PROOlJCTIVITY IMPROVEMENT IN MOTOR CYCLE PLANT OF SINGER BANGLADESH LIMlTED AND ITS SUPPLY CHAIN By ABU SADAT SAYEM ,.- -. , , • ! 1 IInllllUlll1i"IIII~lIm , " .10e148li' , :~ < ~; ---- , ------ . ! Deparunent ofIndustrial & Production Engineering Bangladesh University of Eng incering & Technology Dhaka-lOOO Fehruary,2009, PRODUCTIVITY IMPROVEMENT IN MOTOR CYCLE PLANT OF SINGER BANGLADESH LIMITED AND ITS SUPPI,y CHAIN By ABU SADAT SAVEM Submitted to the Department of Industrial & Produellon Engineering, Bangladesh lJmwrsity of Engineering & Tedlllology Dhaka, in partial fultillment of thc requirements for the degree of MASTER OF ENGINEERING in Industrial & Production Engineering. Dcpartment oflndustrial & Production Engineering Bangladesh Univcrsity ofEngineenng & Technology Dhaka-IOOO February, 2009 CERTIFICATE OF APPROVAL The thesis titled - "Productivity Irnpro,"'ement in Motor Cycle Plant of Singer Bangladesh Umited and its Supply Chain" submitted by Abu Sadnt Sayem, Student No. 040408006P, session April 2004, has been accepted as salisfactory in partial fulfillment of the requirements for the degree of MASTER OF ENGINEERING in Industrial & Producllon Engineering on 24 Febl1laI)', 2009. BOARD OF EXAMll\ERS ~ 01, ------------------- Dr. A K M wlasud (Super~isor) ASSOclate Professor Industrial & ProductIOn Engineering Depattmcnt DUET, Dhaka. m ~ Dr M. Ahsan Akhtar Ha,in (Member) Profes;or and Head lndustnal & Production Enginccnng Department BUET,Dhaka 03 ••~ Dr. Abdullahil Azeem (Member) Associate Professor Industrial & Production Engineering Department DUE'I, Dhaka. Department ofIndustrial & Production Engineering Bangladesh University of Engineering & Teclmology Dhaka-lOOO m CANDIDATE'S DECLERATJON I do hereby declare thatthts work has been done by me and nellher this thesis nor any part of it ha, been submitted elsewhere for the award of any degree or diploma except for publicallon. Countersigned Dr. A K M. Masud Abu Sadat Sayem SupeIVLsor& Associate Professor the Author InduSlrLal& Production Engineenng Department BUEr, Dhaka This dissertation is dedicated to my late father TABLE OF CONTRNS LIST OF .<.GLJRI£S .. VtlL LIST OF TABLES" '" '" '" "'''' ... NOMENCLATURE ACKNOWLEDGEMEI\'TS "'" ...." ... , ABSTRACT CHAPTER 1: INTRODUCTION................................. 1-4 Ll ObJcct.ve,, 2 12 Outlines of Mythologle5 3 L3 OrganizationofThes;5 . 4 CHAPTER 2: LITEUATURE REVmW ...;.................. 5-21 2,1 Productionand Product;Vlty,. 5 22 Efficiency and Effectlvene~s. 7 2,3 Wealth and Welfare...... 8 2.4 OccupationalHealth Hazards andPreventive Mca5ures.. 9 25 Quahty:ManagementSystcms 13 2,6 Benefits ofProduct;vLtyto Implement QMS" 17 2 7 Supply Cham i\ianagement" 18 CHAPTER 3: CO'\IP ANY PROFILE......................... 22-36 3 I I'hstmyofSingcr BangladeshLtd. 22 3 2 Introdu~eSingel motor cycle plant., 23 3 3 Prodllctlonflow chart.. 24 3.4 Stage\VIseinformation 25 vi CHAPTER 4: PROBLEMS IDENTIFICATIONS AND SOLUTIONS . 37-62 ,, 'I ime study analysis .. H l.inc balancing study .. 39 " Auto production belt" .. "',, .... ,,' "., 41 " Assemblers asscssmcnt notice 42 " Time card Analysls ""''', ... , 43 "'.6 In-house training "'''''', ... 