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


LOSS - 2SETUP & ADJUSTMENT LOSS




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


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


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


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


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 :


Sona


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


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



Sona


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


Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT

OVER TIME ON RACK TEETH BROACHINGREMOVAL OF TRAY SHOULD BE EASY


Target140 Secs.

Start15/5/2001


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



Sona


Idea : PROVIDE EYE HOLE

FOR BOLT LOOSENING / TIGHTENING


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 :


Sona


Idea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE

COL SHAFT INJ. MOULDING M/COF MACHINE


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


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



Sona


Idea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER

PLATE


Target10 Secs.

Start19/12/2000


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



Sona


Idea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE

OF MATERIAL REMOVAL FROM HOOPERMOULDING MATERIAL OUT.


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



Sona


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



Sona


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


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



Sona


Idea : Provide special T-allen key

over Time

Problem / present StatusCounter measure :Bench mark20'

Target16'

Start20/05/01


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


Sona


Idea : REDUCE LENGTH OF BOLT


Target25'

Start20/05/01


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


Before20

SonaAfter16



Target18'

Start22/05/01


Team members :

Mr. Pramod Jain

Mr. Tara Chand

Benefits :





Sona


Kaizen Theme : TO REDUCE SET UP TIMEIdea : COMMON MOULD TO BE USED BY REPLACING PARTS ONLY

ON C-67 INJECTION MOULDING M/C


Target415 Secs.

Start10/9/00


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


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


Team members :

RAKES GARGBEFORE5

SATISH GUPTAAFTER2

Benefits :

Result :C/O TIME REDUCED BY 3 MIN.

Analysis :



Sona


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


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 :


Sona


Idea : CHANGE LINE LAYOUT

ON COLL. COLUMN LINE

Problem / present StatusCounter measure :Bench mark40 Pcs/Hr

Target46 Pc/Hr

Start28/8/2000


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



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


LOSS - 3TOOL & JIG CHANGE LOSS


Sheet1

Sona


Kaizen Theme :TO REDUCE HIGH C/OVERIdea :CHANGE THE DESIGN OF ALLEN KEY AND USE BOLT RUNNER FOR



Target700 SEC.

Start1/5/01

Kaizen Finish6/5/01

Team members :

R.BAJAJ

SATYAWAN

SAT PAL

RAMESH CHAND

Benefits :




HIGHAFTER700


WHILE CHANGE OVER




Sona


Kaizen Theme :TO REDUCE CHANGE OVERIdea :CHANGE CHIP TRAY CLAMPING SYSTEM FROM HEX BOLTS TO



Target10 Secs.

Start17/5/2001


Team members :

R.BAJAJ

SATYAWAN

SAT PAL

RAMESH CHAND

Benefits :BEFORE60




BROACHING M/C

WHY:




Sona





Target4 MINS

Start4.6.01

Kaizen Finish4.6.01

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :







Sona


Kaizen Theme : REDUCTION IN DOWN TIMEIdea : TO PROVIDE PLACE FOR KEEPING BROACH ON LINE



Start17/3/2001


Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :





BEFORE10

AFTER4



Sona





Target1-Mins

Start4/6/01

Kaizen Finish8/6/01

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :



WHY :



BOLTAFTER120



Sona


Kaizen Theme : TO REDUCE HIGH CHANGE-Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT



Target140 Secs.

Start15/5/2001


Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :

TROLLEY REMOVAL AND



REDUCED



REMOVAL OF TRAY



Sona


Kaizen Theme : REDUCTION OF NO. OF TURNSIdea : PROVIDE EYE HOLE



Target45 Secs.

Start1/12/00


AFTER140

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :



TIGHTENING OF BOLTS




Sona


Kaizen Theme : TO REDUCE C/O TIME ONIdea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE






Team members :

CHINTESH

PARMOD JAIN

JITENDER

Benefits :

SAVING IN C/O TIME









Sona


Kaizen Theme : QUICK FITMENT OF RUNNERIdea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER

PLATE


Target10 Secs.

