Download - 02-Kobetsu Kaizen
-
KAIZEN IDEA - SHEET
Scope & plan for Horizontal Deployment :
Sl. No. M/c No.Target Dt.Responsibility Status
16 m/cs Jan 2000 BK Jha Completed
Problem/present Status :Frequent break-down of MG welding machine (1304)(Average 4/month) due to failure of wire feeder
Kaizen Theme :Reduction of Break-down in welding
Bench mark4 brush set/monthTarget0Kaizen startNovember 1999Kaizen FinishNovember 1999
Team members : B K Jha4. R K Yadav2. R B Yadav3. R Dhaiya
Result:
Analysis :Why 1:Feeder motor not workingWhy 2:No power supply to armature of motorWhy 3:DC motors carbon contact brush found worn out and carbon deposited on commutatorWhy 4 :Sparking at roating contact while operating and specially while breakingWhy 5:Brush is operating at high voltage and reverse current is applied while breaking
Idea : To provide DC Motor in wire feeder with low operating voltage and to provide breaking with permanent magnet
Bharat Seats Limited
Countermeasures :System changed to low voltage supply and breaking by permanent magnet has reduced break down and brush consumption to zero for 3 years
BenefitsEquipment failure reduced from 4 / month to 0Saving in time loss = 80 min./machine/monthProductivity increased = 133 component/ machineCarbon brush saved per month = 50 setsSaving= Rs 110 x 50= Rs 5500 per month/machine
110 volts DC current
Breaking by ReverseDC Current
Field Magnetism byDC Current
Brush Consumption
Equipment Failure
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 2SETUP & ADJUSTMENT LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Set Up time reduction
Sheet1
PU: Foundry. REF NO:-KAIZEN SHEET
CELL: Core Room
LOSS : Set up
Kaizen Theme :Idea :
Problem / present Status:Counter Measure:Bench Mark
Spacers and studs - 4 nos each and various washers required for ejector plate set up1. Std size spacers are welded to ejector plate. 2. Reinforcement to ejector plate to avoid warpage elliminating use of washers. 3. Use of small bolts in stead of long studs.Target
Start
Kaizen Finish
Team Members :
1.4.
2.5.
3.6.
Benefits:(Mention in PQCDSM as applicable)
Analysis :Result :
Set up time is more
Removal, fixing and adjustment time more
Dismentling and assembly time more asHORIZONTAL DEPLOYMENT
number of parts are morePUM/C NO.PUM/C NO.
Sheet1 (2)
PU: Foundry. REF NO:-KAIZEN SHEET
CELL: Core Room
LOSS : Set up
Kaizen Theme :Idea :
To reduce set up time for ejector plate from 60 mins to 10 mins per occuranceRe design upper ejector plate
Problem / present Status:Counter Measure:Bench Mark60 minutes
Spacers and studs - 4 nos each and various washers required for ejector plate set up1. Std size spacers are welded to ejector plate. 2. Reinforcement to ejector plate to avoid warpage elliminating use of washers. 3. Use of small bolts in stead of long studs.Target10 minutes
StartJan-00
Kaizen FinishMar-00
Team Members :
1.Satish Sohoni4.Pramod Bhagat
2.Amar Patil5.Murdeshwar
3.Lalit Sedani6.
Benefits:(Mention in PQCDSM as applicable)
1Increase in output by 3 nos. per day
2Reduction in consumption of washers
Analysis :Result :3Reduction on cost of long studs
Set up time is more90
80
70
Removal, fixing and adjustmentTime in Minutes60
time more50HORIZONTAL DEPLOYMENT
40PUM/C NO.PUM/C NO.
Dismentling and assembly time more30
as number of parts are more20Foundry22/1
Ejector plate gets warped due to heat10Foundry22/2
JFMAMJJASFoundry22/3
Faulty designMonths
90
80
7070
6060
5050
4040
3030
2020
1010
JFMAMJJASONJFMAMJJAS
N
Sheet2
90
80
70
60
50
40
30
20
10
JFMAMJJASON
Sheet3
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Sheet1
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea :CHANGE THE DESIGN OF ALLEN KEY AND USE BOLT RUNNER FOR
TIME ON RACK TEETH BROACHING M/CTIGHTNING AND LOOSENING OF BOLTS(39 Nos.)
Problem / present StatusCounter measure :Bench mark1490 SEC.
Target700 SEC.
Start1/5/01
Kaizen Finish6/5/01
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :
BROACH ASSEMBLING AND DIS-
Analysis :Result :ASSEMBLING OF BOLTS
WHY: BOLTS LOOSENING AND TIGHTNING TIME ISBEFORE1490
HIGHAFTER700
:OPERATOR HAS TO OPEN AND CLOSE 39 BOLTS
WHILE CHANGE OVER
: ALLEN KEY DESIGN CHANGED AND BOLT RUNNER
PROVIDED ON LINEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea :CHANGE CHIP TRAY CLAMPING SYSTEM FROM HEX BOLTS TO
TIME ON RACK TEETH BROACHING M/CPIN TYPE LOCKING
Problem / present StatusCounter measure :Bench mark60 Secs.
Target10 Secs.
Start17/5/2001
Kaizen Finish17/5/2001
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :BEFORE60
NO NEED OF OPENING BOLTSAFTER10
Analysis :Result :TIME SAVED 50 Secs.
HIGH TIME FOR CHANGING THE CHIP TRAY ON
BROACHING M/C
WHY:
BECAUSE THE CHIP TRAY IS MOUNTED BY BOLTS
WHICH REQUIRES HIGH TIME FOR TIGHTNING ANDScope & plan for Horizontal Deployment :
RETIGHTNINGSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE THE SETUP TIMEIdea : PROVIDE A RATCHET AND SOCKET ON LINE TO REDUCE BOLT LOOSEN-
ON XLO CASE GEAR LINEING AND TIGHTENING TIME
Problem / present StatusCounter measure :Bench mark10 MINS
Target4 MINS
Start4.6.01
Kaizen Finish4.6.01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :BOLTS LOOSENING AND TIGHTENING
WHY BOLTS LOOSENING AND TIGHTENING TIME IS HIGHTIME REDUCED
: ALLEN KEY AND PIPE TAKES MORE TIME TO
LOOSEN & TIGHTEN THE BOLTS
: PROVIDE A RACHET & SOCKETScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE PLACE FOR KEEPING BROACH ON LINE
Problem / present Status : NON AVAIL-Counter measure : PLACE PROVIDED FORBench mark210 Secs.
ABILITY OF RESHARPENED BROACHKEEPING BROACH SET ON LINETarget120 Secs.
Start17/3/2001
Kaizen Finish20/3/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN DOWN TIME
Analysis :Result :FROM 210 SEC TO 120 SEC
THERE WAS NO FIXED PLACE ON LINE FOR BROACHREDUCTION IN DOWN TIME DUE TO NON-AVAILABILITY
SET (OF HORIZONTAL BROACHING M/C)OF RESHARPENED BROACH
BEFORE10
AFTER4
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE CHANGE-OVERIdea : PROVIDE SPL NUT & BOLT, TO AVOID USAGE OF ALLEN KEY FOR TIGHTENING
TIME ON XLO-IAND LOOSENING OF ALLEN BOLTS
Problem / present StatusCounter measure :Bench mark5 Mins.
Target1-Mins
Start4/6/01
Kaizen Finish8/6/01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN CHANGE OVER
Analysis :Result :BY 4 MIN
WHY :
SPECIAL BOLT & NUT ARE REQUIREDCHANGE OVER TIME
- IT IS HARD TO LOOSEN AND TIGHTEN THE ALLENBEFORE210
BOLTAFTER120
- HAND TOOLS ARE REQUIRED. SO TO ELIMINATEScope & plan for Horizontal Deployment :
THIS PROVIDE SPECIAL BOLT & NUTSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT
OVER TIME ON RACK TEETH BROACHINGREMOVAL OF TRAY SHOULD BE EASY
Problem / present StatusCounter measure :Bench mark310 Secs.
Target140 Secs.
Start15/5/2001
Kaizen Finish19/5/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
TROLLEY REMOVAL AND
Analysis :Result :FIXING TIME REDUCED
WHY : CHANGE OVER ON BROACHING M/C TO BEBY 170 Secs.
REDUCED
: DUE TO HIGH CHANGEOVER TIME ON M/CBEFORE5
: OPERATOR HAS TO USE CHAIN PULLEY FORAFTER1
REMOVAL OF TRAY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : PROVIDE EYE HOLE
FOR BOLT LOOSENING / TIGHTENING
Problem / present StatusCounter measure :Bench mark220 Secs.
Target45 Secs.
Start1/12/00
Kaizen Finish3/12/00BEFORE310
AFTER140
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :175 SEC TIME REDUCED FOR
WHY TAKES MORE TIME TO LOOSENING &CHANGEOVER
TIGHTENING OF BOLTS
FULL BOLTS HAVE TO BE REMOVED DUE TO
NO EYE HOLEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE
COL SHAFT INJ. MOULDING M/COF MACHINE
Problem / present StatusCounter measure :Bench mark30 Mins.
HIGH C/O TIME ON COL. SHAFT INJ MOULDING M/CT-SLOTS PROVIDED ON M/C BED & UPPER CLAMPINGTarget23 Mins.
PLATE. NOW CLAMPING BY T-BOLTSStart16/4/2001
Kaizen Finish23/4/2001
Team members :
CHINTESH
PARMOD JAIN
JITENDER
Benefits :
SAVING IN C/O TIME
Analysis :Result :BY 7-MINS
THERE ARE TAPPED HOLES ON M/C BED & UPPERSAVING IN C/O TIME
PLATE FOR CLAMPING THE MOULD. THE THREADSBEFORE220
INSIDE THREE HOLES WASHED OUT. IF ONE BOLT ISAFTER45
SLIPPING WHILE TIGHTENING THEN OPERAOR TRY
TO USE OTHER HOLE OR BIG LENGTH BOLT
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER
PLATE
Problem / present StatusCounter measure :Bench mark20 Secs.
