IE Training Study in TC/Cur-Mold Shop

1.   Object:

Necessary manpower calculation made in TC mold shop.

This study comes from TCcuring shop. There are 13 operators (5 operators / 2*4 shifts, 8 operator/ 3*8shifts) in TC mold shop .The Shop manager and mold technician apply for addmanpower when the presses reach 30. The shop manager will reduce 1 operator at 2*4 shifts and add 3 operators at 3*8 shifts. IE manager is according to shop requisition. Necessary manpowercalculation made in TC mold shop.

Constraints

-PA - PdP

-Quality

-TS 16949 (TC)

-Safety

-IE study is finishedby 07-dec-2001

2.  Study organization

2.1    Investigation

Talk with shop manager,technician and operator in order to master main problem in TC mold shop.Understand main work of operator.

Reference documentation：

Collect referencedocumentation in order to master situation of post:

- Organizationaldiagram of work area

- Post description

-PersonnelListing (Grade, Length of service, Vacation, Schedule, Restrictions, Trainingand validation requirements, Others).

-Work method

-Product flow

-Machine & tools

-Material

-Environment

-Layout

-SPEC

Continuous observation

Continuous observation allowsme to gain a thorough understanding of mold post in short term.

2.2    Observation(sample)

Determine unittime of each activity through Observe(see sheet1, 2)

2.3    Data collection

According toproduction record, calculate and statistic frequency of each activity on oneday. (See sheet1, 2)

Workload of Mold2*4 Shift Operators for 26 presses in TC

Sheet1

Activity	Frequency/day	Unit Time(min)	Total
Repair & rebuild Mold	2.47	90	222
Assemble Mold	2.42	50	242
Expertise & receipt Mold	0.38	120	45
Check container	0.11	600	66
Wash mold	0.22	180	80
change mold	0.41	80	66
Other	1.00	30	30
Communication	1	120	120

Total workload        871/shift

Workload of Mold 3*8 ShiftOperators For 25 presses in TC

Sheet 2

Activity	Frequency/day	Unit Time(min)	Total
Cleaning mold	3.0	60	360
Wash mold	1.5	180	540
Change Mold	2.6	80	416
Deal with CQ	10.0	9.3	186
Assemble Bladder	3.3	14	92
Change Bladder	3.7	12	88
Other	3.0	30	180

Total workload        621/shift

2.4    manpower calculation 

2*4 shifts

%Absenteeism = 8%

Requirement manpower    = total workload / open time (480min)

=871/480

=1.81operators

Necessary manpower    = Requirement manpower / (1 -%absenteeism)

= 1.81 /(1 – 8 %)

=1.967operators

= 2operators

3*8 shifts

%Absenteeism = 7.2 %

Requirement manpower   = total workload / open time (43 0min)

= 621/ 430

=1.44 operators

Necessary manpower    =Requirement manpower / (1 - %absenteeism)

= 1.44 / (1 – 7.2 %)

=1.552 operators

= 2 operators

2.5      Occupationcalculation

2*4 shifts

% Occupation    =total workload /necessary manpower /open time(480min)

=  871 / 2 / 480

=   91 % /operator

3*8 shifts

% Occupation    = total workload /necessarymanpower /open time(430min)

=  621 / 2 / 430

=   65 %/ operator

Absenteeism

If operators want to have CA.we will arrange the third operator of 2*4 shifts to cover CA. So, when oneoperator covers CA, sick leave and so on. The MOLD shops have 1 operator to workat 2*4 shifts. One operator did not work. We will add one operator at 2*4 shifts.

In condition, 11 operatorsare necessary in TC mold shop.

3    Proposal  

3.1    TC4650

According to TC4650, theproduction is 4650 good tires, 30 presses will be used. Some activity need bedone.