41 Service/customer complain analYSls 41 " Total prevent,ve maintenance card. 47 "4,9 Raw materials store , " , " , " , " , ." '8 4W Suitable position ofa,r ,mpact wrench 5C 4.11 Time eeonom,c workmg proce:", .. 50 4.12 Easier engme carner process .. 51 4.13 Wheel balancmg set-up 52 4.14 Introduced pamt booth .. 4.15 Man hour calculation sheet" 55" 4.16 Specml service lools .. 56 4,17 In-house calibration" 57 "8 Pre-quality control 58 4,J 9 Assembler's leave control. ... 59 4,20 Create assembler's setup m specific modeL 60 Smooth supply chain (external)" 61 '"4 22 Smooth supply chain (internal)" 62 CHAPTER 5: RESULTS AND DISCUSSION . 63-70 5.1 Productiv,ty Analysis. 63 5.2 Method ofImprovement of Productivity GO CHAPTER 6: CONCLUTIONS . 71-72 REFERENCE . 73 '" - LIST OF FIGURES FLgure2,1 The scope of Supply Chain Management 19 Figure 2,2 S,ngle layer supply chain 20 Production flow chart ofS,nger Motor Cycle 24 Figure 3 2 ChasS1Spreparation .. figure 3,3 "''heel alignment 26 Figure3,4 Rear fork assembly 27 Figure 3 5 front fork assembly, ,. 28 figure Hi Engme assembly Flgure 3.7 Handle asscmbly .. 30 figure 3.8 Ex-muffler assembly 31 figure 3,9 Seat and fuel tank assembly 32 FIgure 3 10 Pre dehvery m,peclion 33 hgure 3 1I Quality control le,t "'" .... Flgure 3 12 Wind shLeldpreparation .. 35 figure 3, 13 Motor cycle packing and delivery" Figure 4 I a Time study analysis 37 Flgurc 4 l.b Operation mode analysis. 38 Figure 4 2,a Lme balancing study" 39 figure 4,2,b Productivity improvement status" 40 Figure 4 3,a Auto productlOn belt 41 FIgure 4 3,b Aut()mat;on analysIS 42 Vlll ' .. ,.'i[" , •• ••••• ( , Figure 4 4 Assemblers assessment notice ... " , " .... " I'igurc4,5,a 'I imc card, 43 Figure4,5.b Assemblers leave stalus """ ... , 44 Figure46 In-house lramlng .. 'S hgurc4.7,a Service/customer complain analysis .,,''''''''', ... 46 Flgure 4 7 b Service Compliant AnalysIs. 47 FIgure 4 8 Total prevcntl\'C maintenance ~ard """ ... , 48 Figure 4,9,a Raw materials store "''', ... ", ... , 49 FLgure4 9 b Status ofUnhalance Motorcycle 49 F'gure410 Suitable pOSItionof air impact wrench .. "",,.,- 50 Figure 4 II "Iimc economic working process" " Flgure412.a Easier engme carrier process" 51 Flgure4.12 b Engine carner statu~ 52 Figure4,13,a \\'heel balancing set-up., """ ... 53 Figure 4 13 b Wheel balancing setup __ 53 Figurc4,14a Paint booth, 54 FIgure 4 )4,b Introduced paint booth .. _ 55 FIgure 415 Man hour calculation sheet. " Figure 4,16,a Special servlcc tools 56 FLgure4.16b ACllvLtLeSof~pecial scrvLcetools . " FLgure417 In-house calibration, 57 Figure 4, 1g Pre-quality control 58 • Figure 4, 19 A~sembJers leave staius .. _ 59 Figure 4.20 Model WlSC assembler's set-up .. 60 Figure 4.21 Supply chain, external 61 FIgure 4.22 Supply cham, internal"", .. , "., 62 Figure 5 I Yearly productJons 64 Figure 5 2 Labor productivIty " Figure 5.3 O"er time analysis 66 Figure 5.4 Other IndIrect productivity, , 67 Figure 5 5 i\1an-hour calculation .. 