Target10 Secs.
Start19/12/2000
Kaizen Finish19/12/2000
Team members :
CHINTESH
PARMOD JAIN
JITENDER
RAKESH GARG
Benefits :
Analysis :Result :
WHY TAKE MORE TIME TO PUT RUNNER PLATE10 SEC TIME REDUCED FORBEFORE30
ON CAVITYCHANGEOVERAFTER23
NO CHAMFER ON RUNNER PLATE & ACTIVITY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE
OF MATERIAL REMOVAL FROM HOOPERMOULDING MATERIAL OUT.
Problem / present StatusCounter measure :Bench mark8 Mins.
MATERIAL IN THE HOOPER WAS DRAINED OUT BYHOLE IS PROVIDED IN THE BOTTOM OF THE HOOPERTarget2 Mins.
OPERATING THE M/CWITH SHUTTER. NOW MATERIAL IS REMOVEDStart2/4/01
MANUALLYKaizen Finish2/4/01
Team members :
CHINTESH
KIRORI
SATYAWAN
Benefits :
NO WASTAGE OF MATERIAL
Analysis :Result :COST SAVING : Rs 1500/YEARBEFORE20
AFTER10
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO WELD WITH SCREWS TO AVOID USE OF ALLEN KEY WHILE LOOSENING
WHILE CHANGEOVER& TIGHTENING OF SCREWS
Problem / present StatusCounter measure :Bench mark3- Mins.
WHILE CHANGEOVER WASTAGE OF TIME IN LOOSEN-T-HANDLES ARE WELDED WITH SCREWSTarget1 Min
ING & TIGHTENING OF CLAMPING SCREWS OF DOGS,Start24/4/2001
FOR MOULD SETTING OF INJECTION MOULDINGKaizen Finish27/4/2001
MACHINES
Team members :
SATISH GUPTA
HARISH PAHUJA
CHINTESH
Benefits :
Analysis :Result :CHANGEOVER TIME REDUCTION
ALLEN KEYS WERE BEING USED IN LOOSENING &REDUCTION IN DOWNTIME WHILE CHANGEOVER2 MIN / CHANGEOVERBEFORE8
TIGHTENING OF DOG SCREWSAFTER2
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE FIXED PLACE FOR PARTICULAR MODEL FIXTURE PART
TIME ON INJ. MOULDING MACHINENEAR TO OPERATOR
Problem / present StatusCounter measure :Bench mark3 Mins
WASTAGE OF TIME WHILE CHANGEOVER ON INJ.FIXED PLACE PROVIDED FOR FIXTURES OF DIFFERENTTarget0
MOULDING M/C.MODELS WITH THE M/CStart12/4/01
Kaizen Finish15/4/2001
Team members :
CHINTESH
SATYAWAN
LAXMAN
Benefits :
OPERATIVES TIME IN SEARCHING &
Analysis :Result : NO WASTAGE OF TIME IN SEARCH-BRINGING REQUIRED MODEL
FIXTURE OF DIFFERENT MODELS ARE PLACED ON AING OUT FIXTURE PARTS OF PARTICULAR MODELFIXTURE PART SAVED
TABLE OUTSIDE THE LINE. WASTAGE OF TIME IN: OPERATIVE'S TIME OF BRINGING FIXTUREBEFORE3
SERARCHING OUT FIXTURE OF PARTICULAR MODELPARTS FROM TABLE OUTSIDE THE LINE, SAVEDAFTER1
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : Provide special T-allen key
over Time
Problem / present StatusCounter measure :Bench mark20'
Target16'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 4 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
BEFORE3
Scope & Plan for Horizontal DeploymentAFTER0
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : REDUCE LENGTH OF BOLT
Problem / present StatusCounter measure :Bench mark30'
Target25'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Vipinder
Benefits :
Bolt's size : M8*25Bolt's size : M8*15
Analysis :Result :Changeover time reduced by 5'
No. of such Changeover parts = 3
No. of Bolts/ parts = 2
Total Bolts = 6
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Before20
SonaAfter16
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Problem / present StatusCounter measure :Bench mark25'
Target18'
Start22/05/01
Kaizen Finish22/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 7 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE SET UP TIMEIdea : COMMON MOULD TO BE USED BY REPLACING PARTS ONLY
ON C-67 INJECTION MOULDING M/C
Problem / present StatusCounter measure :Bench mark1480 Secs.
Target415 Secs.
Start10/9/00
Kaizen Finish3/10/00
Team members :
RAKESH GARG
G.R. YADAV
MANOJ SHARMA
S.K.GUPTA
CHINTESHBEFORE1480
MOULD WAS REPLACED FOR SET UPONLY REST BLOCKS ARE CHANGED FOR SET UPAFTER415
Benefits :
Analysis :Result :OPERATOR'S FATIGUE REDUCED
SET UP TIME IS MORESET UP TIME REDUCED
BY 1065 Secs.
WHY:Scope & Plan for Horizontal Deployment
BECAUSE DIFFERENT MOULDS ARE USED FORSr.No.M/c No.Target Dt.ResponsibilityStatus
DIFFERENT MODELS
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : REDUCE NO. OF BOLTS & NO. OF TURN FOR TIGHTENING OF REST
REPLACING THE BLOCKBLOCK
Problem / present StatusCounter measure :Bench mark5 MIN.
Target2 MIN.
Start10/6/01
Kaizen Finish13/6/2001
Team members :
RAKES GARGBEFORE5
SATISH GUPTAAFTER2
Benefits :
Result :C/O TIME REDUCED BY 3 MIN.
Analysis :
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : USE ONLY ONE OPERATOR INSTEAD OF TWO ON CASE GEAR LINE
OF CASE GEAR MACHINING LINE
Problem / present StatusCounter measure :Bench mark2
Target1
Start27/05/2001
Kaizen Finish29/5/2001
Team members :
MANOJ SHARMA
GR YADAV
V SETHI
R BAJAJ
CHINTESH
Benefits :
SAVED ONE OPERATOR PER SHIFT
Analysis :Result :
WHY : WHY SHOULD WE PUT ONLY ONE OPERATOR
IN PLACE OF TWO OPERATORSSAVING IN MANPOWER PER SHIFT
BEFORE2
WE CAN PUT TUBE PRESSING M/C ON ASSY LINEAFTER1
BECAUSE ASSY LINE OPERATOR HAS ENOUGH
TIME TO DO THIS OPERATIONScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : CHANGE LINE LAYOUT
ON COLL. COLUMN LINE
Problem / present StatusCounter measure :Bench mark40 Pcs/Hr
Target46 Pc/Hr
Start28/8/2000
Kaizen Finish31/8/2000
Team members :
Benefits :
Analysis :Result :PRODUCTION PER HOUR
WHY : WHY LESS PRODUCTION ON LINEINCREASED
ALL M/Cs STOP DUE TO B/DOWN ON ANY M/CPRODUCTION PER HOUR
BEFORE40
AFTER46
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sheet1
1
Sheet2
Sheet3
TIME IN MIN.
20
16
Time in Minute
Changeover Time at Chamfering Station
Time in Minute
Time in Minute
5
2
TIME(IN MIN.)
REDUCTION IN C/O
40
46
* PLAIN HOLES WERE PRESENT IN THE BLOCK DUE TO WHICH FULL TIGHTENING OF BOLTS WAS REQUIRED
* PLAIN HOLES OF THE BLOCK MODIFIED TO EYES HOLES AS SHOWN, BY WHICH NO. OF TURNS OF HOLES WERE REDUCED
R/M
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
TUBE PRESSING
TROLLEY
1
2
F/M
R/M
2
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
F/M
BEFORE
AFTER
2
1
MBD0021B15E.xls
MBD0021C9A0.xls
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 3TOOL & JIG CHANGE LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Sheet1
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme :TO REDUCE HIGH C/OVERIdea :CHANGE THE DESIGN OF ALLEN KEY AND USE BOLT RUNNER FOR
TIME ON RACK TEETH BROACHING M/CTIGHTNING AND LOOSENING OF BOLTS(39 Nos.)
Problem / present StatusCounter measure :Bench mark1490 SEC.
Target700 SEC.
Start1/5/01
Kaizen Finish6/5/01
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :
BROACH ASSEMBLING AND DIS-
Analysis :Result :ASSEMBLING OF BOLTS
WHY: BOLTS LOOSENING AND TIGHTNING TIME ISBEFORE1490
HIGHAFTER700
:OPERATOR HAS TO OPEN AND CLOSE 39 BOLTS
WHILE CHANGE OVER
: ALLEN KEY DESIGN CHANGED AND BOLT RUNNER
PROVIDED ON LINEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme :TO REDUCE CHANGE OVERIdea :CHANGE CHIP TRAY CLAMPING SYSTEM FROM HEX BOLTS TO
TIME ON RACK TEETH BROACHING M/CPIN TYPE LOCKING
Problem / present StatusCounter measure :Bench mark60 Secs.
Target10 Secs.
Start17/5/2001
Kaizen Finish17/5/2001
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :BEFORE60
NO NEED OF OPENING BOLTSAFTER10
Analysis :Result :TIME SAVED 50 Secs.
HIGH TIME FOR CHANGING THE CHIP TRAY ON
BROACHING M/C
WHY:
BECAUSE THE CHIP TRAY IS MOUNTED BY BOLTS
WHICH REQUIRES HIGH TIME FOR TIGHTNING ANDScope & plan for Horizontal Deployment :
RETIGHTNINGSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE THE SETUP TIMEIdea : PROVIDE A RATCHET AND SOCKET ON LINE TO REDUCE BOLT LOOSEN-
ON XLO CASE GEAR LINEING AND TIGHTENING TIME
Problem / present StatusCounter measure :Bench mark10 MINS
Target4 MINS
Start4.6.01
Kaizen Finish4.6.01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :BOLTS LOOSENING AND TIGHTENING
WHY BOLTS LOOSENING AND TIGHTENING TIME IS HIGHTIME REDUCED
: ALLEN KEY AND PIPE TAKES MORE TIME TO
LOOSEN & TIGHTEN THE BOLTS
: PROVIDE A RACHET & SOCKETScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : REDUCTION IN DOWN TIMEIdea : TO PROVIDE PLACE FOR KEEPING BROACH ON LINE
Problem / present Status : NON AVAIL-Counter measure : PLACE PROVIDED FORBench mark210 Secs.
