EXECUTIVE SUMMARY

This is the study conducted to minimize the losses occurring between two processes
which are Laser process and AGIE process in plant number 105 of Bosch Limited, Nashik.
Nashik plant is one of the important establishments of Bosch in India since last 40 years. With
the constant efforts for quality and delivery commitments, the plant received good acceptance
by customers in EUROPE, USA, and South Asia. At present the export business is about 25%
of plant output.
In plant 105 of Bosch Limited Nashik, various types of nozzles are manufactured. The
main four types of nozzles are CR, CRIN, DSLA and RBCD. In plant 105 of Bosch, 128
operations are performed on 1 part (nozzle). These operations include drilling, short pinning,
chamfering, boring, grinding, heat treatment, carbonizing, hardening, visual inspection,
tempering, aquas cleaning, laser marking and hydro erosion. Only Bosch Company has the
patent of the AGIE technology which uses silver electrodes to drill very tiny holes on nozzles.
Milk runner is appointed by the BVG (Bharat Vikas group) to move parts all over the plant.
To minimize the losses between the laser process and AGIE process, I studied and
implemented the Hiejunka board between laser process and AGIE process.
Heijunka (pronounced hi-JUNE-kuh) is defined as a technique for reducing
unevenness in a production cycle, which in turn reduces waste. It's a Japanese term that means
"leveling" and is a key lean manufacturing method first used by the Toyota Production System
(TPS) to develop production efficiency. Toyota realized that batching isn't sustainable and
that production systems can't continuously respond to sporadic orders without suffering from
uneven productivity levels, inconsistent quality, and overburdening of machines and
employees, all of which results in waste.
Heijunka is often referred to as production leveling in the United States, but the two
terms have the same goal: reducing unevenness in production by avoiding batching, which
results in smaller inventories, lower capital costs and less overburdening of employees.
Heijunka lets you produce products at a steady pace, allowing you to react to fluctuations
based on your average demand. It does this in two ways: leveling by volume and leveling by
type/product.

5
 CHAPTER: 1 - INTRODUCTION TO STUDY

Uneven production processes can be a huge problem for companies that

maintain a smooth workflow. This is where Heijunka comes in. Heijunka is a Japanese
word that means “leveling.” It is a method for reducing unevenness and creating a more
consistent flow in the production process. In this guide, we will discuss what Heijunka
is, how it works, and ways you can implement it into your own business.

What is Heijunka?

Heijunka is a lean manufacturing tool that helps level production and creates a
more consistent workflow. It is often used with lean tools, such as Kanban and Just-in-
Time (JIT) production. Heijunka works by breaking down the overall production
process into smaller, more manageable tasks.

With Heijunka, businesses can better control their production process and avoid
bottlenecks. It also helps to create a more efficient workflow by reducing waste and
increasing productivity. In short, Heijunka is an essential tool for any business looking
to improve its production process.

There are two types of Heijunka: product Heijunka and process Heijunka.
Product Heijunka levels out the types of products being produced, while process
Heijunka levels out the production process itself. In most cases, a combination of
product and process Heijunka is used to achieve the desired results.

How Does Heijunka Work?

Heijunka works by breaking down the overall production process into smaller,
more manageable tasks. This helps to level out production and create a more consistent
workflow.

6
 For example, you run a manufacturing business that produces widgets. Your
widget-making process might look something like this:

 Create widget blueprint

 Order widget parts
 Assemble widget
 Test widget
 Ship widget

With Heijunka, you would break down this process into smaller tasks and then
level out the production of these tasks. So, instead of always creating widgets from start
to finish, you would create a mix of different products at different stages of the
manufacturing process. This would help to avoid bottlenecks and create a more even
workflow.

Ways to Implement Heijunka

There are many different ways to implement Heijunka into your business. The best
way to do this is to assess your production process and see where Heijunka can benefit
most.

