The Use of Kaizen in Tipper Production Line in Arabian Metal Industries Ltd.

King Abdul-Aziz UniversityFaculty of Engineering - Rabigh

Department of Industrial Engineering

IE499 Senior Project

Students Eihab R. Garout #1010837

Abdalrahman M. Bahmaid #1007770

Mohammed R. Alharbi #0910779

AdvisorDr. Hani Shafeek

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Agenda Arabian Metal Industries Ltd.

Kaizen

The Basics of Kaizen

Methodology

The Result

Conclusion

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Arabian Metal Industries Ltd. Arabian Metal Industries Limited (AMI) was establish in 1976

AMI met all challenges by being able to manufacture any product requiring sheet metal fabrication, welding and machining.

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Arabian Metal Industries Ltd.

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Arabian Metal Industries Ltd.

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Kaizen• Kaizen is a Japanese word that means continuous improvement.

• Kaizen is intend to be integrate into the normal day-to-day activities with the focus eliminating waste, creating standards, having a clean and organized workplace.

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The Basics of Kaizen• The Seven Wastes.

• 5S’s.

• Standard Work.

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The Seven Wastes1. Overproduction

2. Wait time

3. Transportation

4. Over processing

5. Inventory

6. Motion

7. Defects/rejects

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5S’s1. Sort

2. Set in order

3. Shine

4. Standardize

5. Systematize

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Standard Work• Standard work is the best, most efficient, safest, and most practical way of doing work.

• It is the process of documenting and standardizing all tasks, so that authorized, standard procedures are use at all times, on all shifts, and by all operators.

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Standard WorkExamples of standard work are:

• Outline Process Chart

• Time Study

• Cycle Time and Takt Time

• Balancing Time

• Flow Process Chart

• Waste Analysis

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Methodology

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Production line Work In ProgressWastesImprove

Methodology 5S’s

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Methodology Standard Work• Outline Process Chart

• Time Study

• Cycle Time and Takt Time

• Balancing Time

• Flow Process Chart

• Waste Analysis

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Outline Process Chart

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Symbol Activity Type of Activity

 

 

 

 

Time Study

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Cycle Time and Takt Time

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Takt time is the rate at which products or services should be

produced to meet the customer demand.

Cycle time is the total time from the beginning to the end

of your process.

Balancing Time

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Workstation

Seq Work Content Time

Total

Flow Process Chart

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Waste Analysis

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The Result

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Present Proposed

Present Situation

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Outline process chart

Present Situation

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Present layout

Present Situation

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Present Layout

Proposed Situation Present layout

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Proposed Situation Present layout

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Present Situation

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Time study

Present Situation

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Time study

Present Situation

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Balancing time

Proposed Situation Balancing time

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Present Situation

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Cycle Time VS Takt Time

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Present Situation Cycle Time VS Takt Time

Present Situation

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Flow Process Chart

Subject Charted: Saving00

Activity: 000

480Method: Proposed 480.4Location: Assembly LineOperative(s):

→ D ∆Parts are Store (Side, Floor, Front and Tail Gate) •Moving Parts to Assembly Line 65 8.8 •Making An assembly for Tippers •Checking the Box tipper after assembly by QC •Moving Tipper box to Subframe zone 0 0 •Working on assembly the box with the subframe 10.2 •Checking By QC •moving to Hydrulic Zone 50 8.5 •Working on Hydrulic Assembly 60 •Checking the tipper by QC •Moving to paint Shop 50 0.5 •Total 165 88 3 4 0 3 1

Tipper Assemply Operation 3 3Transport →

Flow Process Chart Chart No. 2 Sheet No.1 of 1 Summary

Activity Present Proposed

Making Assembly Parts Inspection 3 3Storage ∆

Time (Min) 656.4 176

4 4Delay D 0 0

1 1Distance (m) 810 330

CostLabor

RemarkDescription

MaterialTotal

Qty Distance (m) Time (Min)Symbol

Proposed Situation

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Flow Process Chart

Conclusion• After the comparing between the present and the proposed situation appear that there clarify different between the present and the proposed of layout, distance and time of the production line in Arabian metal industry company.

• That we will safe to company around (1681 m) and (690.13 min) in the transportation of tippers production line.

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Conclusion

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Conclusion

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Thank you for listening

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