Cultural Change in AMM Factory - Alfa Laval India

Lean Kaizen Mela 2013

5S… Cultural change in AMM factory.

What is it?5S is one of the cornerstones of Lean

Basis of a visual factory Fundamental to Total Productive Maintenance

Sort

Set

Shine

Standardise

Sustain

“Lean is doing the right thing at right time, in right quality and right quantity with using minimum resources.”

Messy Factory 5 S Manufacturing Laboratory


A global company…

Alfa Laval is a leading global provider of specialized products and engineered solutions. Creating the best heat transfer, separation and fluid handling technologies in the world for a 130 years, Alfa Laval's products and solutions are used in such areas as food and water supply, energy, environmental protection and pharmaceuticals.


We serve most industries…

BiofuelsBiotech and pharmaceutical

ChemicalsCrude oil refinery

Engine and transportFluid power

Food and beverages HVAC

Industrial fermentation Latex

Machinery

Marine and dieselMetal workingMining and mineral processingOil and gas Power Pulp and paperRefrigeration and air-conditioningSemiconductor systemsSteel and coke oven gasSugarWastewater treatment


AMM Product Folio…

We are specialized in CIP SOLUTIONS (CIP200,CIP400,CIP800,CIP1800,CIP2800)

CLARA MODULES (CLARA 15, CLARA 20, CLARA 80, CLARA 200, CLARA 250)

BREW (80,BREW 250,BREW 301)

PX (PX30,PX55,PX65,AFPX810)

MIXERS (MX 60,MX80,MX90,MX100)

STERILISERS

PASTURISERS & PREHEATERS

ALDOX & CARBOBLEND,

VISCOLINE (VLA/VLM/VLC)


CIP modules & mixers

CIP MODULE

MIXER MODULE


Sterilizers & Aldox and Carboblend

Sterilizers

Aldox and Carboblend


Separator Modules…

CLARA 20 MODULE

CLARA 80 MODULECLARA 200 MODULE

MBPX 810 MODULE

PX MODULE BREW MODULE


Vision!! Operations India is the 2nd manufacturing region, by 2013 the first in establishing the ALPS to achieve World Class Performance

5S is the core of the system.

Objective!! 5S Implementation through

Cultural Change.


Journey started…in Nov 2010


Methodology…

Awareness & Training Workshops Zones

FormationDaily 10 min 5S

Weekly 1 hour 5S

Internal weekly Audit

Gap Analysis Action Implementation Reward & Recognition


Working zones…


Gap Analysis…

13

Before Kaizen After Kaizen

Problem Action Result

Unsafe gang way and unwanted material lying on

shop floor

Unwanted material removed and Place For Everything And Every useful

thing in Its Place

Safe gang way for manual movement no unwanted material

on shop floor

Kaizen Improvement

14



While operating corrugation m/c one extra man needed for start

& stop m/c & also wasting extra time & motion

By fixing remote switch for corrugation m/c

Using remote switch only one man operating m/c which saving time man

power & motion

Kaizen Improvement

15



To much time to search the tools like

grinders,hammers,faceshield

Systematic arrangement done As shown

Kaizen Improvement

16

After Kaizen


To much time to search the tools like

grinders,hammers,faceshield

Systematic arrangement done As shown

Kaizen Improvement

After Kaizen

17


Problem Action ResultHeavy water spillage on shop

floor during testingDischarge sump fabricated As shown, hoses connected to drainage

directly.

Kaizen Improvement24/08/2012 OWNER:-S CHOUGULE, S KAMBALE

18



Dust & burr goes on face because so much gape between face & shield from downside also

shield goes upWhen operator saw down

By making changes on unbreakable shield fix downside

guard & also fix ribbon to downside guard

Face shield proper fitted so no dust & burr goes on face also extra ribbon fitted to new down guard because of this face shield not

moving from face

Kaizen Improvement OWNER:-Mahendra Chougule21/01/2013

19


Problem Action ResultFor VLC,VLM jobs no proper

arrangement for testing, grinding flaring, assembly ,pickling &

transporting which occurs scratch mark, wastage of time & bad quality of

jobs

By making multipurpose trolley By using of trolley easy for testing, grinding flaring, assembly ,pickling & transporting which reduced wastage of time & good quality of jobs

because no scratch mark found on jobs

Kaizen Improvement

20

After Kaizen


VLA mala foods one job needs six bends & twelve weld joint to

one couple

By bending a pipe saving cost & manpower

By bending a pipe saving six bends & twelve weld joint to one couple. we are

making three couple like this which save manpower welding joints & also good

looking

Kaizen Improvement

21


Problem Action ResultNo Specific arrangement for storage of

CIP200L Tank.Tanks getting scratch mark & also

getting damagedNot safe for handling & travelling

By making a fixture By making a fixture reduces wastage of place also improve in quality because not tanks not getting

damaged & not found any scratch mark on itSafe for handling & travelling

Kaizen Improvement

22



Hand injury occurs while tungsten rod grinding on bench

grinder

By providing safety guard for bench grinder

No hand injury occurs because of latest adjustable guard for bench grinder

Kaizen Improvement OWNER :- Mahendra Chougule & prakash salunkhe

02/03/1013

23


Problem Action ResultShell tapping was risky because no

specific arrangement for holding shell. Shell was holding by hands

Chances of hand injury is more wastage of time is more wastage of manpower

found

By making a fixture Safe because shell not needed to hold & chances of injury is less wastage of time is less

No extra manpower needed fixture make in a base frame which not needed extra space

Kaizen Improvement


Improvement photographs…


Who benefits…

Earlier 5S only workshop activity It is not possible in fabrication line

Later

Improves health and safety• Creates a better environment• Items are easier to find, saving time• Less irritation when you can find items easily• Less conflicts with colleague’s because items can be found easily• Improve morale and teamwork• Gives ownership to us• Puts tools at point of use• Less tired at the end of the day

Employees Statements from Alfa Laval 5S Sites


Celebrations…


Appreciation news on Share…


Appreciation news on Share…


THANK YOU…

Business

Cultural Change in AMM Factory - Alfa Laval India