Once you understand how Heijunka works, you can start to implement it into your
own business. Methods for implementing Heijunka include:

 Use Heijunka boards: Heijunka boards are a great way to visualize the production
process and see where Heijunka can be of the most benefit.
 Create a Heijunka schedule: A Heijunka schedule can help you to level out
production and create a more consistent workflow.
 Use Heijunka tags: Heijunka tags are a great way to track which products need to
be produced and in what order.
 Use Heijunka software: There are several different software packages available
that can help you to implement Heijunka into your business

7
CHAPTER: 2 ORGANISATION PROFILE AND INSIGHT OF
BUSINESS ENVIRONMENTS

2.1- ORGANIZATION PROFILE

1. Introduction to BOSCH Ltd.

Fig 1: Bosch Headquarters in Stuttgart, Germany

The Bosch group is e of the leading global supplier of technology and services.
According to preliminary figures, more than 300,000 associates generated scales of
51.4 billion Euros in areas of automotive and industrial technology, consumer goods
and building technology in fiscal 2011. The “Workshop for Precision Engineering and
Electrical Engineering” that Robert Bosch founded in Stuttgart, Germany, in 1886 has
grown in the course of more than one hundred years to become a global player.
Today the Bosch group comprises Robert Bosch GmbH and its more than 350
subsidiaries and regional companies in some 60 countries. If its sales and service
8
partners are included, then Bosch is represented in roughly 150 countries. This
worldwide development, manufacturing and sales network is the foundation for further
group. Bosch spend more than 4 billion Euros for research and development in 2011
and applied for over 4100 patents worldwide with all its products and services, Bosch
enhances the quality of life by providing solutions which are both innovative beneficial.

Precision mechanics and electrical engineering the special ownership structure of

Robert Bosch GmbH guarantees the entrepreneurial freedom of the Bosch group,
making it possible for the company to plan over the long term and to undertake
significant upfront investment in the safeguarding of its future. 92% of share capital of
Robert Bosch GmbH, charitable foundation. The majority of voting rights are held by
Robert Bosch industry KG, and industrial trust. The remaining shares are held by Bosch
family and by Robert Bosch GmbH. The Bosch slogan ‘Invented for life ’is part of its
long tradition, through which it communicates the group’s core competencies and
vision, that include technological leadership, modernity, dynamics, quality and
customer orientation.
BOSCH GROUP, GERMANY, founded in 1951, pioneers the manufacturing of
automotive spark plug and diesel fuel injection equipment in India. Access to the
international technology of BOSCH, with a conscious commitment to the quality of its
more than 9500 employees has made BOSCH the largest manufacturer of diesel fuel
injection equipment in the country and one of the world largest.

Worldwide, the BOSCH group has approximately 232000 employees today. It has
around 253 subsidiaries and associated companies in over 50 countries and the total of
236 manufacturing sites. There are twenty thousand sites, engineers, technicians
engaged in R&D. As a result, Bosch applies for over 2000 patent each year. These place
the company at the top in the entire automotive industry.

9
 Fig 2: BOSCH Global

All around the world, the Bosch Group name stands for competence and product
diversity in the following sectors: electrical and electronics, automotive technology,
power tools and accessories, thermo technology, household appliances, security
systems, broadband networks, automation and packaging technology.

10
2. Bosch (India): -

Fig 3: BOSCH India

11
In India the Bosch Group was founded in 1951, Bosch pioneered the manufacture of
automotive spark plugs and diesel fuel injection equipment in India. Access to the
international technology of Bosch, with a conscious commitment quality of its more than
11,500 employees has made Bosch the largest manufacturer of diesel fuel injection
equipment, auto-electrical, hydraulic gear pumps fir tractor applications, electric power
tools, packaging machines, Blaupunkt car multimedia systems and security systems. Bosch
limited (Motor Industries Co.Ltd.) is the largest subsidiary of Bosch in India. The company
has grown over the years to become the largest auto component manufacturer in the country.
The Bosch group has holds around 70% stake in the company. Bosch Limited operates in all
the business sector of Bosch- Automotive technology, industrial technology and consumer
goods and building technology. It manufactures and trend products as di verse as common
rail injector and components, diesel and gasoline fuel injection equipment, industrial
equipment, auto-electricals, gear pumps, power tools, packaging machines, special purpose
machines, security systems and blaupunkt car audio systems.
It has a nationwide network spanning across 1000 towns and cities in India with over 4000
authorized representations which ensure widespread availability of both products and
services.

