1. Page No : 1Projects & ME - MIS April 2015
Improvements in
Vehicle Despatch Warehouse

2. Page No : 2Projects & ME - MIS April 2015
Objective
• To explain the current processes involved, their
time studies and difficulties.
• Improvements possible in process and equipment
to manage the increase in vehicle production
(from 800/day to 1200/day)

3. Page No : 3Projects & ME - MIS April 2015
Currentscenario
• Production in May’15 - 800 bikes per day
• These bikes are despatched in 3 shifts comfortably
• The average time taken to load one bike into the truck is 105 sec,
using one scissor lift, the bottleneck for the total process
• For improving the efficiency of the process and find the bottleneck,
following 3 major criterions to be considered
A. Hourly Backflush
B. Bike movement for packing
C. Scissor Lift operating Speed

4. Page No : 4Projects & ME - MIS April 2015
A) Backflush
• The hourly backflush data taken over the month of
April and Mid-May shows that there is inconsistency
in number of vehicles being sent to the warehouse.
39
14 3
30
1 4 6 13 14
22
16
34 33
46
83
29
37
46
30
34
19
39
26
46
23
1
71
33
0 10 11 12 2
39
17
45
1
89
47
25
38
17
32
27
23
7
35
53
0
22.5
45
67.5
90
112.5
12-1 am 1-2 am 2-3 am 3-4 am 4-5 am 5-6 am 6-7 am 7-8 am 8-9 am 9-10 am 10-11
am
11-12
pm
12-1 pm 1-2 pm 2-3 pm 3-4 pm 4-5 pm 5-6 pm 6-7 pm 7-8 pm 8-9 pm 9-10 pm 10-11
pm
11-12
am
April May
Hourly Backflush Data For April and May

5. Page No : 5Projects & ME - MIS April 2015
A1) Improvement In Backflush
• An average of 60 vehicles to be delivered each hour from
the assembly area to the warehouse is suggested to make
the packing and despatch process non-cumbersome.

6. Page No : 6Projects & ME - MIS April 2015
B) Bike Movement From Storage To Ready For Despatch Area
• It currently takes 50 sec to bring a packed bike to the
ready to despatch area.
• This process has 2 scopes of improvement. With time
studies conducted, the new process will deliver bikes
at a rate of one bike per 31 sec.
– Addition of 2-way opening VRC doors on 1st and 2nd floor
– Changing floor plan of warehouse on 1st and 2nd floor

7. Page No : 7Projects & ME - MIS April 2015
B1) Improvement In Bike Movement
• The current floor plan does not provide an efficient system of
loading and unloading the VRCs and hence it is time consuming. It
takes 100 seconds to take up a bare bike and bring down one
packed bike per VRC.
• By implementing both sides opening in VRC (on 1st and 2nd floor),
the process flow becomes streamlined and the time for VRCs
reduces to 62 sec per bike per VRC.
• Another essential process to be improved is taking out and re-
stocking of bikes in VRCs, this process has to be done instantly to
reduce idle time, reduce empty cycles and to maximise utilisation.

8. Page No : 9Projects & ME - MIS April 2015
C) Loading Of Bikes Into Trucks
• Currently it is measured that 105 sec are being taken
to load a bike using one scissor lift only.
• This is also one of the time consuming processes
• A suggested solution is to improve the scissor lift
speed from 1.8m/min to 3m/min

9. Page No : 10Projects & ME - MIS April 2015
C1) Improvement In Loading Process
• 15 mins per truck can be saved by reducing idle time of
trucks.
• By using 2 scissor lifts simultaneously 1200 bikes can be
despactched per day.

10. Page No : 12Projects & ME - MIS April 2015
Proposed Layouts For 1st & 2nd Floor
The following advantages can be
achieved with new floor plans:
• Capacity increase by 112
bikes(22%).
• Previous Capacity: 498
• New Capacity: 610
• More space for packing
provided
Requirements:
• Addition of doors for VRCs on
both floors
• New line marking to be done on
the floor

11. Page No : 13Projects & ME - MIS April 2015
VRC Door Addition
• As marked, there is a requirement
of motorized doors to be added on
the 1st and 2nd floors of the VRC.
• This will reduce number of empty
cycles
• Make the process flow stream lined
• Require less space for operations

12. Page No : 14Projects & ME - MIS April 2015
Gate Pass System
• A Gate Pass will be provided to the
truck driver upon entry, that needs to
be submitted to despatch office
• Only after all the required documents
are given to the driver, he be given
the Gate Pass with the seal
• No transport vehicle will leave
without depositing the Gate Pass at
the gate
• This will ensure proper
documentation

13. Page No : 15Projects & ME - MIS April 2015
Manpower Requirement (For Running 2 Shifts, Domestic Only)
• For VRC Operation : 8
• Responsibility: Complete movement of bikes between floors,
despatch area, waiting area and temporary storage.
• For Packing : 6
• For Loading: 12 (6 on each Scissor Lift)
• For marking and verification : 1 (Maximum 2)
• Total Manpower required(for domestic): (8+6+8+2)= 28(per shift)

14. Page No : 16Projects & ME - MIS April 2015
Processes Not Considered In Time Study
• Packing the bike is a time consuming process which
is carried out on the 1st and 2nd floor. But it can be
made faster by deploying more man power. This
process will not bottleneck the system as it is not
machine dependent
• Packed bikes storage time (holding time) is not
considered.

15. Page No : 17Projects & ME - MIS April 2015
Actions
• Lift doors to be added at first priority on upper floors
• Change layout of parking at upper floors
• Idle time of trucks in the loading bay to be reduced
• Introduction of a Gate Pass system is required to ensure the
truck is leaving with all required documents.
• No need to increase speed of scissor lifts. 4.9% improvement in
time is not a substantial improvement and the investment is not
justifiable.
• Backflushing process is required to be made more consistent
• More manpower is required for 2 scissor lifts to be used
simultaneously
• Parking space for 1200 bikes is required in total, proposed
space is the scrap area near the canteen

16. Page No : 18Projects & ME - MIS April 2015
Conclusions
Current scenario:
Bike Production:800 in 2 shifts
Despatch per day: 800 in 3* shifts
Storage space of packed Bikes:
498 nos.
(1 & 2 floor)
Manpower Requirement: 18/shift
Rate of bike despatch: 105 sec per
bike by using 1 scissor lift (2nd lift is
not utilized fully)
(Bottleneck due to loading)
Proposed:
Bike Production: 1200 in 3 shifts
Despatch per day: 1200 in 3 shifts
Storage space of packed Bikes : 610
nos.
(1 & 2 floor)
Manpower Requirement: 28/shift
Rate of bike despatch: 47 sec per bike
using 2 scissor lifts
(By reducing truck idle time and adding VRC
doors)
By reducing idle time, 1 truck can be
loaded in 100 mins instead of 114, and by
using 2 scissor lifts simultaneously 1 truck
can be filled in 50 mins.
Hence time required for loading per bike
reduces to 47 sec per bike.
*3rd shift is mostly used for model matching