TIAGO Engine Assembly

Title

VCC Analysis
Month: March 20
 100
80
60
40
20
0
Average
1.4

P-DOLLEY / 12D-6L DOWL PIN /

0.119
77

TA59 / X3
Mar-20
0.9

SPRINGBAND CLAMP PLIER BP-L-

0.132
70

330BLUEPOINT
Feb-20
1.7

Cum %

DIA8 DOWEL PIN PRESSING DOLLY

0.163
62

- 1.2 CH
Jan-20
1.7

Cost/Engine

SPARE MALLET 40DIA FOR NYLON

0.194
53

HAMMER
Dec-19
2.2

STUD TIGHTENER 3/8"SQDR-M6-

0.327
Nov-19

41

STM106 MEKAST
1.4

Tool Cost Feb 20

Oct-19
Tool Cost Analysis Engine Assembly Line (TIAGO)

0.9

P-DOLLEY/10D-6L DOWL PIN/ALT

0.355

21
Target Tool

& AC BKT/X3
Monthly Consumption Tool

Sep-19

0.400
0.300
0.200
0.100
0.000
3.9

Tool/Engine

100
80
60
40
20
0
Aug-19
0.7

P-DOLLEY / 12D-6L DOWL PIN /

0.041
74

TA59 / X3
SPRINGBAND CLAMP PLIER BP-S-
0.046
71

225BLUEPOINT
Jul-19
1.2

STUD DRIVER F/M8STUD4M8SD-

0.049
67

1/2IN SQDR DI
SOCKET
0.054
E10X1/2"DRIVE( KINGTONY-
64
Jun-19
1.7

437510M )
NYLON/HDPE HAND HAMMER

0.055
60
40MM W/HANDLE PAT

Cum %
May-19

H/D REV.RATCHET-

0.056
56
1.2

1/2"SQ.DR.4779-KINGTONY
DIA8 DOWEL PIN PRESSING DOLLY

0.057

Cost/Engine
52
- 1.2 CH
Apr-19
0.5 DOLLY FOR CRANKSHAFT OIL SEAL

0.057
48
REAR

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SOCKET E12X1/2"DRIVE 437512M

0.063
44
KINGTONY

FY 18-19
1.2
P-DOLLEY/10D-6L DOWL PIN/ALT

0.096
Tool Cost Apr 19 - Mar 20

40
& AC BKT/X3
STUD TIGHTENER 3/8"SQDR-M6-

0.109
FY 17-18
STM106 MEKAST

33
2.1
HOSE CLIP PLIER 719985 220

0.149
HOFFMANN

25
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
SPARE MALLET 40DIA FOR NYLON

0.240 0.209

15
HAMMER

0.160
0.080
0.000
 100
80
60
40
20
0
0.03
100

A3 XEROX PAPER REAM - 75 GSM

Average
4.4

0.07

Cotton Knitted H/G White 9.65" 7G

99

1.2 NA Engine History card (Blue

0.07
Mar-20

98

colour)
4.8

COTTON CHINDHI SWEAT QUALITY

0.10
96

1.25X1.25ft
Feb-20

0.14

PAINT MASKING TAPE 72mmx45M

4.4

94

Cum %

ADHESIVES ACTIVATOR LOCTITE

0.15
91

7075 HENKEL
Jan-20
4.1

1.2 NGTC Engine History

0.21

Cost/Engine
87

card(Green clr)
LINT FREE CLOTH 80% POLY+20%
0.24
82

COTTON
Dec-19
4.8

0.27

PAINT MASKING TAPE 48mmx45M

77

1.2NA MBU Engine History

0.29
71

card(White clr)
Nov-19
3.4

ENGINE BARCODE STICKER (75X35

0.46
64

MM, WHITE)
IDM Cost Feb 20

ADHESIVE SPEED BONDER LOCTITE

0.81
Oct-19

54

324
3.2
IDM Cost Analysis Engine Assembly Line (TIAGO)

Target IDM

NYL KNIT GLOVE W/POLY-URE-

1.58

36

TH.COAT-CL1-KEL
Monthly Consumption IDM

2.00
1.50
1.00
0.50
0.00
Sep-19
5.8

IDM/Engine

100
80
60
40
20
0
Aug-19

0.08
4.7

PAINT MASKING TAPE 72mmx45M

99

HAND GLOVE NYLON 11.5 LINT FR

0.09
97

GREY LINED
Jul-19
3.6

0.12
PAINT MASKING TAPE 48mmx45M
95

ADHESIVES ACTIVATOR LOCTITE

0.12
92

7075 HENKEL
Jun-19
5.6

0.17
90 Cotton Knitted H/G White 9.65" 7G

Cum %
1.2 NGTC Engine History

0.19
86
card(Green clr)
May-19
3.8

LINT FREE CLOTH 80% POLY+20%

0.22
81
COTTON

Cost/Engine
COTTON CHINDHI SWEAT QUALITY

0.24
77
1.25X1.25ft

Apr-19
5.5

1.2NA MBU Engine History

0.25

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71
card(White clr)
E PULLON (PU COATED) BLACK