Start19/12/2000


Team members :

CHINTESH

PARMOD JAIN

JITENDER

RAKESH GARG

Benefits :

Analysis :Result :






Sona


Kaizen Theme : TO REDUCE MINOR STOPPAGEIdea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE






Team members :

CHINTESH

KIRORI

SATYAWAN

Benefits :



AFTER10



Sona


Kaizen Theme : TO REDUCE DOWNTIMEIdea : TO WELD WITH SCREWS TO AVOID USE OF ALLEN KEY WHILE LOOSENING






MACHINES

Team members :

SATISH GUPTA

HARISH PAHUJA

CHINTESH

Benefits :






Sona


Kaizen Theme : TO REDUCE CHANGEOVERIdea : TO PROVIDE FIXED PLACE FOR PARTICULAR MODEL FIXTURE PART






Team members :

CHINTESH

SATYAWAN

LAXMAN

Benefits :








Sona


Kaizen Theme : Reduce ChangeIdea : Provide special T-allen key

over Time


Target16'

Start20/05/01


Team members :

Mr. Pramod Jain

Mr. Tara Chand

Benefits :



BEFORE3



Sona


Kaizen Theme : Reduce Change over TimeIdea : REDUCE LENGTH OF BOLT


Target25'

Start20/05/01


Team members :

Mr. Pramod Jain

Mr. Vipinder

Benefits :





Total Bolts = 6



Before20

SonaAfter16


Kaizen Theme : Reduce Change over TimeIdea : Provide sppecial T-allen key


Target18'

Start22/05/01


Team members :

Mr. Pramod Jain

Mr. Tara Chand

Benefits :





Sona





Target415 Secs.

Start10/9/00


Team members :

RAKESH GARG

G.R. YADAV

MANOJ SHARMA

S.K.GUPTA

CHINTESHBEFORE1480


Benefits :



BY 1065 Secs.



DIFFERENT MODELS

Sona


Kaizen Theme :TO REDUCE C/O TIME OFIdea : REDUCE NO. OF BOLTS & NO. OF TURN FOR TIGHTENING OF REST



Target2 MIN.

Start10/6/01


Team members :

RAKES GARGBEFORE5

SATISH GUPTAAFTER2

Benefits :


Analysis :



Sona


Kaizen Theme : TO INCREASE PRODUCTIONIdea : USE ONLY ONE OPERATOR INSTEAD OF TWO ON CASE GEAR LINE



Target1

Start27/05/2001


Team members :

MANOJ SHARMA

GR YADAV

V SETHI

R BAJAJ

CHINTESH

Benefits :


Analysis :Result :



BEFORE2





Sona


Kaizen Theme : TO IMPROVE EFFICIENCYIdea : CHANGE LINE LAYOUT



Target46 Pc/Hr

Start28/8/2000


Team members :

Benefits :




BEFORE40

AFTER46



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


Time in Minute

Time in Minute

0

0

5

2

TIME(IN MIN.)

REDUCTION IN C/O

40

46



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


LOSS - 4START UP LOSS



LOSS - 5MINOR STOPPAGE & IDLING LOSS


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


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)


Example of Minor Stoppage and Idling Loss


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.


Sl. No.M/c. No.Target Dt.ResponsibilityStatus

Not applicable.

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To reduce the blackmix spillage in the lower spindle.To increase dia of lower punch.

DepartmentR6


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.




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



Not applicable.

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To reduce the Black mix spillage below roll crusher unit.To scrap the Black Mix & make it fall in the hopper.

DepartmentR6


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




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.



Not applicable

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To reduce cleaning time (scheduled downtime) of tamping.To eliminate manual jig removing.

DepartmentR6


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




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.



Not applicable.

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To eliminate equipment failure of TampingTo avoid the dust going inside the bearing.

DepartmentR6 Assembly.


Seizure of bearing 6203 RS causing jerkyProtective cover provided to the 6203 bearing.LocationTamping

motion of conveyor

Bench Mark6 Hours / 2 time/year.