ABILITY OF RESHARPENED BROACHKEEPING BROACH SET ON LINETarget120 Secs.
Start17/3/2001
Kaizen Finish20/3/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN DOWN TIME
Analysis :Result :FROM 210 SEC TO 120 SEC
THERE WAS NO FIXED PLACE ON LINE FOR BROACHREDUCTION IN DOWN TIME DUE TO NON-AVAILABILITY
SET (OF HORIZONTAL BROACHING M/C)OF RESHARPENED BROACH
BEFORE10
AFTER4
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE CHANGE-OVERIdea : PROVIDE SPL NUT & BOLT, TO AVOID USAGE OF ALLEN KEY FOR TIGHTENING
TIME ON XLO-IAND LOOSENING OF ALLEN BOLTS
Problem / present StatusCounter measure :Bench mark5 Mins.
Target1-Mins
Start4/6/01
Kaizen Finish8/6/01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN CHANGE OVER
Analysis :Result :BY 4 MIN
WHY :
SPECIAL BOLT & NUT ARE REQUIREDCHANGE OVER TIME
- IT IS HARD TO LOOSEN AND TIGHTEN THE ALLENBEFORE210
BOLTAFTER120
- HAND TOOLS ARE REQUIRED. SO TO ELIMINATEScope & plan for Horizontal Deployment :
THIS PROVIDE SPECIAL BOLT & NUTSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE HIGH CHANGE-Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT
OVER TIME ON RACK TEETH BROACHINGREMOVAL OF TRAY SHOULD BE EASY
Problem / present StatusCounter measure :Bench mark310 Secs.
Target140 Secs.
Start15/5/2001
Kaizen Finish19/5/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
TROLLEY REMOVAL AND
Analysis :Result :FIXING TIME REDUCED
WHY : CHANGE OVER ON BROACHING M/C TO BEBY 170 Secs.
REDUCED
: DUE TO HIGH CHANGEOVER TIME ON M/CBEFORE5
: OPERATOR HAS TO USE CHAIN PULLEY FORAFTER1
REMOVAL OF TRAY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : REDUCTION OF NO. OF TURNSIdea : PROVIDE EYE HOLE
FOR BOLT LOOSENING / TIGHTENING
Problem / present StatusCounter measure :Bench mark220 Secs.
Target45 Secs.
Start1/12/00
Kaizen Finish3/12/00BEFORE310
AFTER140
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :175 SEC TIME REDUCED FOR
WHY TAKES MORE TIME TO LOOSENING &CHANGEOVER
TIGHTENING OF BOLTS
FULL BOLTS HAVE TO BE REMOVED DUE TO
NO EYE HOLEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE C/O TIME ONIdea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE
COL SHAFT INJ. MOULDING M/COF MACHINE
Problem / present StatusCounter measure :Bench mark30 Mins.
HIGH C/O TIME ON COL. SHAFT INJ MOULDING M/CT-SLOTS PROVIDED ON M/C BED & UPPER CLAMPINGTarget23 Mins.
PLATE. NOW CLAMPING BY T-BOLTSStart16/4/2001
Kaizen Finish23/4/2001
Team members :
CHINTESH
PARMOD JAIN
JITENDER
Benefits :
SAVING IN C/O TIME
Analysis :Result :BY 7-MINS
THERE ARE TAPPED HOLES ON M/C BED & UPPERSAVING IN C/O TIME
PLATE FOR CLAMPING THE MOULD. THE THREADSBEFORE220
INSIDE THREE HOLES WASHED OUT. IF ONE BOLT ISAFTER45
SLIPPING WHILE TIGHTENING THEN OPERAOR TRY
TO USE OTHER HOLE OR BIG LENGTH BOLT
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : QUICK FITMENT OF RUNNERIdea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER
PLATE
Problem / present StatusCounter measure :Bench mark20 Secs.
Target10 Secs.
Start19/12/2000
Kaizen Finish19/12/2000
Team members :
CHINTESH
PARMOD JAIN
JITENDER
RAKESH GARG
Benefits :
Analysis :Result :
WHY TAKE MORE TIME TO PUT RUNNER PLATE10 SEC TIME REDUCED FORBEFORE30
ON CAVITYCHANGEOVERAFTER23
NO CHAMFER ON RUNNER PLATE & ACTIVITY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE MINOR STOPPAGEIdea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE
OF MATERIAL REMOVAL FROM HOOPERMOULDING MATERIAL OUT.
Problem / present StatusCounter measure :Bench mark8 Mins.
MATERIAL IN THE HOOPER WAS DRAINED OUT BYHOLE IS PROVIDED IN THE BOTTOM OF THE HOOPERTarget2 Mins.
OPERATING THE M/CWITH SHUTTER. NOW MATERIAL IS REMOVEDStart2/4/01
MANUALLYKaizen Finish2/4/01
Team members :
CHINTESH
KIRORI
SATYAWAN
Benefits :
NO WASTAGE OF MATERIAL
Analysis :Result :COST SAVING : Rs 1500/YEARBEFORE20
AFTER10
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE DOWNTIMEIdea : TO WELD WITH SCREWS TO AVOID USE OF ALLEN KEY WHILE LOOSENING
WHILE CHANGEOVER& TIGHTENING OF SCREWS
Problem / present StatusCounter measure :Bench mark3- Mins.
WHILE CHANGEOVER WASTAGE OF TIME IN LOOSEN-T-HANDLES ARE WELDED WITH SCREWSTarget1 Min
ING & TIGHTENING OF CLAMPING SCREWS OF DOGS,Start24/4/2001
FOR MOULD SETTING OF INJECTION MOULDINGKaizen Finish27/4/2001
MACHINES
Team members :
SATISH GUPTA
HARISH PAHUJA
CHINTESH
Benefits :
Analysis :Result :CHANGEOVER TIME REDUCTION
ALLEN KEYS WERE BEING USED IN LOOSENING &REDUCTION IN DOWNTIME WHILE CHANGEOVER2 MIN / CHANGEOVERBEFORE8
TIGHTENING OF DOG SCREWSAFTER2
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE CHANGEOVERIdea : TO PROVIDE FIXED PLACE FOR PARTICULAR MODEL FIXTURE PART
TIME ON INJ. MOULDING MACHINENEAR TO OPERATOR
Problem / present StatusCounter measure :Bench mark3 Mins
WASTAGE OF TIME WHILE CHANGEOVER ON INJ.FIXED PLACE PROVIDED FOR FIXTURES OF DIFFERENTTarget0
MOULDING M/C.MODELS WITH THE M/CStart12/4/01
Kaizen Finish15/4/2001
Team members :
CHINTESH
SATYAWAN
LAXMAN
Benefits :
OPERATIVES TIME IN SEARCHING &
Analysis :Result : NO WASTAGE OF TIME IN SEARCH-BRINGING REQUIRED MODEL
FIXTURE OF DIFFERENT MODELS ARE PLACED ON AING OUT FIXTURE PARTS OF PARTICULAR MODELFIXTURE PART SAVED
TABLE OUTSIDE THE LINE. WASTAGE OF TIME IN: OPERATIVE'S TIME OF BRINGING FIXTUREBEFORE3
SERARCHING OUT FIXTURE OF PARTICULAR MODELPARTS FROM TABLE OUTSIDE THE LINE, SAVEDAFTER1
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : Reduce ChangeIdea : Provide special T-allen key
over Time
Problem / present StatusCounter measure :Bench mark20'
Target16'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 4 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
BEFORE3
Scope & Plan for Horizontal DeploymentAFTER0
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : Reduce Change over TimeIdea : REDUCE LENGTH OF BOLT
Problem / present StatusCounter measure :Bench mark30'
Target25'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Vipinder
Benefits :
Bolt's size : M8*25Bolt's size : M8*15
Analysis :Result :Changeover time reduced by 5'
No. of such Changeover parts = 3
No. of Bolts/ parts = 2
Total Bolts = 6
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Before20
SonaAfter16
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : Reduce Change over TimeIdea : Provide sppecial T-allen key
Problem / present StatusCounter measure :Bench mark25'
Target18'
Start22/05/01
Kaizen Finish22/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 7 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE SET UP TIMEIdea : COMMON MOULD TO BE USED BY REPLACING PARTS ONLY
ON C-67 INJECTION MOULDING M/C
Problem / present StatusCounter measure :Bench mark1480 Secs.
Target415 Secs.
Start10/9/00
Kaizen Finish3/10/00
Team members :
RAKESH GARG
G.R. YADAV
MANOJ SHARMA
S.K.GUPTA
CHINTESHBEFORE1480
MOULD WAS REPLACED FOR SET UPONLY REST BLOCKS ARE CHANGED FOR SET UPAFTER415
Benefits :
Analysis :Result :OPERATOR'S FATIGUE REDUCED
SET UP TIME IS MORESET UP TIME REDUCED
BY 1065 Secs.
WHY:Scope & Plan for Horizontal Deployment
BECAUSE DIFFERENT MOULDS ARE USED FORSr.No.M/c No.Target Dt.ResponsibilityStatus
DIFFERENT MODELS
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme :TO REDUCE C/O TIME OFIdea : REDUCE NO. OF BOLTS & NO. OF TURN FOR TIGHTENING OF REST
REPLACING THE BLOCKBLOCK
Problem / present StatusCounter measure :Bench mark5 MIN.
Target2 MIN.
