Supplier-Input-process-Output-Customer Analysis for Buggy Tank Manufacturing Process

Assignment Title: Do a Supplier‐Inputs‐ProcessOutputs‐Customers (SIPOC) Chart Analysis to propose what a buggy tank manufacturing process would involve regarding critical information and key stakeholders of the manufacturing operations.

Introduction:

A SIPOC (Supplier-Input-process-Output-Customer) diagram is used to identify all the important key elements of a process before the work begins. It is an easy way to define a project that may seem complex and is not well scoped. It is usually employed in the Measure phase of DMAIC process used in Six Sigma (iSixSigma, 2013). SIPOC outline is additionally used to kick-begin critical thinking inside the business procedure. Above all else, the graph is helpful if the group needs to concede to the normal language and comprehension of the procedure. It does proves to be a good tool for problem solving and mapping of a particular process (iSixSigma, 2013).

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The success of any project depends on the stakeholders or partners of the project. A stakeholder is a person who is a part of the process of the project in a direct or indirect way. The project outcome is a combined result of all the inputs, the various processes included till the desired product is completed and finally delivered to the customer. A SIPOC diagram thus give a brief overview and better understanding of a process involved in any project along with all the dependent parameters. In this process more emphasis is given to the improve quality and reduce downtime of the machine

Supplier

Input

Process

Output

Customer

Steel

Plant

Steel Sheets

Shop floor Processes:

Cutting

Folding

Tack Weld

Robo weld

Final Inspection

Leak testing

Thread tapping

Rework

Fuel Tank

Buggy buyer

Weld-it

Welding Rod

Buggy

Dealership

owner

AB works

Filler Cap

Worker wages

Service

Department

SNK Valves

Breather

Profit to company

NCV works

Fuel outlet port

Employer

Workers

Company

Machines

Input Metrics

Process Metrics

Output Metrics

     1.Process responsiveness.

     2.Process output.

     3.Material storage and Quality

               1. Rework percentage/shift.

               2. Defects at each station.

               3. process efficiency.

1.Process accuracy.

2.Pass rate/shift.

3.Overall finish.

Quality

     1. Time to receive order.

     2. Time to receive shipping info.

     3. Time to order raw materials.

               1. Number of process steps.

               2. Time to complete tank.

               3. Time delay between steps.

               4. Time to deliver tanks.

               5. Time for Rework.

1.Process Cycle time

2.Time/part

           Time

      1.Amount of raw material           

        required/day.

      2.Electricity bill and overheads.

               1. Number of process steps.

2. Wastage at each station.

               3. Machine maintenance.

1. Cost per tank.

2. Cost of staff.

3. Cost of   transportation.

4. Cost of package

Cost

 

 

Description:

The SIPOC diagram represents the processes required for the assembly a fuel tank. The tank has various subcomponents which are supplied by the suppliers. The key stakeholders on the process include the Steel plant that supplies the steel sheets of 2 and 3mm for tank and baffles respectively. Welding rods are supplied by Weld-it. The filler caps are custom made to suit the purpose and are supplied by AB works. SNK valves supplies non-return type of valves which are suitable for this application. NCV works being the supplier of fuel outlet port. The inputs for the process include steel sheets, Welding rods, filler caps, breather and fuel outlet port.

For good quality product the process efficiency is major aspect taken into consideration. Process efficiency depends on the pass rate and accuracy of production. The material used for tank making also taken into consideration. From storage to material handling. If the material is damaged it will affect the end result.

Tank assembly data:

Material

Steel

Process

Sheet Metal fabrication

Thickness

2.00mm(tank)

1.00mm(Baffle)

Order Quantity

50 RHS , 50 LHS = 100/week

 

Process

Operation

Quantity

Time(sec)

Tank cutting

Laser cutting

6

110

Baffle cutting

Laser cutting

3

70

Folding

Manual folding

7

105

Baffle assembly

Manual welding

6

180

Tack weld

Manual welding

12

180

Robot Weld

Robot welding

5

69

Leak testing

Pressure check

1

150

Final Assembly

Manual tap and fit

1

405

Inspection

Visual

1

60

Rework

Manual/machine

1

300

TOTAL

43

1629 (secs)

 

 

27.15(mins)/tank

 

Process:

The shift begins with an order confirmation. The tank is made out of steel and hence it is laser cutting of the right and left tank with the baffle parts in the desired shape and dimension at the beginning of the process at the cutting station. The data for folds is fed in the laser machine. At the manual folding machine all folds from 1-6 are completed followed by the assembly of the baffle in the partially closed tank and welded in place before the final fold 7 is completed. The tank is then fixed and tack weld to fill the corners. Then filler cap is installed and tacked into position. Further the tank is tested for leaks by applying water pressure. If any leak is found it is then marked and sent back to the rework area. 3% of the tanks are sent back for rework. The passed tanks are then sent to the final assembly area where threads are cut onto the filler cap and on the tank where filler is fitted so the fuel cap fits on it perfectly. At the final inspection area the tanks is checked for any defects before being sent to the dispatch section. If there are any defects in the tank it is then sent to the rework station so that all defects are modified by grinding, welding and if needed reassembly.

 

Red line- Welding

Blue line- Fold

Black line-Outline

 

Conclusion:

The tanks are to be delivered at a rate of 50 buggy sets/week which is total of 100 tanks/week. Each tank takes about 27.15mins to complete. Each shift consist of 6.5hr for 5 days/week which is equivalent to 13 tanks/day and 65 tanks/week which is very less than the projected forecast. The manufacturer needs to reduce the changeover time and increase the shift time or keep two shifts to achieve the required target of 100 tanks.

 

References:

iSixSigma. (2013). SIPOC Diagram | iSixSigma. [online] Available at: https://www.isixsigma.com/tools-templates/sipoc-copis/sipoc-diagram/ [Accessed 30 Aug. 2019].