3.1.1   2*4 shifts

workload

Workload of Mold2*4 Shifts Operators for TC4650 presses in TC

Activity	Frequency/day	Unit Time(min)	Total
Repair & rework Mold	2.96	90	266
Assemble Mold	2.90	50	290
Expertise & receipt Mold	2.00	120	240
Check container	0.40	480	194
Wash mold	0.26	180	94
Changer mold	0.50	80	80
Other	1	30	30
Communication	1	120	120

Totalworkload     1314/shifts

manpower calculation 

%Absenteeism = 8 %

Requirement manpower   = total workload / open time(480min)

= 1314/480

=2.73 operators

Necessary manpower      = Requirement manpower / (1 - %absenteeism)

= 2.73 /(1 – 8 %)

=2.967 operators

= 3 operators

Occupation calculation

% Occupation      = total workload / necessary manpower / open time (480min)

=   1314 / 3 / 480

=    92 % / operator

3.1.2     3*8 shifts

Workload

Workload of Mold3*8 Shifts Operators for TC4650 presses in TC

Activity	Frequency/day	Unit Time(min)	Total
PM	3.00	72	432
Wash mold	1.85	180	666
Change Mold	3.17	80	507
Deal with CQ	12.00	9.3	223
Assemble Bladder	5.85	14	164
Change Bladder	5.85	12	140
Other	3.00	30	180

Totalworkload        771/shifts

manpower calculation 

%Absenteeism =7.2%

Requirement manpower   = total workload / open time(430min)

= 771/430

=1.79operators

Necessary manpower= Requirement manpower/(1 -%absenteeism)

= 1.79 / (1 – 7.2 %)

=1.932operators

= 2 operators

Occupation calculation

% Occupation = total workload /necessary manpower /open time(480min)

=   771 / 2 / 430

=    90 % (each operator)

Absenteeism

If operators want to have CA.we will arrange the third operator of 2*4 shifts to cover CA. So, when operatorof 2*4 shifts covers CA, sick leave and so on. The mold shops have 2 operatorsto work at 2*4 shifts. Occupation of 2 operators will reach 134%. We will add one operator at 2*4 shifts.

In condition, 12 operatorsare necessary in TC mold shop.

3.2    PA2002

According to PA2002, theProduction is 3700 good tires, 25presses will be used. Someactivity need be done.

3.2.1     2*4 shifts

Workload of Mold 2*4 Shifts Operators for PA2002 presses in TC

Activity	Frequency/day	Unit Time(min)	Total(min)
Repair & rework Mold	2.47	90	222
Assemble Mold	2.42	50	242
Expertise & receipt Mold	2.00	120	240
Check container	0.40	600	243
Other	1	30	30
Communication	1	120	120

Total workload      1097/shifts

manpower calculation 

%Absenteeism =8%

Requirement manpower       = total workload / open time (480min)

= 1097/480

=2.28operators

Necessary manpower= Requirement manpower / (1-%absenteeism)

= 2.28 / (1 – 8%)

= 2.48operators

= 3 operators

Occupation calculation

% Occupation   = total workload /necessarymanpower /open time(480min)

=   1097/3 / 430

=   77 %/each operator

Workload of Mold 3*8 Shifts Operators for PA2002 presses in TC

Activity	Frequency/day	Unit  Time(min)	Total(min)
Wash mold	1.72	180	619
Change Mold	3.01	80	482
Cleaning mold	3.0	60	360
Deal with CQ	10.0	9.3	186
Other	3.00	30	180
Assemble Bladder	3.70	14	104
Change Bladder	3.30	12	79

Totalworkload    670/shifts

manpower calculation 

%Absenteeism =7.2%

Requirement manpower   = total workload / open time(430min)

= 670/430

=1.55 operators

Necessary manpower= Requirement manpower / (1 -absenteeism)

= 1.55/ (1 – 7.2 %)

=1.679operators

= 2 operators

Occupation calculation

% Occupation    = total workload /necessarymanpower /open time(480min)

= 670 / 2 / 430

=   78 % /operator

Absenteeism

If operators want to have CA.we will arrange the third operator of 2*4 shifts to cover CA. So, when thethird operators cover CA, sick leave and so on. The MOLD shops have 2 operatorsto work at 2*4 shifts. Occupation of 2 operators will reach 114%. We will arrange 3*8 shifts to help 2*4shifts. Average Occupation is 90 % (% Occupation = (114%+78%+78%)/3=90%).

In condition, 11 operatorsare necessary in TC mold shop.

4     Conclusion

Meeting

According to PA2002, the meeting decides that the mold shop willreduce 2 operators.

Cost  & Gain

11 operators will ensureproduction in TC mold shop. When 2 operators reduced , the company will gain 48,000RMB (2000RMB *12m/year* 2 operators).

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