Start10/6/01
Kaizen Finish13/6/2001
Team members :
RAKES GARGBEFORE5
SATISH GUPTAAFTER2
Benefits :
Result :C/O TIME REDUCED BY 3 MIN.
Analysis :
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO INCREASE PRODUCTIONIdea : USE ONLY ONE OPERATOR INSTEAD OF TWO ON CASE GEAR LINE
OF CASE GEAR MACHINING LINE
Problem / present StatusCounter measure :Bench mark2
Target1
Start27/05/2001
Kaizen Finish29/5/2001
Team members :
MANOJ SHARMA
GR YADAV
V SETHI
R BAJAJ
CHINTESH
Benefits :
SAVED ONE OPERATOR PER SHIFT
Analysis :Result :
WHY : WHY SHOULD WE PUT ONLY ONE OPERATOR
IN PLACE OF TWO OPERATORSSAVING IN MANPOWER PER SHIFT
BEFORE2
WE CAN PUT TUBE PRESSING M/C ON ASSY LINEAFTER1
BECAUSE ASSY LINE OPERATOR HAS ENOUGH
TIME TO DO THIS OPERATIONScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO IMPROVE EFFICIENCYIdea : CHANGE LINE LAYOUT
ON COLL. COLUMN LINE
Problem / present StatusCounter measure :Bench mark40 Pcs/Hr
Target46 Pc/Hr
Start28/8/2000
Kaizen Finish31/8/2000
Team members :
Benefits :
Analysis :Result :PRODUCTION PER HOUR
WHY : WHY LESS PRODUCTION ON LINEINCREASED
ALL M/Cs STOP DUE TO B/DOWN ON ANY M/CPRODUCTION PER HOUR
BEFORE40
AFTER46
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sheet1
1
Sheet2
0
0
Sheet3
0
0
TIME IN MIN.
0
0
0
0
0
0
0
0
0
0
8
2
3
1
3
0
20
16
Time in Minute
1480
415
Changeover Time at Chamfering Station
Time in Minute
Time in Minute
0
0
5
2
TIME(IN MIN.)
REDUCTION IN C/O
40
46
* PLAIN HOLES WERE PRESENT IN THE BLOCK DUE TO WHICH FULL TIGHTENING OF BOLTS WAS REQUIRED
* PLAIN HOLES OF THE BLOCK MODIFIED TO EYES HOLES AS SHOWN, BY WHICH NO. OF TURNS OF HOLES WERE REDUCED
R/M
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
TUBE PRESSING
TROLLEY
1
2
F/M
R/M
2
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
F/M
BEFORE
AFTER
2
1
MBD0021C9A0.xls
MBD0021B15E.xls
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 4START UP LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 5MINOR STOPPAGE & IDLING LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
GENERAL PROBLEMS ON MINOR STOPPAGES Efforts to actualize as losses are not sufficient.
Actions taken are poor .-Only emergency measures are taken as temporary measures.
Phenomena are not discerned fully.
Obstruction to unattendance operation. -Operators are used for restoration.-Minor stoppages keep operators from operating multiple stations or machines.-One minor stoppage will ruin the effects of unattendance operation during breaks. JIPM, 1994
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
KAIZEN PROGRAM TO IMPROVE MINOR STOPPAGE LOSSWhere they occur, how many, how frequently, with what product, when, and in what condition (including condition by program)
Survey the actual condition of phenomena1. Understand present status JIPM, 1994
Stratify phenomenaPM analysisList all Fuguai that can be considered2. Analyze Phenomena
Attach Efu in place for each slight defect or Fuguai Check during Jishu-Hozen activities
Keep equipment and machines cleanAttaching and removing Efu3. Identify, Restore and Improve slight defect and Fuguai
Verify effects Reflect in Jishu-Hozen criteriaSelect problems for zero minor stoppages4. Verify Results
Timing, Installation angle, vacuum pressure, vibrationAcceleration and deceleration timing, sensor suitability, sensor mounting conditions, chute shape, coolant condition, air blow condition, positioning mechanism, clearance, accuracy of each part, fitting accuracy, condition and method of disposing chips.
Compare with design conditionsImprove design weaknesses5. Study optimal conditions
Improve parts and members with short lifeImprove dirty locations. (Ideas to eliminate needs for cleaning)6. Longer MTBF
Fixation of fluctuation factors, prediction of changes, and automatic restoration of variations
Zero minor stoppages7. Challenge to Unattendance Operation (In Zero Minor Stoppages)
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Minor Stoppage and Idling Loss
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
MN
Soft Energy Business Group
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaiun Theme :Idea :
To reduce the minor stoppage of Tamping.To increase no of slots available for can locating.
DepartmentR6
Problem / Present Status :Counter Measure :
Can getting stuck between star wheel & hopper guide leading to stop the flow of cans to tamping m/c.Increased no of slots from 37 to 48 by increasing the diameter of starwheel, there by reduce the RPM of starwheel.LocationTamping
Bench Mark78min, /499 Occ/Month.
TargetZero
Kaizen Regn. No.R6/178/00
Kaizen Start Date20.12.99
Kaizen Finish Date02.07.00
Team Members :
Mahesh, Deepak, Jayaraj, Chandrashekar, Nagaraju.May-007676
Analysis :Result :Jun-008080
1. Can not located in the star wheel slot.Jul-007878
Benefits :Aug-0000
2. No. of slots available for locating the can is less.
1. Minor stoppage reduced to zero .
3. RPM of the star wheel is more.
2. Production Increased by 23400 nos per month.
4. Machine designed that way.
3. Rejection reduced from 2075 Nos. to Zero per month.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Not applicable.
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To reduce the blackmix spillage in the lower spindle.To increase dia of lower punch.
DepartmentR6
Problem / Present Status :Counter Measure :
Blackmix oozing out between the holder receiver & Lower punch.Increased the dia of lower punch to 10.60 Clearance per side - 0.045mm.LocationTamping
Bench MarkSpillage 10 kg / month.
TargetZero.
Kaizen Regn. No.R6/049/00
Kaizen Start Date28.04.2000
Kaizen Finish Date28.05.2000
Team Members :
Nagaraju, Ballal, Mahesh,Chandrakanth, Raghu
Analysis :Result :
1. Bobbin being formed by pressing the BlackBenefits :
Mix in the Holder by the punches.Mar-001111
2. Black Mix oozing between the Holder &1. Blackmix oozing reduced from 10kg toApr-001010
Lower Punch1.5 Kgs / monthMay-001010
3. Holder Inner Dia is 10.69mm.Jun-001.51.5
4. Lower Punch Outer Dia is 10.55mm.Jul-0011
5. Clearance between two is 0.07mm / side.Aug-001.51.5
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Not applicable.
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To reduce the Black mix spillage below roll crusher unit.To scrap the Black Mix & make it fall in the hopper.
DepartmentR6
Problem / Present Status :Counter Measure :
Blackmix Sticks to the belt & doesnt fall in the hopper & falls in the guard.Provide a scrapper to the coveyor so that excess Black mix again falling to the feeding hopper.LocationTamping
Bench Mark2kg / day.
Target0
Kaizen Regn. No.R6/025/00
Kaizen Start Date07.06.00
Kaizen Finish Date22.07.2000
Team Members :
Nagaraju, Chandrakanth, Raghu, Shivakumar.May-005050
Analysis :Result :Jun-005050
Jul-0000
1. Due to the wetness of the Black Mix,Benefits :Aug-0000
it is sticking to the conveyor belt.
1. No Black mix spillage.
2. No cleaning of Blackmix required.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Not applicable
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To reduce cleaning time (scheduled downtime) of tamping.To eliminate manual jig removing.
DepartmentR6
Problem / Present Status :Counter Measure :
5 min required to remove the jigs during cleaning time.1. Provided cover for Proximity sensor there by inactivating it during cleaning time & gate opened to collect jigs automatically.LocationTamping
Bench Mark5 min / day.
Target0
Kaizen Regn. No.R6/053/00
Kaizen Start Date12.07.00
Kaizen Finish Date27.07.00
Team Members :
M. Nagaraju / Chandrakanth, Raghu D.R
Analysis :Result :
1. At the end of the shift, jigs ( 100 Nos ) toJig collecting time reduced.Benefits :Jun-0055
be removed manually.Jul-0055
2. Person can not concentrate on any other1. Manual strain reduced to remove 100 Jigs.Aug-0000
work during this period.2. Morale increase.
3. About 5 min required to remove the jigs.3. Jigs dirty avoided.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Not applicable.
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To eliminate equipment failure of TampingTo avoid the dust going inside the bearing.
DepartmentR6 Assembly.
Problem / Present Status :Counter Measure :
Seizure of bearing 6203 RS causing jerkyProtective cover provided to the 6203 bearing.LocationTamping
motion of conveyor
Bench Mark6 Hours / 2 time/year.
Target0
Kaizen Regn. No.R6/012/00
Kaizen Start Date08.04.2000
Kaizen Finish Date28.04.2000
Team Members :
R. Mahesh / Lokesh M. Nagaraju / Chandrakanth, Raghu D.R
Analysis :Result :
1. Graphite and blackmix enters in to the bearingEquipment Failure due to bearing reducedBenefits :
to Zero.Apr-0066
2. No protective cover provided1. Bearing failure reduced to zero.May-0000
Jun-0000
2. Production increased by 216000 nos.Jul-0000
3. Machine designed that wayAug-0000
3. Cost reduction by Rs. 600/-.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Not applicable.
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To eliminate the adjustment loss.To provide lock nut.
DepartmentR6
Problem / Present Status :Counter Measure :
During continuos operation of the machine piston lock nut getting loosend causing piston to stop half way.Spanner grip & lock nut provided.LocationTamping
Bench Mark2 times 40 min/6month.
TargetZero.
( Ref. Sketch.)