0.30
65
FY 18-19
HAND GLOVES

0.42
4.7

IDM Cost Apr 19- Mar 20

1.2 NA Engine History card (Blue
colour)

59
0.50
ENGINE BARCODE STICKER (75X35

FY 17-18
MM, WHITE)
6.2

49
ADHESIVE SPEED BONDER LOCTITE

0.76
324

38
7.0
6.0

5.0
4.0

3.0
2.0

1.0

0.0
NYL KNIT GLOVE W/POLY-URE-

0.90
21
TH.COAT-CL1-KEL

1.60
1.20
0.80
0.40
0.00
Fixed IDM Cost Analysis Engine Assembly Line (TIAGO)
Monthly Consumption Fixed IDM
4.0
3.5
3.5
3.0 2.9
3.0
2.6
2.4 2.4
2.5 2.2 2.2 2.2
2.1 2.0
2.0 1.7
1.4 1.5
1.5
1.0
0.5
0.0
FY 17-18 FY 18-19 Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Average

IDM Fixed/Engine Target IDM Fixed

Fixed IDM Cost Apr 19 - Mar 20 IDM Fixed Cost Feb 20

96 100
1.00 100 100 1.00 0.81 89 100
0.76 95 78
86 80 0.75 64 80
0.75 75
0.50
56 0.42 60 41 0.46 60
0.50 0.50 0.29
0.25 40 0.21 40
34 0.19 0.12 0.25 0.15
0.25 20 0.07 20
0.00 0 0.00 0

1.2 NGTC Engine History

1.2 NA Engine History card (Blue

ENGINE BARCODE STICKER (75X35

1.2NA MBU Engine History

ADHESIVES ACTIVATOR LOCTITE

ENGINE BARCODE STICKER

1.2 NA Engine History card (Blue

1.2 NGTC Engine History

1.2NA MBU Engine History

ADHESIVES ACTIVATOR LOCTITE

ADHESIVE SPEED BONDER

ADHESIVE SPEED BONDER

(75X35 MM, WHITE)

card(Green clr)
card(Green clr)

card(White clr)
card(White clr)

7075 HENKEL
LOCTITE 324
7075 HENKEL
LOCTITE 324

MM, WHITE)

colour)
colour)

Cost/Engine Cum % Cost/Engine Cum %

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Variable IDM Cost Analysis Engine Assembly Line (TIAGO)
Monthly Consumption Variable IDM
4.5
4.0 3.8
3.5 3.4
3.0
3.0
2.5 2.4
2.5 2.2 2.2 2.1 2.2
2.1 1.9 2.0
2.0 1.7
1.5
1.0
1.0
0.5
0.0
FY 17-18 FY 18-19 Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20 Average

IDM Variable/Engine Target IDM Variable

Variable IDM Cost Apr 19 - Mar 20 IDM Variable Cost Feb 20

94 98 98
1.800 85 90 100 2.000 96 99 100 100
77 1.576 86 92
1.300 67 80 1.500 76 80
0.903 56 65
42 60 60
0.800 1.000
0.304 0.235 0.216 0.172 40 40
0.300 0.116 0.091 0.077 0.014 0.500 0.269 0.245
20 0.142 0.104 0.067 0.025 20
-0.200 0 0.000 0
LINT FREE CLOTH 80% POLY+20%

Cotton Knitted H/G White 9.65" 7G

HAND GLOVE NYLON 11.5 LINT FR

E PULLON (PU COATED) BLACK HAND

COTTON CHINDHI SWEAT QUALITY

PAINT MASKING TAPE 48mmx45M

PAINT MASKING TAPE 72mmx45M

HOSIERY CUT CLOTH

NYL KNIT GLOVE W/POLY-URE-

LINT FREE CLOTH 80% POLY+20%

Cotton Knitted H/G White 9.65" 7G

PAINT MASKING TAPE 48mmx45M

PAINT MASKING TAPE 72mmx45M

COTTON CHINDHI SWEAT QUALITY

A3 XEROX PAPER REAM - 75 GSM

NYL KNIT GLOVE W/POLY-URE-
TH.COAT-CL1-KEL

TH.COAT-CL1-KEL
GREY LINED
1.25X1.25ft

COTTON

1.25X1.25ft
COTTON
GLOVES

Cost/Engine Cum % Cost/Engine Cum %

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 Tool & IDM Cost- Action Plan

Sr. No. Prblem Weightage Root Cause Containment action Permanent Action Target Date Responsibility Action Status

Material in BOM but

0.79 Rs/Engine still booking on Indirect Material Booking Done in Pankaj/Vishal Patil Y
1 ADHESIVE SPEED BONDER LOCTITE 324
15% Direct material
Material

Material in BOM but

ADHESIVES ACTIVATOR LOCTITE 7075 0.27 Rs/Engine still booking on Indirect Material Booking Done in Pankaj/Vishal Patil Y
2 HENKEL 5% Direct material
Material

0.79 Rs/Engine Hand Gloves issued on Awareness given to correct Part Part No. to be mentioned 30.05.2018
3 H/GLOVES SIZE-9 SENSILITE 48-101-ANSELL Pankaj/Mahesh G
15% wrong Part No. No. in MR Slip

ENGINE BARCODE STICKER 75X35 MM 0.46 Rs/Engine Material to be added in Material Booking Done in
4 Pankaj/Vishal Patil Y
PP WHITE 9% BOM Direct material

COTTON CHINDHI SWEAT QUALITY 1.25X1.25ft

0.18 Rs/Engine Pallet Cleaning Frequency Vaccuume Cleaner to be

5 Pallet Cleaning Pankaj/Ashish Shivarkar Y
3.61% Increased arranged

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