Patch Cord Test Certificate Plastic Bag 3*4 Poly Bag