The company is headquartered at Bangalore with manufacturing facilities in Bangalore,

Nasik, Naganathapura and Jaipur. All the 4 plants are TS 16949 and 14001 certified.
The plant wise capital expenditure for the year 2013 is as follows:

Fig 4: Plant wise capital expenditure

12
3. Presence of Bosch in India:

Fig 5: Bosch in India

13
4. Bosch Nasik:
During the year 2011, the Nasik plant achieve the highest production levels of nozzle holder
assembly, DSLA nozzle and common rail injectors. The plant manufactured the 100 mico.
NHA-Injector, which was a new milestone achieved. To keep pace with the growing
demand, the plant made an investment of rupees 2,715 mico. In its production facilities. The
plant was honored with CII-EXIM Bank’s ‘commendation for significant achievements in
business Excellence’ for the year 2011 as well as ‘Golden Peacock Environment
Management Award’ from the Maharashtra government.
BOSCH Nasik also abbreviated as Bosch/NaP in the Bosch World, is one of the four pillars
of Bosch Group in India. The company is situated in city which is one of the holy cities of
India and is full of natural resources and manpower. This has contributed in the development
and growth of the company in the city. The Bosch/NaP is located at Satpur in Nasik. The
total plant area comprises around 404,140 sq m

The plant has five functioning workshops with well-planned and international quality
structure. The plants and buildings are well supplied with necessary facilities such as water,
electricity and ambiators, which make the working as pleasure. The plant i s surrounded with
good landscaping and plantation giving the feeling of another world in the city. The good
landscaping is the characteristic of the plant.

The Nasik plant was started in 1969 with 43 employees and by the year 1974, the factory
went to full production of nozzles, nozzle holder assemblies, element and delivery valves,
adding an industrial dimension to the largest private sector multinational company with a
3000 strong work force. With firm commitment for quality, BOSCH Nasik bags ISO 9001
in year 1992 and QS-9000 in year 1997.

14
Injector

Fig 6: Nasik Plant Aerial View

15
5. BOSCH PRODUCTS:

Following are some pictures of products manufactured at NaP, BOSCH.

Fig 7: Common Rail Injector

Nozzles DN Nozzles Nozzles

DL

CRI injector components Nozzles Conventional injectors

DLL

NOZZLES –
DSLA+CR Injectors Horn type injector
KCA
Fig 8: Injectors and Nozzle

16
 At the Nasik plant’s Nozzles and nozzle holders are manufactured which are used in the fuel
injection system of diesel engines. The Bosch NaP is specialized in manufacturing a variety
of nozzles and nozzle holders and that are at the cheapest possible rate.

6. Product Information

1. Fuel Injectors
Fuel ignition system is used for admitting fuel into internal combustion engines. It had
become the primary fuel delivery system used in automotive engines replacing the
carburetors due to emission problems.

Main components of fuel ignition system are:

 Fuel pump

 Fuel pressure regulator

 Electronic engine control unit (ECU)

 Fuel injectors
Fuel injector sprays the pressurized fuel into the engine on being signaled by the ECU.
The duration of the injector opening is proportional to the fuel being delivered.

17
2. Introduction to Nozzles

Fig 9: Nozzle

Nozzle

DSLA CR P Type

Fig 10: Nozzle classification

18
3. Nozzle body:
Company is market leader in fuel injectors used in automobile industry. Fuel injector is
heart of engine as it sprays the fuel into the combustion cylinder. It consists of
cylindrical and internally hollow body through which a needle is passed that is held by
means of spring against nozzle at bottom of the body. It has inlet bore for diesel at
inclination to the body of injector which enters the hollow section of the body.