Kaizen Regn. No.R6/056/00
Kaizen Start Date12.06.2000
Kaizen Finish Date21.07.2000
Team Members :
Lokesh M. Nagaraju / Chandrashaker, Shivakumar
Analysis :Result :
1. Due to the continues reciprocating motion of the piston nut getting loosen.Adjustment Loss reduced to Zero.Benefits :
Jun-004040
1. There is no spanner grip & lock nut.Jul-0000
Aug-0000
Production increased by 12000 nos
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To reduced the equipment failure due to break wire cut.To avoid the break wire cut.
DepartmentR6
Problem / Present Status :Counter Measure :
Separator pulling break wire getting cut for every 15 days.The break wire dia changed to 2mm. Break wire material changed to spring stell instead of MS wire.LocationSeparator
Bench Mark2 per month & 15 min. Occ.
TargetZero.
Kaizen Regn. No.R6/023
Kaizen Start Date06.06.2000
Kaizen Finish Date
Team Members :
Nagaraju / shivakumar/Chandrakumar/Raghu
Analysis :Result :
Jul-003030
Breakwire dia is less (dia 1mm)Benefits :Aug-0000
1. Equipment failure due to breakwire cut reduced to zero.
2. Cost of the spring steel wire per unit ;is less, when compared to break wire.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To Eliminate the Equipment failure due to cutter breakage.To avoid the sleve going down.
DepartmentR6 Assembly
Problem / Present Status :Counter Measure :
Separator sleeve loosen and dropping on the cutter.Provide a circlip to the sleve.LocationSeperator
Bench Mark3 Times, 80 mintes.
TargetZero.
Kaizen Regn. No.R6/067/00
Kaizen Start Date25.04.00
Kaizen Finish Date02.05.00
Team Members :
Analysis :Result :Nagaraju / Balarajan / Chandrakumar / Savitha.
1. Grub screw for holding the sleeve loosing.
Benefits :
2. Due to vibration of machine.Apr-008080
Cutter breakage Zero. [Saving of Rs. 3000/-]May-0000
Jun-0000
Jul-0000
Aug-0000
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
1230.09.00Nagaraj1 to be done.
2115.10.00Nagaraj4 to be done.
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To eleminates the failure of B28 Belt.To provide Bigger Dia of pully.
DepartmentR6 Assembly.
Problem / Present Status :Counter Measure :
B28 belt fails very frequenty.Allignement correted. Pully Dai changed from 90 mm.. To 120 mmmmLocationSeperator
Bench Mark2 belts/month.
TargetZero.
Kaizen Regn. No.R6/068/00.
Kaizen Start Date12.04.2000
Kaizen Finish Date01.05.2000
Team Members :
Analysis :Result :K.C Lokesh / Rajesh / Nagaraju / Prasanth.
1. Alligement of mikky pully to the belt pully not OK.
Benefits :Mar-0022
2. Speed cannot be varried.Apr-0022
1. Belt failure zero [saving per month Rs.300/-]May-0000
Jun-0000
Jul-0000
Aug-0000
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To eliminate the failure of photo sensor.To avoid the failure of sensor.
DepartmentR6 Assembly.
Problem / Present Status :Counter Measure :
Photo sensor fails due to over hanging of cables.Provide a guard over the sensor to avoid the vaccum pipe touching to the sinser & cable.LocationTamping
Bench Mark2 times & 75 min.
TargetZero.
Kaizen Regn. No.R6/069/00
Kaizen Start Date12.03.2000
Kaizen Finish Date18.04.2000
Team Members :
Analysis :Result :K.C Lokesh / Rajesh / Nagaraju / Prasanth.
During mannual cleaning & due to over hanging of the calbe, Vacuum pipe touches the senor.
Failure of Photo sensor is Zero.Benefits :
Mar-007575
1. Production Increased by 45000 nos.Apr-0000
45000May-0000
2. Saving of Rs.1000Jun-0000
Jul-0000
Aug-0000
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
Department
Problem / Present Status :Counter Measure :
Location
Bench Mark
Target
Kaizen Regn. No.
Kaizen Start Date
Kaizen Finish Date
Team Members :
Analysis :Result :
Benefits :
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL PTI LIMITED
KAIZEN IDEA SHEET
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
Department
Problem / Present Status :Counter Measure :
Location
Bench Mark
Target
Kaizen Regn. No.
Kaizen Start Date
Kaizen Finish Date
Team Members :
Analysis :Result :
Benefits :
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
Done
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
MN
30
0
0
0
0
&A
Page &P
Minutes
40
0
0
0
Minutes
30
0
0
Minutes
13
15
0
0
Minutes
KaizenDone
0
0
0
0
0
0
In kg.
0
0
0
0
In kg.
0
0
0
Minutes
0
0
0
0
0
Hours.
0
0
0
Minutes
00
00
Minutes
00
00
00
00
00
00
BPL
BPL
BPL
BPL
BPL
BPL
BPL
BPL
Minutes
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Qty.
0
0
0
0
0
0
Minutes.
Lower PunchDia 10.55mm
HolderI D 10.69mm
Lower PunchDia 10.60mm
Clearance / side0.07mm
Clearance / side0.045mm
Kaizen Done
Kaizen Done
BlackmixHopper
Conveyor Belt
Scraper for removing Blackmix
Kaizen Done
Protective Cover
Bearing
Kaizen Done
Kaizen Done
Cutter
Can
Separator Paper
Metal Sleeve
Circlip
Kaizen Done
BPL
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 6REDUCED SPEED LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Speed lossManufacturer recommended speed 85 mm/secBut actual speed is 35 mm/secBeforeMain RamTie RodAfterMachine restored as per Manufacturer recommended speed of 85 mm/secMachine : Vertical Curing PressOperation : Press Curing
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 7DEFECT & REWORK LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
JIPM, 1994GENERAL PROBLEMS ON DEFECTSDefects tend to be left as they are because the situation does not improve even if countermeasures are taken- Approaching method is wrongSporadic and chronic losses are not understood-Errors by engineers who think only in the realm of organisation developed technologiesActual conditions of on-site is not understood. ( Work, setup, equipment, etc.) Methods of seizing and exploring factors are poor-Defects are not taken up as defects-Defects are not considered to affect phenomena Rework is not considered as losses
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
KAIZEN PROGRAM FOR DEFECT LOSSESProcess and location where defect is generatedRelations between equipment accuracy, method and conditions and quality.Comparative study (non-defectives, defectives and other machines)Study of mechanismMechanism, jigs, tools, setup and machining conditions 1. Stratification of Defect Phenomena JIPM, 1994
List factors by cause and effect diagrams and 4M analytic chartsList important factors and draft Kaizen Countermeasures3. 4 M Analysis and Countermeasure DraftingPrepare a plan for Kaizen ImplementationImplement Kaizen and set conditionsVerify resultsStratification of remaining defect phenomenaPhysical analysis of PhenomenaContributing conditionsAnalyze correlations with 4MStudy of what the human resources and equipment condition must beStudy machining conditions4. Countermeasure Implementation and Result Verification 5. Implement PM Analysis
Study of measuring methodSurvey accuracyRestore and improve Fuguai6. Identification of Defects and Implementation of Countermeasures
Verify resultsStudy accuracy to be maintainedSet and execute control criteria7. Verifications of Results and Prevention of RecurrenceClarify quality standard and quality characteristic valuesThrough stratification of defect modes
ABC analysis, time series data, Cp value, unadjusted time series data2. Survey of Defect Process and Location
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
1
Lucas TVSKAIZEN IDEA SHEETKaizen Reg. NoC.codePillarL.no.Sl.NoDate Regd. 14.10.2000
RTHSKK15001
FIE DivisionCell : Rotor Hard StageM/c Desc:Gauging bench-BlohmM/c No: M 12046
Kaizen Theme : Energy Loss EliminationBench markKaizen Start : Nov 1st
Before ImprovementAnalysisTargetKaizen Finish : Non 15 th
Team Members
1.M.N.Ganesh 2.A.Bilalhussain 3. E.Balaji
Results & Benefits
Air leak
Idea
After Improvement
Action Taken
Push-buttonNo air leak
Airflow Inlet
No air leak
Air leak
Airflow Inlet
Air leak
Air - gauge
Air - gauge
Air - gauge
Air - gauge
AIR SUPPLY TO GAUGEONLY WHEN PUSH BUTTON IS PRESSED
Pneumatic circuit modified with a push button ,so that,whenever the push button is pressed air will be supplied to the gauge and no air supply whenever the push button is realeased.
COST SAVING/GAUGE Rs = 17.20 /DAY FOR 55 GAUGES =950/DAY . SAVING /ANNUM = Rs2.85Lakhs .
Arrest air wastage when gaugwe is not in use.
Air wastage through the one mm hole in the air gauges when not in use
No. control valve for the air circuit
Wastage of compressed air through air gauges when not in use.
Air wastage is eliminated by closing the circuit(push button) after usage.
Scope for Horizontal Deployment - No off Places : 55
Kaizen Sustainanace Status:_ Reversible Irreversible 4
If Kaizen is Reversible -Standard to be Updated _ JH Std _TBM Std _Why-ok Std. _Set-up Std.
PUSH BUTTON
AIR FLOW INLET
AIR FLOW INLET
AIR LEAK
AIR LEAK
noza80
Lucas TVSKAIZEN IDEA SHEETKaizenCell CodePillarLoss No.Sl. No.Date Registered
Regn. No.NOZAKK580Dec-00
FIE DivisionCell:NOZZLEM/c. Desc.:
Bench MarkTwice/shiftKaizen StartJan-01
BEFORE IMPROVEMENTANALYSISTARGET0Kaizen finishJan-01
TEAM MEMBERS
At unloading station washing baskets collide with eachRaghupathy
otherSenthil kumar
Swaminathan
Transporter is not stopping if basket in unloading station
is not movedRESULTS & BENEFITS
P4QCDS
Limit switch is slipping from the basket
Minor stoppage loss eliminated
Limit switch lever width is less.
Mix-up of matched nozzle and needle eliminated
AFTER IMPROVEMENTIDEA
To increase limit switch contact area
ACTION TAKENCOST SAVING RS.