68 <h' LIST OF TABLES Table 4.1 Productivity analysis _ 38 Table 4.2 Productivity improvement ""'''''', .., 40 Table 4.3 Auto beltproductlon __ " Table 4.4 Assemblers leave stalus 44 Table 4.5 Service compliant status _ 46 Table 4,6 Status of un baJa nee motorcycle. " Table 4 7 Engine carrier implemented " .., ...... , 52 'lable48 Wheel balancmg setup __ ..... " , ... , 53 Table 4 9 UtilizatIOn of paml booth ."",, ... , 54 Table 4 10 Activities ohpecial service tools ... , 56 Table4.11 Assemblen. leave control status" 59 Table412 Supply chain analysis, externaL. , ... " , .. " Table4.13 Supply cham analysiS, internal 62 TableS I Data for yearly production" 63 Table 5.2 Labor productivity improvement .... " , ... - 64 Table 5 3 Over time analysis __ 65 Table 5.4 Other indirect activllles 66 Table 5.5 Data [or yearly productivlly .. 67 NOMENCLATURE MC Motor L-yde QC Quality control SST Special service tools PDT Pre delivery mspection ILQ TntematlOnallabor organiz.ation WHO World health orgamzation QMS Quality management system CUI CapaCltlve discharge ignition UTC t ILghtcnSlOncoil 'rPM Total preventive mamtcnance CKD Complete knocked dO"ll AIW Air impact wrench SMC Singer manufactunng complex PQe Pre quality control "" Aclmowledgements The author is deeply indebted to Dr. AKM Masud, Associate Professor of the Department of Industrial and productlOn Engineering, Bangladesh University of Engmeefmg & Te~hnology for hIs guidance, help and encouragement through the progre% of the thesIs. The author would llke to acknowledge hLssense ofgralitude to Mr, Mahbub Jami!, Ihe honorable Chairman, Managing Director & ChIef Executive Officer of Singer Bangladesh LImited for providing facl1lties and a%istanee to make possible 10 complete the course, The author aha expressed his gratitude and speclalthanks to Mr, Mosbarraf Hossam, the honorable .Manufactunng Director of Smger Bangladesh L,mlted for his support and kind interest;n this thesis work. Beyond the cducatlOnal and techmcal guidance, the author deepest thanks must go to hIS parents who made h,S undergraduate and graduate educatlOn possible. Fmally the author "ffers hls sincere thanks to all assemblers and supervIsors in singer motor cycle plant who either directly or indirectly helped in various WdYS to complete thi< thesis. ~Ill Abstract ProductLon LSconcerned WIththe a~tivity of producing goods and/or serviccs that mcans production lS thc quantity of output produced, while productivity is conccrncd with thc efficienllllilization ofrcsourccs (input) m producing goods and/or services (output), so productivity is thc ratio of the output produced to the input used, The objectIve of this lhesis work LSto Improve producti vit) and the qual ity of the produ~t of STl\'GER molor eycle plant. To achIeve this goal few phenomcna and techniyues are applied. Such as improvemcnt of the proce,s of the production first. That'3 why lime study, Illle balan~ing, production dCSlgn and the development assemblers multi-skilled al diffelent stages are esselllial To elimmate materials waiting and mimmlze production loss for model ~hange, the supply chain has been studied, Secondly to achieve the quality of the product applied quality management system, pre quality control and analyze service complamt feedback for which a pcrformance committee has been formed. Finally to attam minimum prodllction few tecluuques are apphcd. Such a3, proper stonng