The nozzle consists of stepped cylinder and needle pin .The stepped cyl inder known
as nozzle body, is manufactured in soft and hard stages. The needle is manufactured in
the needle hard stage. The assembly stage combines both these parts into nozzle
assembly. Functional parameters of nozzle body are the inlet hole, spray holes and
guide bore. Precision requirements of these parameters are in microns.
Needle is fitted into the guide bore, where the step of the pin coincides with the pressure
chamber. The pin is held into the injector assembly by means of spring. At rest, the pin
is resting on the sack hole of the nozzle.

Nozzle Holder
Cap Nut Inlet Bore
Nozzle

Fig 11: Injector

19
 sea
t

Fig 12: Nozzle body

Fig 13: Nozzle Assembly

20
When the fuel enters the nozzle body through inlet hole, its pressure is high than the
force at which the pin is held by the spring in rest position. This difference in pressure
causes the pin to rise and the fuel gets sprayed through spray holes on the external
periphery of the seat. When the flow through the inlet stops, the impact of the pin causes
to atomization of the fuel through the spray holes.

The nozzle assembly is critical considering the clearance between the needle and the
guide bore for flow of fuel. During machining and finishing, particles in microns are
formed. To wash out these particles, aqueous cleaning is done for the internal sections
of the body and assembly. These particles are in the range 15 x 10-6 mm (microns) to
200 x 10-6 mm. Presence of these particles above certain limits are detrimental to the
functionality. It is essential to check the number of particles present in them. This is
done by means of Cleanliness test.

7. Types of Nozzles:
DN nozzles: These are the pintle type nozzles. Pintle-type nozzles have a coaxial jet
and are used in pre-combustion chamber engines and turulent chamber engines. The
nozzle opening pressures it between 115 and 400 bar.

Fig 14: DN Nozzle

21
8. Orifice Nozzles:
These Orifice nozzles or Pintaux nozzle have several Spray orifices and are required
for engines with direct injection. The nozzle opening pressure is between 180 and 400
bar. For larger engines (more than 75 kW) also cooled nozzles are used. These are
termed as: DL, DLL, DSLA etc. these types are orifice types of nozzles but the
difference in them is the shaft diameter and length of the collar.

Fig 15: Orifice Nozzle DSLA, DL, DLL.

22
8. Nozzle Designation:
Every nozzle body has particular number on the collar embarked by the laser marking.
Different lots are formed for manufacturing based on this designation. Specifications
of these designation is explained as follows.

9. Designation Standards:

Diesel engines require fuel injectors. Heavy vehicles and four wheelers
consist of multi cylinder engine and fuel injector for each of them. While
traditionally, these engines have fixed sequence of fuel injection which often
results in the inefficient and insufficient supply of diesel to the cylinders.
Common rail consists of single rail which supplies fuel to all injectors and
23
supplies that cylinder with fuel which is deficient detected by sensors.
Recently it has started to manufacture CR (common rail) nozzle. But it does
not have dedicated line for CR nozzle manufacturing. To establish this,
company is interested in knowing the critical parameters to be monitored.
Currently, there are dedicated lines for DSLA nozzles.

Serial no Product Started in Emission Norm

1 Nozzle Holder &
Nozzles
2 DLL Nozzle (DI) 1974

3 BS 2 Noz. Holder- P 2000 BS 2

Type
4 Chevy Injectors 2002
(Export)
Euro 4

5 Bx Injectors (Export) 2003

6 NBFE (Injectors) 2008 BS 2

7 CRI Components 2006

8 CRI Injectors 2008 BS 4

As a strategic measure, Common Rail Injector (CRI) products were introduced which
can meet emission norms up to BS4. The CRI component exports started in 2006.The
CRI production was started in 2007 & new product CRI contribution is planned to grow
to 50% of NaP turnover by 2010.
From 2006, NaP started production of parts for Common Rail injectors. A world class
production facility is set-up for this contemporary product which is identified under
Export Oriented Unit. This has catapulted NaP into the big league as a supplier of parts
to International Production Network of Bosch. Common Rail Injector assembly
production is launched at NaP from 2007 for which there are customers from Indian OE market.
Another prime project for NaP is low-cost Common Rail Injector (CRI1)., especially being
made for the Asian market and was launched in 2008. This product is a strategic move to
support the Asian and Indian markets need of Low Priced Vehicle (LPV) in coming year.