Target0




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/-.



Not applicable.

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To eliminate the adjustment loss.To provide lock nut.

DepartmentR6


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.)




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



Done

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To reduced the equipment failure due to break wire cut.To avoid the break wire cut.

DepartmentR6


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 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.



Done

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To Eliminate the Equipment failure due to cutter breakage.To avoid the sleve going down.

DepartmentR6 Assembly


Separator sleeve loosen and dropping on the cutter.Provide a circlip to the sleve.LocationSeperator

Bench Mark3 Times, 80 mintes.

TargetZero.




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



1230.09.00Nagaraj1 to be done.

2115.10.00Nagaraj4 to be done.

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To eleminates the failure of B28 Belt.To provide Bigger Dia of pully.



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.



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



Done

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



To eliminate the failure of photo sensor.To avoid the failure of sensor.



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.




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



Done

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



Department


Location

Bench Mark

Target

Kaizen Regn. No.

Kaizen Start Date

Kaizen Finish Date

Team Members :

Analysis :Result :

Benefits :



Done

BPL PTI LIMITED

KAIZEN IDEA SHEET

DRY CELL DIVISION.



Department


Location

Bench Mark

Target

Kaizen Regn. No.

Kaizen Start Date

Kaizen Finish Date

Team Members :

Analysis :Result :

Benefits :



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


LOSS - 6REDUCED SPEED LOSS



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


LOSS - 7DEFECT & REWORK LOSS


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


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



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


LOSS - 8SHUT DOWN LOSS


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




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


1. Minimise The Number Of Screws In The Existing1. 5 Piece Fixture Is Replaced With A Single Piece

Fixture.Fixture.


Action:Action:


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:


K A I Z E N

cc

sep




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


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.


Action:Action:


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:


K A I Z E N

sep

K A I Z E N


LOSS - 10MOTION LOSS


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


LOSS - 11LINE ORGANISATION LOSS


Example of Organisation Loss Reduction


Sheet1

Sona


Idea :CHANGE THE DESIGN OF ALLEN KEY AND USE BOLT RUNNER FOR



Target700 SEC.

Start1/5/01

Kaizen Finish6/5/01

Team members :

R.BAJAJ

SATYAWAN

SAT PAL

RAMESH CHAND

Benefits :




HIGHAFTER700


WHILE CHANGE OVER




Sona


Idea :CHANGE CHIP TRAY CLAMPING SYSTEM FROM HEX BOLTS TO



Target10 Secs.

Start17/5/2001


Team members :

R.BAJAJ

SATYAWAN

SAT PAL

RAMESH CHAND

Benefits :BEFORE60




BROACHING M/C

WHY:




Sona





Target4 MINS

Start4.6.01

Kaizen Finish4.6.01

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :







Sona


Idea : TO PROVIDE PLACE FOR KEEPING BROACH ON LINE



Start17/3/2001


Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :





BEFORE10

AFTER4



Sona





Target1-Mins

Start4/6/01

Kaizen Finish8/6/01

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :



WHY :



BOLTAFTER120



Sona


Idea : PUT A TROLLEY UNDER CHIP AND COOLANT TRAY SO THAT



Target140 Secs.

Start15/5/2001


Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :

TROLLEY REMOVAL AND



REDUCED



REMOVAL OF TRAY



Sona


Idea : PROVIDE EYE HOLE



Target45 Secs.

Start1/12/00


AFTER140

Team members :

A.K. DASGUPTA

MANOJ SHARMA

R. BAJAJ

Benefits :



TIGHTENING OF BOLTS




Sona


Idea : TO PROVIDE T-SLOTS ON THE MACHINE BED & UPPER CLAMPING PLATE






Team members :

CHINTESH

PARMOD JAIN

JITENDER

Benefits :

SAVING IN C/O TIME









Sona


Idea : MODIFICATION OF RUNNER PLATE BY PROVIDING CHAMFER

PLATE


Target10 Secs.

