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Reduction of lead time in conversion efficiency l.jpg

Reduction of Lead Time in Conversion Efficiency

Presented by:

Swati Agarwal

81057


Agenda l.jpg

Agenda

  • Objectives

  • Company Profile

  • The Process

  • Findings

  • 1. Case & dials Preparation

  • 2. Assembly of Spares

  • 3. Running Test

  • 4. Strapping

  • Conclusion


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Objectives

  • Understand the process:

    four sub-phases

  • Lead time

    for different variants and dial colors

  • Reduction of lead time

    an attempt to improve the conversion process and improve efficiency


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Company Profile

  • Titan Industries is the world's sixth largest wrist watch manufacturer and India's leading producer of watches

  • It is a joint venture between one of India's most respected business organizations, the Tata Group, and the TIDCO

  • The company has manufactured more than a 100 million watches till date; and has a customer base of over 80 million


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Company Profile Contd..

  • The Titan portfolio has over 60% of the domestic market share in the organized watch market.

  • The company has 247 exclusive showrooms christened ‘World of Titan’, making it amongst the largest chains in its category backed by 700 after−sales−service centers


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Divisions of TIL

  • Watch Division

    1. Started in 1987

  • Precision Engineering Division

    1. started in 2002

    2. leading manufacturers of Precision Parts forautomotive and aerospace Industries

  • Jewellery Division

    1. established in 1995 under the

    name Tanishq


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The Process

FPS

Assembly

Dial Fixing

Hand Fixing

Encasing

Case and dials Preparation

Stem cutting and winding

Quality Test

Process inspection final Inspection WRT

Running test

Strapping

Dispatch

Finished Watch store


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Findings


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Case & Dials Preparation


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Contd..

Observations:

  • Longer time taken due to the sophistication of the work

  • Rework in B/C stamping

  • The 3 processes i.e. glass cover unwrapping, PMH separation and B/C opening is done by the same person one after the another.

  • The throughput rate in this case is 89sec


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Contd..

Actions Suggested:


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Contd..

  • Use of air pipes installed to dry the ink to prevent smudging


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Assembly of spares


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Contd..

Observations:

  • Wait for stems after stems cutting

  • Excessive Rework

  • Cleaning glass covers takes most of the time

  • Wait for availability of spares

  • Repair

  • Mixed crowns


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Contd..

Actions suggested:

  • stems to be send for cutting after hands fixing

  • the glass-covers trays should be covered with cellophane papers

  • Ensure availability of all spares before issue of work order

  • Quality checks at each stage to reduce rejection rate


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Contd..

  • Separate personnel for repair

  • It is observed that the maximum movement time is after dial fixing. Make the dials fixing and the hands fixing personnel sit closer.

  • The crowns and stems should be separated out at the preliminary stages to stop wastage of time


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Running Test

  • Standardized phase, automatic machine processes

  • manual work is limited to inspection of watches for dents, dirt and time variation and repair of the watches

  • The time span for each of the tasks like dynamic test, dial down oven, dial up etc is fixed and can only be reduced if some new machinery is adopted for the process


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Contd..

  • Only area of improvement is repair work, a rework

  • Proper rechecks at assembling stage

  • Is a very crucial phase as it ensures quality of the watches. Thus the time spent on RT is worth it.


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Strapping


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Contd..

Observations:

  • Strapping is done in-house as well as sub-contracted to three vendors

  • Strapping consists of pressing the pin or screw tightening. This often leads to scratches or dents on the glass cover

  • The manpower used is multi-skilled.

  • Chaotic layout


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Observed Layout


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Contd..

Actions Suggested:

  • The layout should be better planned so as to allow smooth flow of spares from one workstation to another


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Dispatch

Entry/exit

Entry of consignment/supervisor

Spacer fixing

S

T

R

A

P

P

I

N

G

W

I

P

Packing in cartons

W

I

P

Putting

In

Containers

And

Sticker

Fixing

Clamping and wrapping

Final Inspection

Suggested Layout


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Conclusion

  • A total reduction of 40% and 34% respectively observed in case and dials preparations for fixed and non-fixed B/C resp. in case & dials preparation

  • A reduction of 41% in auto belt due to reduction of movement time

  • The new layout ensured smooth flow of work from one work station to the other.


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