24
 10. Functions of the nozzle: -

1. Correct atomization:
Correctly atomize the fuel into small particles so that it mixes properly with air.
2. Proper distribution:
The spray from nozzle should be such that fuel is evenly distributed in the combustion
space.
3. Injection pressure:
Higher the injection pressure betters the dispersion and penetration of the fuel into all
the desired location in combustion chamber.
4. Density of air in the cylinder:
If the density of compressed air in the combustion chamber is high then the resistance
to the moment of the droplets is higher and dispersion of the fuel is better.
5. Physical properties of fuel:
Properties like self-ignition vapor pressure, viscosity etc. play an important role in the
distribution of fuel.
6. Prevention of impingent on walls:
Prevention of fuel from impinging directly on walls of combustion chamber or piston
because striking the walls decomposes and produces carbon deposits. This cause smoky
exhaust as well as increase in fuel combustion.
7. Mixing:
Mixing of fuel and air in case of non-turbulent type of combustion chamber should be
taken care by the nozzle.
8. Metering:
The nozzle should meter the injected fuel and prepare the fuel.

25
 11. Project Area: Plant 105 (MFN2)

MFN 2: Manufacturing of Nozzles

208 119

105
108

506

Plant overview

26
 12.Products at MFN2:

MFN (building 105 shaded in yellow color) is the nozzle production area of the BOSCH
Plant in Nasik. Both of my projects reside in this plant. This part of the plant focuses
on the manufacturing of two main types of nozzles and their respective nozzles i.e.
DSLA and CR nozzles, among other types.

In this department the nozzle manufacturing is done by the following three phases viz.

A. Soft stage
B. Hard Stage
C. Hardening
D. EDM/HE
E. Assembly
F. Needle

27
28
 CHAPTER 3: PROCESS METHODOLOGY
Heijunka Board:
 The Heijunka board has 40 slots with all the machine numbers of AGIE machines
written on it (For example machine 1 – 20294, machine 2 – 20295, machine 3 – 20318
and so on).
 On this board the PPC (Production and Planning control) of the plant arranges the lot
cards according to plant’s plan of production.
 One lot card is used for one tray which contains 50 parts (nozzles).
 The PPC of the plant 105 of BOSCH company uses 6 shift plan (plan for 2 days) for all
manufacturing processes in the plant.
 The BOSCH company has 3 shifts per day of which one shift is of 8 hours; shift 1 -
6am to 2pm, shift 2 – 2pm to 10pm and 10pm to 6am.
 There are total 320 lot cards allotted for each shift which has to be completed in one
shift.
 70% of the work should be completed 4 hours before the shift ends.
Date No of lot cards Work done in %
24/9/2022 128 60%
29/9/2022 92 71.26%
4/10/2022 73 77.18%
10/10/2022 120 62.50%
17/10/2022 104 67.50%
21/10/2022 88 72.50%
26/10/2022 218 31.87%
31/10/2022 207 35.31%
7/11/2022 178 44.37%
11/11/2022 104 67.50%
16/11/2022 111 65.31%
21/11/2022 177 47.18%
25/11/2022 128 44.37%
30/11/2022 124 61.25%
5/12/2022 148 59.37%

29
LASER Process:
 There are 4 main types of nozzle manufactured in plant 105 of BOSCH Limited Nashik.
 The laser section is divided into two sections according to the body type used for the
manufacturing of the nozzle.
 In first section CR and DSLA nozzles are printed and in second section P type and RBCD
nozzles are printed.
 The code printed on nozzle indicates type of nozzle, date of printing and the country of
manufacturing (India/China/Germany).
 The laser machine is fully automatic in which each tray lakes 3 minutes to print and each
tray contains 50 nozzles.
 During the laser process the parts are in black trays which are made of plastic. One
worker is appointed to shift the parts from black trays to metal trays.
 If the parts are not in metal trays, they can’t proceed for further operations i.e., Aquas
cleaning and AGIE process.
 As the parts cannot proceed for further operations there are loses.

