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A small award winning Presentation....from M/S Perfect Industries, C65,Focal Point .Ludhiana..India--Mob no: -+91 75083-37007.Best Kaizen in New Product Design-------Thanks to the honorable JUdgES......
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Date:-24/12/13Presentation by:- Baldeep Singh Prepared by:- Amandeep Singh
We are manufacturing automobile fasteners & special items as per customer requirement.
An ISO-TS 2001:16949 Company
Before After
Comments:1)
1. Burr observed after trimming process
2. Burr found more sharp after heat treatment.
3.Customer failed the screws due to burr
4. Screws are used in aluminum compressors after tightening the screw , burr damaged the surface it increase the risk of leakage of compressor.
Comments :- 1. Quality Improved no burr observed with new designed tooling .
2. No need to trim hex at another machine.
3.Production increased.
4.Party approved the samples.
Benefits : cost pro quality time money
KAIZEN PART NAME :- Hex Screw M5×25
IDEA EXECUTE BY :- Design & Dev. Dept.
Title:- Improved Tooling Design Company name :-Perfect Industries (India)
Tooling Design by: :- Mr. Maninder Singh
KAIZEN SAVING
3
TITLE:- Improved tooling design
PART NAME :- Hex screws M5×25
Description Before After
Daily Production
100 ×8=16800 23120 ×8= 24960
Machines & tooling used for
Bolt header + trimming machine
Multi Station Bolt Forging machine
Electricity Consumed (per day)
.746×3=2.23 units per hour 2.23units×8 hours=17.90 units17.90×6=rs107/
Machine Process removed.
0 cost
Manpower Used
2 nos. 1 nos
Man hours Used
16 hours per day
8 hours per day
Rejection 5% 0.02%
Material Saved- .003gram(material saved from
one piece) .003×rs70=5250/Trimming tooling saved=1400/Electricity Saved- Daily 17.90 units saved (17 .90×rs 6.00=107/)Manpower Saved Rs.194x 7 =Rs.1358/Rejection decreased from 5% to .02%=9840/TOTAL SAVINGS FROM A LOT OF 1 LAC PIECES= 5250+1400+107+1358+9840=17955
KAIZEN INVESTEMENT Skilled Operator salary =2800/7 daysTooling =Rs.18000/ PAY BACK TIME – 1 .5 daysBENEFITS1. Customer Satisfaction & zero complaint2. QUALITY IMPROVED3. PRODUCTIVITY INCREASE 4. LESS MANPOWER 5. MACHINE PROCESS SAVED
HORIZONTAL DEPLOYMENT- YES