Lead time reduction through lean techniques on filter drier component by modifying fixture design – Case study

Abstract

In a manufacturing company, it is important to improve the cycle time and achieve the projected lead time. Delivering the goods on time and in good quantity is important factors to satisfy the customer. To stay inside the competitive market consumer orders is vital. So customer pleasure is considered as one of the many objectives of a company. In this paper filter drier has been taken into account and its cycle time is studied. Current state Value stream mapping (CSVSM) for existing methodology has been plotted and the bottleneck of the process was found during the cap assembly. Based on customer demand, Takt time and production time is plotted. The cup assembly process takes more time than the Takt time. The problem for time taken was analyzed with lean tools and Cause and effect diagram. A new fixture design was created to reduce the cycle time of the cup assembly. Future state value stream mapping (FSVSM) was plotted. The production of filter drier has been increased from 818.3 numbers to 1285 numbers and the bottleneck process time has been reduced from 33 s to 21 s.