CttB Presentation_Arya Dash

02/05/23Restricted © Siemens plc 2013 All rights reserved.

I DT MC MF-CONPresentation Template v.3.0

TP585-001

Lean Cell Design ProjectArya Dash, Manufacturing Engineer, SIEMENS PLC

Restricted © Siemens plc 2013 All rights reserved.


TP585-001Page2

What do we do at Siemens Congleton?

Siemens in Congleton employs 450 employees and is a Global supplier of industry-specific drives that control AC Motor speed by

varying the current and frequency. The market extends across 190 countries with annual revenue of £74m last

year.Applications: SKiiP

Heat-sink

Electronics



TP585-001Page3

Where it all started- Business Need!!

• Old product• Demand has dropped from ‘21’ to ‘12’units a shift.• Number of operators in the cell have been reduced from 3 to 1.• Inefficient layout for ‘One person Build Process’• Current output is only 7 units a day.

My Job: Shrink the size of the cell to make space for a new product Upgrade capacity to improve the output with one person working in the cell



TP585-001Page4

What’s wrong with the current cell: Understanding the challenges

•Takes up a lot of space!!

Total Area: 110 sq. m•Excess Motion!!

134 Steps per unit

•Excess Inventory:

•Poor Delivery Performance!!



TP585-001Page5

How did I address the challenges?

•Initial investigation and experience•Process Simulation and CalculationWhy?

•Designed smarter storage solutions (Karakuri Systems)- Reduced floor space

•Reduced the number of tools- Cost Avoidance

•Amalgamated work stations- Improved build times and motion

•Designed slick workstations with quick change over capabilities- Reduced Waiting and Downtime

Current State PFA

Data Gathering, Standard Times etc.

CIP Brainstorm



TP585-001Page6

Cardboard Mock up:Construct mock up of workstation using cardboard

• Go through the build process and decide the best place for material / parts

• Bearing in mind storage quantities• Correct container size• Placement of tools• Simulate first production without screwing or

soldering

Duration: approx. 3 days

Cardboard Mock Up- Getting the ‘Buy-in’ Zero Defects & Continuous Improvement



TP585-001Page7

New LCD Workstation:

• Order and delivery of the new LCD Workstation/ESD work tops

• Revise production layout and plan as required

• Reevaluate standard time

• Capture savings

Final Install Zero Defects & Continuous Improvement



TP585-001Page8

Achievements

Before Target set by Simulation

Achieved by the Team

Reduction in %

Annual Cost Savings (£)

Floor Space 110 sq. m 55 sq m 47.5 sq. m

57% 26,040.00

Standard Time/output

40.2 29.3 26.5 34% £3,500(based on forecast)

Motion 134 steps per unit

68 steps per unit

56 steps per unit

52% 780.00

Tooling 22 14 14 36% 8,000.00

WIP £2,670 £1,470 £1,470 45% 12,00.00

Total Savings

£39,520

Total Investment:£5,000



TP585-001Page9

Learning Outcomes

• Reflective Learning- How else could have I approached it?• Good Engineer?• Strategic Problem Solving• Use of New Simulation Software• Teamwork• Decision Making• Effective Communication

CttB Presentation_Arya Dash

Documents

Transcript of CttB Presentation_Arya Dash