Analysis of Production Cycle Time for various

Manufacturing Processes at Seizo Automotive Pvt.

Ltd.
Provided by Vidyuth T, Sandip Kumaar,
Narein Shankar,
College of Engineering Guindy,
as part of their
Internship Training Program

ABSTRACT

Cycle Time analysis offers essential insights into a manufacturing company’s production
capacity and net required output for the targeted period. By understanding cycle time,
businesses can identify problems in their process flow and develop strategies for improving
efficiency. This could involve streamlining redundant steps, automating manual activities, or
eliminating unnecessary tasks. By reducing the amount of time spent on each cycle,
companies can increase throughput and free up resources for other essential tasks. The
following review provides the cycle time for multiple operations conducted at the
manufacturing plant through a data sheet. This is followed by a comprehensive summary of
the nature of the processes being performed, reasons for delay or shortage in output, and
subsequent process optimization solutions that can be implemented.

INTRODUCTION

Cycle time analysis involves measuring and analyzing the average time it takes for a process
or activity to be completed from start to finish. This includes all steps taken from beginning to
end – including preparation, setup, execution, review, delivery, and completion. Cycle time
describes the operations required to run an enterprise product unit. Cycle Time also
encapsulates non-production time factors, e.g. up-stream, mid-stream, or downtime. Queuing
duration relating to the downstream delay factor.

Cycle Time is used for measuring different components of production including,

1. Manufacturing: Inventory cycle time measures how long it takes to turn raw materials
into finished goods. The following report utilizes computation of manufacturing time.
2. Operating cycles: Operating cycle time measures how long it takes a company to buy
goods, sell them, and receive cash.
 3. Machine Control Units: Cycle time can help analyse long-term data from machine
control units to optimize machine cycle times. For example, it can help identify
possible causes for cycle time deviations, responsible machine parts, and possible
wear parts.

METHOD OF ANALYSIS

The calculation of cycle time involved the following steps:

• Time for the required number of components was recorded by computing time from
end of the previous stroke of press machine to end of stroke required to produce the
given number of components
• The above procedure is repeated five times to obtain five different sets of readings.
• Average reading is computed for a given operation and a given number of components
• Time taken for 1 component is found and subsequently converted for 85% efficiency
• Targeted UPH is obtained by computing the number of components produced in 1 hr

The obtained data values are entered into a datasheet for the specific operation. Similar
procedures are repeated for the various existing operations and a complete set of data is
achieved. It is required to note that the following assumptions have been made while
recording the cycle time:

• Operator is working at 100% efficiency

• In the case of tools having both left and right orientations, data is similar for both
types and net operation does not change and only tool design varies.
• The machine does not show any defects and no maintenance errors
• If a tandem series operation is being run, transfer time between the individual
processes has been included while recording the cycle time.

CYCLE TIME DATASHEET

The Excel datasheet for cycle analysis has been enclosed within the link provided below,
https://1drv.ms/x/c/7664e5b855619f95/EQKKCWQ4csdAvpj-
bWqqW1gBL4jV3xwcWjNDceCPicc0QQ?e=59Dil4

Experimental evidence has been provided in the form of videos of the different operations
and compiled in google drive. The following link attached can be used to access the videos,
https://drive.google.com/drive/folders/1BQJGevn3ppmSx7RZsH_yP1Aapum47NUq?usp=sharing
INFERENCES AND SOLUTIONS

The following observations were made through the cycle time analysis for different
manufacturing operations in the company:

• Operators were finding it difficult to separate out sheet metal blanks from the stack
and put them into the blank fixture in the tool die. Hence, a magnetic sheet metal
separator can be used which efficiently pulls apart sheets from the stack successively.

Figure 1: Magnetic sheet metal separator; Source: CanTech International

 Figure 2: Operator finding difficulty in separating sheet metal

• Press operators are not able to identify orientation and alignment for fitting the
workpiece into the die fixture. Certain complex parts require 5-6 trials of checking and
fitting to finally arrive at the proper orientation. This contributes to much delay in run
time. Hence, a colour (or any symbol) coding system can be established to allow
operators to easily identify which portion of the workpiece sits where; by matching
the colours in the fixture and workpiece.

The following steps can be practised to prevent any delay in operation due to lack of
understanding of alignment and position:
1. The workpiece is obtained after undergoing the previous operation
2. The feeder or supporting operator marks colour on one zone or more
depending on the complexity of the product, according to colour chart
established.
3. The tool die for the next operation already has the same colour(s) at
the respective position
4. The operator performing next operation matches the colours and
places the workpiece correctly.
 Figure 3: Operator taking time to figure out alignment of blank

• Operators are unable to remove certain finished workpieces easily e.g. T83, T16, etc.
due to very close tolerances in mating of die fixture and blank. To allow for easier and
efficient removal and fixing, lubricants can be provided for such operations.
 Figure 4: Operator getting delayed due to difficulty in removing the workpiece from die

• The company manufactures many products on a massive scale using tandem series
operation. The series of part-wise operations involves transfer from one part
operation to the next. This transfer takes place using an inclined plane. However many
operators attack the inclined plane in the wrong direction such that the upper level is
attached to the next operation. This can be solved by marking the upper level so that
the operator knows this level should come for the previous operation and the
downward slope for the successive operation(s).
• Supervisors must ensure that operators working a tandem series operation must be of
similar production capabilities as if there is a difference in the production speeds of
the individual operators, the total line may get affected.
• Space can be provided near the worktable for operators to keep raw blank. As the
operation progresses, the feeder may continue to place new stack of blanks onto the
space provided. This way continuous operation and run time can be ensured for the
operator.
CONCLUSION

Overall, cycle time is a valuable metric that can be used to inform the continuous
improvement of your processes. By understanding how long each task, function or activity
takes, you can identify areas where improvements can be made. This allows organizations to
identify areas where improvements can be made and help them stay competitive by ensuring
customer satisfaction and overall profitability. Based on our observations at Seizo Automotive
Pvt. Ltd., we found that,

Majority of the operations and tools have been run efficiently.

Most delay during run time has been due to,

➢ Difficulty in removing blank from raw material stack

➢ Inability to understand position and alignment of workpiece with respect to die
➢ Difficulty in removing workpiece for close tolerance operations

The operators must be provided with basic understanding of cycle time and the need to
simplify operation. They must also be educated on methods used to speed up operations.
Supervisors must ensure that the major factors affecting run time and lead time are
monitored and kept at check.