2Limit switch lever is modified.This Kaizen is
Reversible4Irreversible
If Reversible, to be included in
JH Standard
WHY OK Standard
TBM Standard
SETTING Standard
Number of HD Possiblenil
(Please see reverse side for details)
&L&"Arial,Regular"Prepared By:
At unloading station washing baskets collide with each other
At unloading station washing baskets are not colliding with each other
375
Lucas TVSKAIZEN IDEA SHEETKaizenCell CodePillarLoss No.Sl. No.Date Registered
Regn. No.WelQM73752/9/01
FIE DivisionCell:Sub-assy - WeldingM/c. Desc.:Projection welding
Bench Mark Per Month80Kaizen Start2/9/01
BEFORE IMPROVEMENTANALYSISTARGET0Kaizen finish2/28/01
TEAM MEMBERS
2Defective weldingK. SAMPATHK.KANNAN
K. GOVARTHAN
2Component moving during welding operationG.M.S. GOPINATH
S. NITHIYANANTHAN
2Component position shiftRESULTS & BENEFITS
PQ4CDS75
2No clamping of component
Sep-0075
2Provision of ball catch for loadingOct-0052
Nov-0022
Dec-004
6Jan-018
AFTER IMPROVEMENTIDEAFeb-010
Difficult to move with the help of the Ball Catcher.
ACTION TAKENCOST SAVING RS.19,200 Per Annum
2Introduced ball catch in the top electrodeThis Kaizen is
Reversible4Irreversible
If Reversible, to be included in
4JH Standard
WHY OK Standard
TBM Standard
SETTING Standard
Number of HD Possible
Page &P
&L&"Arial,Regular"Prepared By: Fil & Sol Team.
375
Rejection Trend.
Kaizen Done
MBD0000FA2E.bin
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 8SHUT DOWN LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
slurry
BPL LimitedB:ABZ:F: 0001
Alkaline Battery Division
EXCELL T P MIssue No: 2
Dept:Page: 1 of 1
Name:K.J.JayaprakashType of Problem*Kaizen No:ABK/688/2000
Pillar:PMA / B / CStart Date:6/15/00
Theme:To Eliminate EQ. Failure (1a)*A - Adjustment / Parts changeEnd Date:8/15/00
*B - No action *C - Setup / Trial
Machine / Line:Slurry Machine / LR 6 - 1
Problem Description:Gelling Agent & KOH Leaks From Wet cup Of Slurry Pump Which Causes Slurry
Dispensing Abnormality Resulting In Plunger Damage.
Bench Mark:4 Occ / MonthTarget:' Zero '
ANALYSIS
WHY ? 1 : The Clearance Between Plunger & SealWHY ? 4 : The Plunger Seals Are Used More Than Its
Increases.Life Time.
WHY ? 2 : The Plunger Surface Is With Scratch
Marks.
WHY ? 3 : The Zinc Particles Enter Between Plunger
And Seals.
IMPLEMENTATION
Idea:Counter Measure :
1. To Replace The Plunger Seals ( 3 No.s ) Regularly1. The Plunger Seals ( 3 No.s ) In All Pumps Replaced
In All Pumps On A Time Based MaintenanceOnce In 1.5 Mill Pcs Production Initially & Changed To
System To Prevent The Costly Plunger From WearingOnce In 3.5 Mill Pcs Production After Doing Condition
Out.Based Monitoring.
BEFORE KAIZENAFTER KAIZEN
Action:Action:
RESULTS GRAPHFOLLOW - UP
How to Maintain?1. By Changing All Plunger Seals
Once In 3.5 Mill Pcs production13-May
Irrespective Of Wearout Rate.15-May
16-Jun
Horizontal1. LR 6 - 227-Jul
Deployment in :2. LR 03 - 12-Aug
3. LR 03 - 220-Sep
14-Oct
Benefits:1. Plunger Replacement Is 'Zero' .20-Oct
2. OCV Rejection Reduced By4-Nov
250ppm.
Prepared By:M. SURESHChecked By :Approved By:
(Name)(Dept.Head)(Sub-Committee)
slurry
36659
36661
36693
36734
36740
36789
36813
36819
36834
cc
BPL LimitedB:ABZ:F: 0001
Alkaline Battery Division
EXCELL T P MIssue No: 2
Dept: CONSOLIDATED CANPage: 1 of 1
Name:Nataraj & S.M.ShrikanthType of Problem*Kaizen No:ABK / 674 / 2000
Pillar:PMA / B / CStart Date:1/20/01
Theme:TO Reduce Schedule Down Time*A - Adjustment / Parts changeEnd Date:1/25/01
Loss (8)*B - No action *C - Setup / Trial
Machine / Line:Pellet Insertor / LR 6 - 1
Problem Description:Sensor Position Shifts During Maintenance Activity.
Bench Mark:70 Mins / MonthTarget:' Zero '
ANALYSIS
WHY ? 1 : Sensor Position Changes During Sensor
Cleaning Process.
WHY ? 2 : Sensor Fixture Is Madeup Of 5 Pieces
And Tightened With 6 Screws.
IMPLEMENTATION
Idea:Counter Measure :
1. Minimise The Number Of Screws In The Existing1. 5 Piece Fixture Is Replaced With A Single Piece
Fixture.Fixture.
BEFORE KAIZENAFTER KAIZEN
Action:Action:
RESULTS GRAPHFOLLOW - UP
How to Maintain?1. Match Marking.
2. Checking Of Screw Tightness13-May
Once / 15 Days.15-May
16-Jun
Horizontal1. LR 6 - 2 Apr - 200127-Jul
Deployment in :2-Aug
20-Sep
14-Oct
Benefits:Production / Hr Increased To20-Oct
8790 Pcs.4-Nov
Prepared By:V. MANOJChecked By :Approved By:
(Name)(Dept.Head)(Sub-Committee)
K A I Z E N
cc
sep
BPL LimitedB:ABZ:F: 0001
Alkaline Battery Division
EXCELL T P MIssue No: 2
Dept: CELL ASSEMBLYPage: 1 of 1
Name:K. J. Jayaprakash.Type of Problem*Kaizen No:ABK / 780 / 2001
Pillar:QMA / B / CStart Date:1/10/01
Theme:To Reduce Low OCV Defects.*A - Adjustment / Parts changeEnd Date:2/8/01
*B - No action *C - Setup / Trial
Machine / Line:SEPERATOR / LR 6 - 1
Problem Description:Seperator Bottom Disc Getting Inserted In Slant Condition Causing Internal Shorting
Resulting In High, Low OCV Defects.
Bench Mark:550 ppmTarget:50 ppm
ANALYSIS
A - Seperator Bottomm Disc ( Formed ).5. The Vaccum Pressure At Inserting pin is More Than
B - Bottom Disc Transfer Guide.8.0 cm Hg.
C - Clearance Between Transfer Guide & Forming PinsWHY NOT OK ? :
WHY OK ? :1. Bottom Disc Is Getting Damaged During Transfer Due
1. Bottom Disc (A) Is Uniformly Formed (No Flatneass)To Damage At The Entrance Of Transfer Guide (B).
2. Bottom Disc Transfer Is Smooth With Transfer2. Out Of 18 Stations In 4 Stations Insertor Pin
Guide (B) Clearance Of 3.0 mm.Straightness Found More Than 0.06 mm.
3. The Main Seperator Sealing Is In Good Condition3. Insertor Bottom Guide Found With Biwax.
Such That It Does Not Unwind.
4.The Straightness Of Inserting Pin Is Within 0.02mm.
IMPLEMENTATION
Idea:Counter Measure :
1. To Change The Design Of The Bottom Transfer1.Bottom Transfer Guide With 2.5 mm Thickness Replaced
Guide With Less Thickness ( - 0.5 mm ) To AvoidInstead Of 3.0 mm.
Forming Pin Touching The Transfer Guide While2. Insertor Pins Leveling Done To Bring Back The
Retracting.Straightness Less Than 0.02 mm.
3. All Insertor Bottom Guides Cleaning Done With Toluine.
BEFORE KAIZENAFTER KAIZEN
Action:Action:
RESULTS GRAPHFOLLOW - UP
How to Maintain?1.By Cleaning Insertor Pins & Guides
Once In 1.5 Mill Pcs Prodn.13-May
2. By Having Online Control For Rejn.15-May
16-Jun
Horizontal1. LR 6 - 2 - Mar 200127-Jul
Deployment in :( For Cleaning / Hourly Monitoring )2-Aug
20-Sep
14-Oct
Benefits:1. Rejection Value Reduced By20-Oct
Rs 7500 / Month.4-Nov
2. Spare Cost Saving Rs 15000 / Yr.
Prepared By:M. SURESHChecked By :Approved By:
(Name)(Dept.Head)(Sub-Committee)
K A I Z E N
sep
K A I Z E N
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 10MOTION LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Operating Motion lossMix pockets kept away from the workstation and operator need to walk to take the mix pocket. (Walking distance upto 1 meter)3 secs per cycle1 sec per cycleMix pockets kept near the the workstation to reduce the walking and easy collection of mix pockets. (No walking)Machine : Gang press-3Operation : CuringBeforeAfter
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 11LINE ORGANISATION LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Organisation Loss Reduction
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Sheet1
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea :CHANGE THE DESIGN OF ALLEN KEY AND USE BOLT RUNNER FOR
TIME ON RACK TEETH BROACHING M/CTIGHTNING AND LOOSENING OF BOLTS(39 Nos.)
Problem / present StatusCounter measure :Bench mark1490 SEC.
Target700 SEC.
Start1/5/01
Kaizen Finish6/5/01
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :
BROACH ASSEMBLING AND DIS-
Analysis :Result :ASSEMBLING OF BOLTS
WHY: BOLTS LOOSENING AND TIGHTNING TIME ISBEFORE1490
HIGHAFTER700
:OPERATOR HAS TO OPEN AND CLOSE 39 BOLTS
WHILE CHANGE OVER
: ALLEN KEY DESIGN CHANGED AND BOLT RUNNER
PROVIDED ON LINEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea :CHANGE CHIP TRAY CLAMPING SYSTEM FROM HEX BOLTS TO
TIME ON RACK TEETH BROACHING M/CPIN TYPE LOCKING
Problem / present StatusCounter measure :Bench mark60 Secs.
