Background
Client is one of the pioneers in Auditorium seats manufacturer, supplier, and exporter. With business carried out both in and out of India, they have executed more than 1000+ project.
Challenges
•The presence of quality issues within production processes, specifically concerning welding, was a matter of concern. We have observed issues such as welding spatters and irregular bead thickness, which have the potential to impact the overall quality of products. Welding spatters can lead to aesthetic defects and affect the integrity of the welds, while irregular bead thickness may compromise the structural integrity of the components. Addressing these quality issues was a priority, as it not only ensures that products meet the highest standards but also contributes to customer satisfaction and safety.
•The improper allocation of manpower for welding operations was a big concern in manufacturing process, particularly when producing chairs. This issue acts as a significant bottleneck that severely impacts productivity and the overall production of chairs. One of the most prominent consequences is a marked decrease in productivity, directly affecting ability to meet production targets and timelines. This not only leads to potential delays in chair manufacturing but also increases production costs and resource utilization inefficiencies.
What We Did:
Designing a welding fixture to eliminate secondary operations
Our journey towards process improvement began with the strategic design and meticulous development of a specialized welding fixture aimed at reducing the need for a labour-intensive secondary operation, namely deburring. This transformation not only streamlined manufacturing process but also delivered significant enhancements in various facets of production.
Step 1: Design and Conceptualization
The process commenced with the conceptualization of a welding fixture tailored for precise and accurate welds. Every facet of this fixture was meticulously considered to minimize burrs and imperfections in the welded joints. Crucially, this phase was informed by a comprehensive time study and process study, providing invaluable insights for the fixture’s design.
Step 2: Prototyping and Evaluation
Following the initial design phase, prototypes were crafted and rigorously evaluated. This step allowed us to refine and fine-tune the fixture for optimal performance. The design’s effectiveness in eliminating the need for deburring was rigorously assessed through a combination of quality rejections.
Step 3: Time Study and Process Study Refinement
In tandem with the prototyping phase, an extensive time study was conducted to ascertain the fixture’s efficiency in welding operations. This study provided invaluable data, guiding further refinements to the fixture’s design. Concurrently, a detailed process study was carried out to ensure seamless integration within existing production workflow.
Step 4: Design Finalization and Implementation
With insights garnered from the time study, process study, and prototype evaluation, the welding fixture’s design was finalized. It was then seamlessly integrated into production process, effectively reducing the need for deburring & quality rejections.
Quality Enhancement
With the implementation of the new welding fixture, there was a remarkable reduction in quality issues. The precision and consistency of the welds resulted in cleaner, smoother joints, eliminating the need for time-consuming and costly deburring.
Manpower Rationalization
In previous manufacturing process, seven individuals were tasked with welding and subsequent deburring. However, the introduction of the welding fixture streamlined operations, reducing the manpower requirement to just one highly skilled operator. This rationalization was meticulously informed by time and process studies, ensuring the new workflow was both efficient and effective.
Productivity Surge
The adoption of the new welding fixture had a profound impact on productivity. We witnessed a substantial increase in the number of units produced, with output numbers soaring from 100 to an impressive 200 units.
In summary, the design and development of the welding fixture, driven by detailed time and process studies, alongside rigorous design creation and evaluation, not only eliminated the need for deburring but also resulted in a significant reduction in manpower, a remarkable increase in productivity, and a noteworthy enhancement in product quality. This comprehensive transformation reflects unwavering commitment to continuous improvement, creating a more efficient, cost-effective, and high-quality manufacturing process.
Sustained Change – Our Journey
Our journey began with the strategic design and meticulous development of a specialized welding fixture, aimed at eliminating the need for a labour-intensive secondary operation like deburring. This endeavour resulted in impressive initial gains: a notable reduction in required manpower, a significant boost in productivity, and a marked improvement in overall product quality. To ensure that these improvements were not fleeting but became integral to operations, we adopted a multi-faceted approach to sustained change in company.
First, we invested in comprehensive training programs for workforce, equipping them with the necessary skills and knowledge to fully utilize the welding fixture’s capabilities. This step was essential in maximizing the fixture’s potential and maintaining consistent high-quality output.
Next, we established a rigorous performance monitoring system, which includes regular audits and feedback loops. Additionally, we’ve cultivated a culture of continuous improvement within organization. This involves encouraging innovative thinking and valuing suggestions from employees at all levels. By creating an environment where new ideas are embraced and tested, stay at the forefront of manufacturing efficiency.
In summary, our journey of sustained change is characterized not only by the initial transformation but by unwavering commitment to ongoing excellence. Through targeted training, vigilant performance monitoring, and a culture of continuous improvement, we ensure that the benefits of our innovative welding fixture persist, delivering enduring reductions in manpower, consistent productivity gains, and a higher standard of product quality.
Key results
• Daily productivity has increased from 100 units to 200 units.
• The workforce has been downsized from 7 to 1
• Quality concerns have been significantly diminished.
• The need for deburring operations has been eliminated.