Start19/12/2000


Team members :

CHINTESH

PARMOD JAIN

JITENDER

RAKESH GARG

Benefits :

Analysis :Result :






Sona


Idea : TO PROVIDE A HOLE IN THE BOTTOM OF THE HOOPER, TO TAKE THE






Team members :

CHINTESH

KIRORI

SATYAWAN

Benefits :



AFTER10



Sona


Idea : TO WELD WITH SCREWS TO AVOID USE OF ALLEN KEY WHILE LOOSENING






MACHINES

Team members :

SATISH GUPTA

HARISH PAHUJA

CHINTESH

Benefits :






Sona


Idea : TO PROVIDE FIXED PLACE FOR PARTICULAR MODEL FIXTURE PART






Team members :

CHINTESH

SATYAWAN

LAXMAN

Benefits :








Sona


Idea : Provide special T-allen key

over Time


Target16'

Start20/05/01


Team members :

Mr. Pramod Jain

Mr. Tara Chand

Benefits :



BEFORE3



Sona


Idea : REDUCE LENGTH OF BOLT


Target25'

Start20/05/01


Team members :

Mr. Pramod Jain

Mr. Vipinder

Benefits :





Total Bolts = 6



Before20

SonaAfter16



Target18'

Start22/05/01


Team members :

Mr. Pramod Jain

Mr. Tara Chand

Benefits :





Sona





Target415 Secs.

Start10/9/00


Team members :

RAKESH GARG

G.R. YADAV

MANOJ SHARMA

S.K.GUPTA

CHINTESHBEFORE1480


Benefits :



BY 1065 Secs.



DIFFERENT MODELS

Sona


Idea : REDUCE NO. OF BOLTS & NO. OF TURN FOR TIGHTENING OF REST



Target2 MIN.

Start10/6/01


Team members :

RAKES GARGBEFORE5

SATISH GUPTAAFTER2

Benefits :


Analysis :



Sona


Idea : USE ONLY ONE OPERATOR INSTEAD OF TWO ON CASE GEAR LINE



Target1

Start27/05/2001


Team members :

MANOJ SHARMA

GR YADAV

V SETHI

R BAJAJ

CHINTESH

Benefits :


Analysis :Result :



BEFORE2





Sona


Idea : CHANGE LINE LAYOUT



Target46 Pc/Hr

Start28/8/2000


Team members :

Benefits :




BEFORE40

AFTER46



Sheet1

1

Sheet2

Sheet3

TIME IN MIN.

20

16

Time in Minute


Time in Minute

Time in Minute

5

2

TIME(IN MIN.)

REDUCTION IN C/O

40

46



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


LOSS - 13MEASUREMENT & ADJUSTMENT LOSS


Example of Adjustment Downtime Loss Reduction


LOSS - 14ENERGY LOSS


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


Example of Power consumption reduction


Carton Box for SealingMotor for driving the BeltLimit Switch for starting the motor

Empty

KAIZEN IDEA SHEETBPL PTI LIMITED

DRY CELL DIVISION.



To prevent the breakage of locknut for shankTo avoid breakage of locknut

DepartmentBattery Can


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.


4. Due to the above the locknut had cracked at theSl. No.M/c. No.Target Dt.ResponsibilityStatus

collet holding side. (Refer sketch)


DRY CELL DIVISION.



Avoid failure of purspring frequently.Provide a stripper inspite of pursprings.

DepartmentTool Room


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



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.



120/8/2kAbhinandan

225/9/2k

319/10/2k

424/11/2k


DRY CELL DIVISION.



Avoid complication in machining and manufacturingRedesign R20 jacket forming shaft from two pieces to single piece.

cost reduction.

DepartmentTool Room


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



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.


KAIZEN IDEA SHEETBPL PTI

02-Kobetsu Kaizen

Documents

kaizen sheetcell

kaizen finishnovember

kaizen finishmar

assembly time

time reductionsheet1pu

time loss

various washers

kaizen idea sheetscope