Target10 Secs.
Start17/5/2001
Kaizen Finish17/5/2001
Team members :
R.BAJAJ
SATYAWAN
SAT PAL
RAMESH CHAND
Benefits :BEFORE60
NO NEED OF OPENING BOLTSAFTER10
Analysis :Result :TIME SAVED 50 Secs.
HIGH TIME FOR CHANGING THE CHIP TRAY ON
BROACHING M/C
WHY:
BECAUSE THE CHIP TRAY IS MOUNTED BY BOLTS
WHICH REQUIRES HIGH TIME FOR TIGHTNING ANDScope & plan for Horizontal Deployment :
RETIGHTNINGSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE THE SETUP TIMEIdea : PROVIDE A RATCHET AND SOCKET ON LINE TO REDUCE BOLT LOOSEN-
ON XLO CASE GEAR LINEING AND TIGHTENING TIME
Problem / present StatusCounter measure :Bench mark10 MINS
Target4 MINS
Start4.6.01
Kaizen Finish4.6.01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :BOLTS LOOSENING AND TIGHTENING
WHY BOLTS LOOSENING AND TIGHTENING TIME IS HIGHTIME REDUCED
: ALLEN KEY AND PIPE TAKES MORE TIME TO
LOOSEN & TIGHTEN THE BOLTS
: PROVIDE A RACHET & SOCKETScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE PLACE FOR KEEPING BROACH ON LINE
Problem / present Status : NON AVAIL-Counter measure : PLACE PROVIDED FORBench mark210 Secs.
ABILITY OF RESHARPENED BROACHKEEPING BROACH SET ON LINETarget120 Secs.
Start17/3/2001
Kaizen Finish20/3/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN DOWN TIME
Analysis :Result :FROM 210 SEC TO 120 SEC
THERE WAS NO FIXED PLACE ON LINE FOR BROACHREDUCTION IN DOWN TIME DUE TO NON-AVAILABILITY
SET (OF HORIZONTAL BROACHING M/C)OF RESHARPENED BROACH
BEFORE10
AFTER4
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE CHANGE-OVERIdea : PROVIDE SPL NUT & BOLT, TO AVOID USAGE OF ALLEN KEY FOR TIGHTENING
TIME ON XLO-IAND LOOSENING OF ALLEN BOLTS
Problem / present StatusCounter measure :Bench mark5 Mins.
Target1-Mins
Start4/6/01
Kaizen Finish8/6/01
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
REDUCTION IN CHANGE OVER
Analysis :Result :BY 4 MIN
WHY :
SPECIAL BOLT & NUT ARE REQUIREDCHANGE OVER TIME
- IT IS HARD TO LOOSEN AND TIGHTEN THE ALLENBEFORE210
BOLTAFTER120
- HAND TOOLS ARE REQUIRED. SO TO ELIMINATEScope & plan for Horizontal Deployment :
THIS PROVIDE SPECIAL BOLT & NUTSr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT
OVER TIME ON RACK TEETH BROACHINGREMOVAL OF TRAY SHOULD BE EASY
Problem / present StatusCounter measure :Bench mark310 Secs.
Target140 Secs.
Start15/5/2001
Kaizen Finish19/5/2001
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
TROLLEY REMOVAL AND
Analysis :Result :FIXING TIME REDUCED
WHY : CHANGE OVER ON BROACHING M/C TO BEBY 170 Secs.
REDUCED
: DUE TO HIGH CHANGEOVER TIME ON M/CBEFORE5
: OPERATOR HAS TO USE CHAIN PULLEY FORAFTER1
REMOVAL OF TRAY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : PROVIDE EYE HOLE
FOR BOLT LOOSENING / TIGHTENING
Problem / present StatusCounter measure :Bench mark220 Secs.
Target45 Secs.
Start1/12/00
Kaizen Finish3/12/00BEFORE310
AFTER140
Team members :
A.K. DASGUPTA
MANOJ SHARMA
R. BAJAJ
Benefits :
Analysis :Result :175 SEC TIME REDUCED FOR
WHY TAKES MORE TIME TO LOOSENING &CHANGEOVER
TIGHTENING OF BOLTS
FULL BOLTS HAVE TO BE REMOVED DUE TO
NO EYE HOLEScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE
COL SHAFT INJ. MOULDING M/COF MACHINE
Problem / present StatusCounter measure :Bench mark30 Mins.
HIGH C/O TIME ON COL. SHAFT INJ MOULDING M/CT-SLOTS PROVIDED ON M/C BED & UPPER CLAMPINGTarget23 Mins.
PLATE. NOW CLAMPING BY T-BOLTSStart16/4/2001
Kaizen Finish23/4/2001
Team members :
CHINTESH
PARMOD JAIN
JITENDER
Benefits :
SAVING IN C/O TIME
Analysis :Result :BY 7-MINS
THERE ARE TAPPED HOLES ON M/C BED & UPPERSAVING IN C/O TIME
PLATE FOR CLAMPING THE MOULD. THE THREADSBEFORE220
INSIDE THREE HOLES WASHED OUT. IF ONE BOLT ISAFTER45
SLIPPING WHILE TIGHTENING THEN OPERAOR TRY
TO USE OTHER HOLE OR BIG LENGTH BOLT
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER
PLATE
Problem / present StatusCounter measure :Bench mark20 Secs.
Target10 Secs.
Start19/12/2000
Kaizen Finish19/12/2000
Team members :
CHINTESH
PARMOD JAIN
JITENDER
RAKESH GARG
Benefits :
Analysis :Result :
WHY TAKE MORE TIME TO PUT RUNNER PLATE10 SEC TIME REDUCED FORBEFORE30
ON CAVITYCHANGEOVERAFTER23
NO CHAMFER ON RUNNER PLATE & ACTIVITY
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE
OF MATERIAL REMOVAL FROM HOOPERMOULDING MATERIAL OUT.
Problem / present StatusCounter measure :Bench mark8 Mins.
MATERIAL IN THE HOOPER WAS DRAINED OUT BYHOLE IS PROVIDED IN THE BOTTOM OF THE HOOPERTarget2 Mins.
OPERATING THE M/CWITH SHUTTER. NOW MATERIAL IS REMOVEDStart2/4/01
MANUALLYKaizen Finish2/4/01
Team members :
CHINTESH
KIRORI
SATYAWAN
Benefits :
NO WASTAGE OF MATERIAL
Analysis :Result :COST SAVING : Rs 1500/YEARBEFORE20
AFTER10
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO WELD WITH SCREWS TO AVOID USE OF ALLEN KEY WHILE LOOSENING
WHILE CHANGEOVER& TIGHTENING OF SCREWS
Problem / present StatusCounter measure :Bench mark3- Mins.
WHILE CHANGEOVER WASTAGE OF TIME IN LOOSEN-T-HANDLES ARE WELDED WITH SCREWSTarget1 Min
ING & TIGHTENING OF CLAMPING SCREWS OF DOGS,Start24/4/2001
FOR MOULD SETTING OF INJECTION MOULDINGKaizen Finish27/4/2001
MACHINES
Team members :
SATISH GUPTA
HARISH PAHUJA
CHINTESH
Benefits :
Analysis :Result :CHANGEOVER TIME REDUCTION
ALLEN KEYS WERE BEING USED IN LOOSENING &REDUCTION IN DOWNTIME WHILE CHANGEOVER2 MIN / CHANGEOVERBEFORE8
TIGHTENING OF DOG SCREWSAFTER2
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : TO PROVIDE FIXED PLACE FOR PARTICULAR MODEL FIXTURE PART
TIME ON INJ. MOULDING MACHINENEAR TO OPERATOR
Problem / present StatusCounter measure :Bench mark3 Mins
WASTAGE OF TIME WHILE CHANGEOVER ON INJ.FIXED PLACE PROVIDED FOR FIXTURES OF DIFFERENTTarget0
MOULDING M/C.MODELS WITH THE M/CStart12/4/01
Kaizen Finish15/4/2001
Team members :
CHINTESH
SATYAWAN
LAXMAN
Benefits :
OPERATIVES TIME IN SEARCHING &
Analysis :Result : NO WASTAGE OF TIME IN SEARCH-BRINGING REQUIRED MODEL
FIXTURE OF DIFFERENT MODELS ARE PLACED ON AING OUT FIXTURE PARTS OF PARTICULAR MODELFIXTURE PART SAVED
TABLE OUTSIDE THE LINE. WASTAGE OF TIME IN: OPERATIVE'S TIME OF BRINGING FIXTUREBEFORE3
SERARCHING OUT FIXTURE OF PARTICULAR MODELPARTS FROM TABLE OUTSIDE THE LINE, SAVEDAFTER1
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : Provide special T-allen key
over Time
Problem / present StatusCounter measure :Bench mark20'
Target16'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 4 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
BEFORE3
Scope & Plan for Horizontal DeploymentAFTER0
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : REDUCE LENGTH OF BOLT
Problem / present StatusCounter measure :Bench mark30'
Target25'
Start20/05/01
Kaizen Finish20/05/01
Team members :
Mr. Pramod Jain
Mr. Vipinder
Benefits :
Bolt's size : M8*25Bolt's size : M8*15
Analysis :Result :Changeover time reduced by 5'
No. of such Changeover parts = 3
No. of Bolts/ parts = 2
Total Bolts = 6
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Before20
SonaAfter16
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Problem / present StatusCounter measure :Bench mark25'
Target18'
Start22/05/01
Kaizen Finish22/05/01
Team members :
Mr. Pramod Jain
Mr. Tara Chand
Benefits :
Analysis :Result :+Changeover Time reduced by 7 minutes
Only one hand was being used for screwing/unscrewing the bolt that result in more time and fatigue+Operator's fatigue reduced.