30
 Date No of black trays at No of black trays at 5pm
10am
24/9/2022 10 12
29/9/2022 23 25
4/10/2022 35 33
10/10/2022 55 57
17/10/2022 44 48
21/10/2022 68 65
26/10/2022 41 49
31/10/2022 12 28
7/11/2022 114 83
11/11/2022 52 20
16/11/2022 92 101
21/11/2022 75 50
25/11/2022 48 42
30/11/2022 44 33
5/12/2022 33 9

No of black trays on FIFO rack

120

100
No of black trays

80

60

40

20

No of black trays at 10am DateNo of black trays at 5pm

31
Aquas cleaning:
 Aquas cleaning is used to clean the parts after laser printing.
 In this cleaning process the parts are washed using washing agent at high temperature to
remove small impurities and dust particles left in the nozzle.
 Then they are heated in the machine up to 200-degree Celsius temperature to remove
washing agent particles and water particles from the nozzle.
 There are two machines of aquas cleaning in which three trays can be inserted at a time
for one cycle. One cycle takes around 4 to 5 minutes to clean all the parts inside the
machine.
 The operator of Aquas cleaning machine has a float of left-over parts in AGIE room and
parts which are in FIFO rack after laser printing process.
 The role of the operator is to check which AGIE machine has less parts or no parts and
clean parts accordingly.
 He communicates with the managers of laser and AGIE sections for which parts to be
cleaned first and accordingly cleans the parts.
 After cleaning he mentions machine numbers in AGIE room on the lot cards to which
the parts need to be provided and maintains the float to which machine and how many
parts are provided in AGIE room.
 Then he gives the trays of parts to milk runner which delivers the trays to AGIE room.
 There are losses in AGIE because of late float updating at the aquas cleaning operators
end by the AGIE and Laser managers.

32
Date Time updated by AGIE Time updated by
(pm) LASER (pm)
24/9/2022 1:55 2:20
29/9/2022 1:45 2:11
4/10/2022 2:18 2:35
10/10/2022 1:47 2:38
17/10/2022 2:18 2:35
21/10/2022 1:55 2:25
26/10/2022 1:58 2:20
31/10/2022 1:57 2:39
7/11/2022 1:58 2:40
11/11/2022 1:54 2:16
16/11/2022 1:56 2:45
21/11/2022 1:55 2:25
25/11/2022 2:05 2:15
30/11/2022 1:50 2:40
5/12/2022 1:55 2:10

Chart Title
3:21
2:52
2:24
1:55
Time

1:26
0:57
0:28
0:00

Date
Time updated by AGIE (pm) Time updated by LASER (pm)

33
Milk Runner:
 Milk runner is person who delivers the cleaned parts from aquas cleaning machine to
AGIE room and empty metal trays from AGIE to the laser machine.
 The milk runner is appointed by BVG.
 The milk runner completes 13 rounds/runs from aquas to AGIE, AGIE to HE (Hydro
Erosion) and he to aquas cleaning in one shift.
 Milk runner needs to complete 7 – 25min rounds in which he delivers the parts from
aquas to laser and empty trays from laser.
 Milk runner needs to complete 6 – 37 min rounds in which he delivers the parts from
aquas to AGIE, parts from AGIE to HE department and empty metal trays to aquas
cleaning.
 He delivers the parts to each machine in AGIE room given by the aquas cleaning machine
operator.

