Modification of Milling and Turning Tool Inserts Plant Layout in a Tool Manufacturing Company

Abstract

This work is pertaining to modification of milling and cutting tool inserts plant layout in Production Unit.. Extensive work has been carried out using value stream mapping (VSM) to identify the problems, bottlenecks, cycle time, down time, work-in-process inventory, material movement constraints, production flow lines etc in the existing system. Modification of present layout in PU5 leading to creation of separate layout for five operations of milling inserts manufacturing activity, addition of machines required, and reducing the job allocation time from 24 hours to 6 hours has resulted in a lot of improvements. Significant improvements are; 

• Lead time of milling inserts manufacturing is reduced from 14.092 days to 5.95 days and that of turning inserts is reduced from 12.392 days to 5.58 days. Percentage reduction in Lead time is 57.77% and 54.97% respectively. 
• Work-in-process Inventory is reduced from 210550 units to 110600 units, reduction of 47.5 percent. 
• Material handling distance is reduced from 315 meters to 265 meters. Value added percent for Turning Inserts is increased from 15.04 % to 45.02% and for milling inserts from 13.012 % to 42.02%.

(iv) Centralization of coolant supply system resulted better space utilization and flexibility in effecting changes in machines locations. 

(v) With the new overhead electric connections, the power line can be dropped down and used by the required machines and the need to re-wire and re-do the entire electric connection for layout changes is eliminated.

Based on the study and in consultation with company executives the present Mixed-flow line is converted into Mixed-flow line zone To Parallel dedicated flow lines zone To Mixed-flow line zone in two plants.This resulted in development of separate reconfigured layout.