Scope & Plan for Horizontal Deployment
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Kaizen Theme : TO REDUCE SET UP TIMEIdea : COMMON MOULD TO BE USED BY REPLACING PARTS ONLY
ON C-67 INJECTION MOULDING M/C
Problem / present StatusCounter measure :Bench mark1480 Secs.
Target415 Secs.
Start10/9/00
Kaizen Finish3/10/00
Team members :
RAKESH GARG
G.R. YADAV
MANOJ SHARMA
S.K.GUPTA
CHINTESHBEFORE1480
MOULD WAS REPLACED FOR SET UPONLY REST BLOCKS ARE CHANGED FOR SET UPAFTER415
Benefits :
Analysis :Result :OPERATOR'S FATIGUE REDUCED
SET UP TIME IS MORESET UP TIME REDUCED
BY 1065 Secs.
WHY:Scope & Plan for Horizontal Deployment
BECAUSE DIFFERENT MOULDS ARE USED FORSr.No.M/c No.Target Dt.ResponsibilityStatus
DIFFERENT MODELS
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : REDUCE NO. OF BOLTS & NO. OF TURN FOR TIGHTENING OF REST
REPLACING THE BLOCKBLOCK
Problem / present StatusCounter measure :Bench mark5 MIN.
Target2 MIN.
Start10/6/01
Kaizen Finish13/6/2001
Team members :
RAKES GARGBEFORE5
SATISH GUPTAAFTER2
Benefits :
Result :C/O TIME REDUCED BY 3 MIN.
Analysis :
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : USE ONLY ONE OPERATOR INSTEAD OF TWO ON CASE GEAR LINE
OF CASE GEAR MACHINING LINE
Problem / present StatusCounter measure :Bench mark2
Target1
Start27/05/2001
Kaizen Finish29/5/2001
Team members :
MANOJ SHARMA
GR YADAV
V SETHI
R BAJAJ
CHINTESH
Benefits :
SAVED ONE OPERATOR PER SHIFT
Analysis :Result :
WHY : WHY SHOULD WE PUT ONLY ONE OPERATOR
IN PLACE OF TWO OPERATORSSAVING IN MANPOWER PER SHIFT
BEFORE2
WE CAN PUT TUBE PRESSING M/C ON ASSY LINEAFTER1
BECAUSE ASSY LINE OPERATOR HAS ENOUGH
TIME TO DO THIS OPERATIONScope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sona
Sona Koyo Steering Systems Ltd.KAIZEN IDEA - SHEET
Idea : CHANGE LINE LAYOUT
ON COLL. COLUMN LINE
Problem / present StatusCounter measure :Bench mark40 Pcs/Hr
Target46 Pc/Hr
Start28/8/2000
Kaizen Finish31/8/2000
Team members :
Benefits :
Analysis :Result :PRODUCTION PER HOUR
WHY : WHY LESS PRODUCTION ON LINEINCREASED
ALL M/Cs STOP DUE TO B/DOWN ON ANY M/CPRODUCTION PER HOUR
BEFORE40
AFTER46
Scope & plan for Horizontal Deployment :
Sr.No.M/c No.Target Dt.ResponsibilityStatus
Sheet1
1
Sheet2
Sheet3
TIME IN MIN.
20
16
Time in Minute
Changeover Time at Chamfering Station
Time in Minute
Time in Minute
5
2
TIME(IN MIN.)
REDUCTION IN C/O
40
46
* PLAIN HOLES WERE PRESENT IN THE BLOCK DUE TO WHICH FULL TIGHTENING OF BOLTS WAS REQUIRED
* PLAIN HOLES OF THE BLOCK MODIFIED TO EYES HOLES AS SHOWN, BY WHICH NO. OF TURNS OF HOLES WERE REDUCED
R/M
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
TUBE PRESSING
TROLLEY
1
2
F/M
R/M
2
XLO-1
XLO-2
XLO-3
WASHING M/C
GAUGE TABLE
F/M
BEFORE
AFTER
2
1
MBD0021B15E.xls
MBD0021C9A0.xls
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 13MEASUREMENT & ADJUSTMENT LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Adjustment Downtime Loss Reduction
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
LOSS - 14ENERGY LOSS
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
VVVVVa
Sheet2
PU : CENTRAL PUKAIZEN SHEET
Kaizen Theme :Idea : TO CONVERT WATER COOLED PACKAGE A/C INTO USER FRIENDLY
TO REDUCE POWER CONSUMPTIONAIR COOLED PACKAGE A/C.
Problem / present Status:Counter Measure:Bench Mark4.5 KW
1ST FL. AD. EDP DPET.WATER COOLED A/C SYSTEM.USED.PUMP & COOLER TOWER ELEIMINATED.TargetZero
Start01-Mar-01
Kaizen Finish15-Apr-01
Team Members :
1.S.S.DIGHE
2.U.S.JOSHI
3.M.V.AGASHE
Benefits:
KW OF WATER PUMP & COOLING TOWER FAN= 4.5 KW
= 4.5 KW X 0.80 ( LOAD FACTOR ) 24 HRS.
= 86.4 UNITS / DAY
Analysis :Result := 31536 UINITS / YEARS ( 365 DAYS)
AS A SYSTEM IS WATER COOLED, IT IS REQUIRED WATER PUMP, COOLING TOWER AND WATER. ALSO SYSTEM IS VERY OLD (15 YESRS) HENCE NOT VERY EFFICIENT.ELIMINATED 5 HP CONDENSOR WATER PUMP AND 1 HP COOLING TOWER FAN AND SAVEED IN ELECTRICAL POWER CONSUMPTION.= Rs.133081 ( Rs.4.22 / KWH )
Scope & Plan for Horizontal deployment :
Sr.NoM/c. NoTarget dtResponsibilityStatus
WATER PUMP
COOLING TOWER
CONDENSOR
A/C UNIT
A/C UNIT
CONDENSOR
WATER COOLED A/C SYSTEM
AIR COOLED A/C SYSTEM
ELIMINATED 3000 LITERS/DAY WATER AND SAVED MUNICIPAL COSTWATER.
COST OF INSTALLATION @ Rs. 85000
USER FRIENDLY OPERATION
PAY BACK WITHIN ONE YEAR
LOSSENERGY
Sheet3
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Example of Power consumption reduction
TPM Club IndiaFocussed Improvement Pillar Confederation of Indian Industry
Carton Box for SealingMotor for driving the BeltLimit Switch for starting the motor
Empty
KAIZEN IDEA SHEETBPL PTI LIMITED
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
To prevent the breakage of locknut for shankTo avoid breakage of locknut
DepartmentBattery Can
Problem / Present Status :Counter Measure :
LocationR20 Impact press. M/c no. 5
Locknut getting cracked at the collet holding sideThe collet size was reduced from 66.5mm to
ofter sometimeto 63.0mmBench Mark2 locknuts broken on 26.12.99 & 12.01.2000
TargetZero breakdowns
Kaizen Regn. No.214
Kaizen Start04.02.2000
Kaizen Finish15.02.2000
Team Members :
C K JitheshNaveen
Analysis :Result :PapannaKumar
1. The collet for holding the shank was more inNo breakage of shank holding locknut
lengthBenefits :
Zero breakdowns due to breakage of shank holding nut
2. Because of which when locknut was being
tightened, the collet being more in length
prevented the shank from being fully tightened.
3 As the shank was often getting loosened
it was again being tightened every day at the
start of the shift.
Scope & Plan for Horizontal Deployment
4. Due to the above the locknut had cracked at theSl. No.M/c. No.Target Dt.ResponsibilityStatus
collet holding side. (Refer sketch)
KAIZEN IDEA SHEETBPL PTI LIMITED
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
Avoid failure of purspring frequently.Provide a stripper inspite of pursprings.
DepartmentTool Room
Problem / Present Status :Counter Measure :
LocationR6-Bottom plate press
Almost for every time tool is loaded, purspringsProvide stripper with spring loaded.
were to be changed and also during operationBench MarkPursprings to eject strip
it used to fail & cause damage to the tool.
TargetAvoid failure of pursprings
Kaizen Regn. No.TR/02/00
Kaizen Start21.03.2000
Kaizen Finish22.05.2000
Team Members :
Abhinandan
Analysis :Result :Math
Deepak Naik
Purspring when fitted on to the punch, if it is littleBetter performance.Benefits :
loose it used to get loosened during purspring1. Easy in assembling.
and some springs used to break, because it can2. Reduce timeloss for resetting tool and
not sustain more compression than that is requiredfitting purspring during operation.
to eject the strip.3. No consumption of purspring.
4. Better performance.
Scope & Plan for Horizontal Deployment
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
120/8/2kAbhinandan
225/9/2k
319/10/2k
424/11/2k
KAIZEN IDEA SHEETBPL PTI LIMITED
DRY CELL DIVISION.
Believe in the BestMADDUR.
Kaizen Theme :Idea :
Avoid complication in machining and manufacturingRedesign R20 jacket forming shaft from two pieces to single piece.
cost reduction.
DepartmentTool Room
Problem / Present Status :Counter Measure :
Very much difficulty in manufacturing the formingMake a forming shaft single piece.LocationR20 Body maker
shaft, more machining time.
Bench MarkMore cost and difficulty in machining
TargetReduction in cost, Better performances
Kaizen Regn. No.TR/01/00
Kaizen Start15.04.2000
Kaizen Finish25.06.2000
Team Members :
Jayarajan
Analysis :Result :
1. For forming the jacket the forming shaft notBenefits :
necessarily be split to make the jacket go into the1. Easy machining .
shaft.2. Better performances.
3. Reduction in manufacturing cost.
2. It can be a single piece with 0.2 lesser diameter
than that of the jacket.
Sl. No.M/c. No.Target Dt.ResponsibilityStatus
KAIZEN IDEA SHEETBPL PTI