AGIE Process:
 There are total 40 machines on which AGIE process is performed on the nozzle.
 Each machine can perform AGIE process on 4 parts simultaneously, one machine takes
approximately 4 to 4.5 mins to complete one cycle of AGIE process on one machine.
 In GIE process 4 parts are mounted on one machine for drilling operations.
 The diameter of the holes drilled on the nozzle lies between 3 microns to 5 microns.
 The diameter of silver electrode used to drill the holes in the tip of the nozzle lies between
3 microns to 5 microns.
 According to the need of the customer the number of holes drilled on tip of nozzle are
decided.
 The number of holes on the tip of nozzle lies between 3 and 8 according to the demand
of customer and application of nozzle.
 The nozzle undergoes hydro erosion process (HE) after AGIE process to remove the Ag
particles from the holes.
 The hydro erosion process is also used to check weather the diameter of holes is accurate
or not.
 If there is defect in holes created by AGIE process, Hydro erosion process detects it, the
product is again sent back to AGIE process to make sure the given criterion is satisfied.
34
 CHAPTER 4: PROCESS ANALYSIS
Heijunka Board:
 The board has two segments for the 2 days (6-shift plan).
 In one segment the lot cards for one day are kept and in remaining segment the lot cards
for next day are kept.
 In one day segment there are three sections for three shift.
 Each shift section contains 320 lot cards which need to be completed in that shift only.
 Each lot cards refers to one metal tray which contains 50 parts

LASER Process:
 LASER operator takes the lot card from Heijunka board as per the requirement from the
AGIE room.
 It takes 4 to 4.5 minutes to print parts in one tray. (50 parts)
 The parts are in black tray before and during the laser process.
 One worker is appointed to shift the parts from black tray to metal tray.
 In sufficient number of metal trays at the laser process causes loss in AGIE as the parts
is in black trays, as only black trays are available in LASER process.

Aquas Cleaning Process:

 Operator receive the float from AGIE and float from laser FIFO rack at the beginning of
the shift.
 Delay of each float causes loss at AGIE.
 Three metal trays are inserted in Aquas Cleaning machine at a time for one cycle.
 Each cycle takes 4 to 5 mins to clean the parts in the Aquas Cleaning machine.
 As Aquas Cleaning machine operator has the float of LASER and AGIE, he manages
the flow of parts between LASER and AGIE.
 The float contains all the numbers of machines in AGIE and part numbers which is to be
delivered to each machine.
 A lot card contains the information about the part and the machine on which the next
operation is going to be performed.

35
Milk Runner:
 He completes 13 rounds of plant delivering the parts and empty trays.
 He makes 6-37 minutes round and 7-25 minutes round in one shift.
 In 37 minutes, round one extra stop adds to his route that is HE (hydro-erosion)

AGIE Process:
 There are 40 machines of AGIE process in AGIE room where each machine can perform
AGIE process on 4 parts in one cycle.
 It takes approximately 4 minutes to complete one cycle on each AGIE machine.
 If one machine in AGIE room stops for 28 minutes, the company bares a loss between
42,000 to 56,000 as cost of one nozzle lies between 1,500 to 2,000.
 AGIE process uses silver electrodes of diameter ranging from 3 micron to 5 microns.
 The holes on the tip of the nozzle made from silver electrodes has diameter range
between 3 microns to 5 microns.

36
 Chapter 5: Conclusion

BOSCH first established in India in 1951 with plants over the country in four cities
(Banglore-1951; Nashik-1969; Naganthapura-1989; Jaipur-1999), has setup
manufacturing plant of nozzles for diesel engines to create a world-wide supply chain.
These nozzles being a vital-components in diesel engine, only manufactured by
BOSCH limited, with a patent over their product.

I, Mayur Jadhav, had the opportunity to work with the company as an intern over the
project “A STUDY ON HEIJUNKA BOARD BETWEEN LASER AND AGIE”.
I suggest few ideas to reduce the losses of the company due to low workmanship
between the stages which will in turn help in production:

 Finally, analyzing all the factors between the processes, LASER and AGIE, I
propose that, there is a need to increase the number of metal trays in their
inventory.
 There should be an appointing of an extra milk runner between the laser and
AGIE to move parts in lesser time, which will reduce the losses.
 The float given to the Aquas cleaning operator should be updated before the
shift ends and not after He / She arrives to the plant.
 There is a need to improve the communication between workers of LASER and
AGIE, hence, a communication system/device should be setup between LASER
and AGIE to solve the issue. This will help to recognize which AGIE machine
is out of parts and can be fulfilled with the parts asap.

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