OCTOBER 19-20, 2012 - YMCA University of Science & Technology

Proceedings of the National Conference on
Trends and Advances in Mechanical Engineering,
YMCA University of Science & Technology, Faridabad, Haryana, Oct 19-20, 2012
(iii) Elimination of the NVA Activities by making the necessary changes in work methods
Each of the 42 activities identified were critically examined to eliminate or reduce the NVA activity associated
with that parameter. In each case, it was observed that, few small changes in the layout at the individual
workstation lead to drastic reduction in the work content. For example, few changes in activity – Placement of
Front and Rear locators, operation time can be reduced by placing the front and rear locators nearer to the
bonding bay and fixing it onto the super structure of the assembly line.
Similar exercise was done for all the 42 activities associated with Existing Method. After evaluating the actual
process it was identified that 5 activities were found to be taking more time than required, and 11 were identified
as non-value added activities. By modification of 5 activities and elimination of 11 activities, total operation time
of 3 minutes 58 seconds was reduced, thereby reducing the number of activities from 42 to 31. Hence the total
operation time for Body Side Panel Bonding Process gets reduced to 5 minutes and 53 seconds from 9 minutes
56 seconds. With the changes made in 5 activities and elimination of 11 activities there is a reduction of 41% of
operation time.
6. Results and Analysis
Before the new standards were established, an extensive and thorough analysis and review of each activity was
conducted in Stage 15 of assembly line. The existing process had 42 activities and the time taken to complete the
process was 9 minutes and 39 seconds. After evaluating the actual process it was identified that 5 activities were
found to be taking more time than required, new time standards were established for these activities which are
given Table 1.
Table 1 Details of Operation Time Reduction
Operation Name
Existing
Time in
Seconds
Modified
Time in
Seconds
Reduction
Time in
Seconds
Take the front locator 12.6 7.56 5.04
Take the rear locator 12.6 7.56 5.04
Insert rear bottom locator into the top locator 6.84 4.68 2.16
Dispense adhesive 5.76 3.6 2.16
Sealant Application Process time 126.72 86.4 40.32
Total 164.52 109.8 54.72
Table 2 Details of Operation Time Elimination
Eliminated Operation Name
Operation Time
in Seconds
Collect the body side panel 12.96
Place the locators on the LH and RH panel 21.6
Inspect the flushness and gap 6.48
Adjust the fitness of the panel 4.32
Disengage the Panel 9.36
Place back the panels onto the storage Rack 17.28
Use cotton cloth 0.72
Using the Scuffing Tool 40.32
Clean the scuffed area 57.6
Get the Masking Tape 4.68
Fix the masking tape onto the chassis 9.72
Total 184.32
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