Journey To Achieve World Class Level of Performance Thru ... Manufacturing in a... · Level of Performance Thru Lean Manufacturing in a Developing Economy . ... is held at MSIL where

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Journey To Achieve World Class Level of Performance Thru Lean Manufacturing in a Developing

Economy


Outline

• Cluster Approach to upgrade the quality of Tier – 2 vendors.

• Evolution of Lean Manufacturing .• Adoption of Lean Manufacturing Practices at Tier – 1

vendors.• Selected Case studies pertaining to :

• Quality• SMED• Productivity

• Selected Kaizens evolved during the implementation of Lean Manufacturing at Tier – 1 Vendors.


INTRODUCTION

MACE was created in 2004 by Maruti Suzuki [ Largest passenger car manufacturer in India with over 50 % market share ]and a group of 21 Member Vendors.

Objectives : To propagate among vendors best practices in fields of quality, cost & technical orientation through training, consultancy and support services .To help vendors reach world class levels of performanceTo organize short term training and education programmesTo help vendors to improve productivity and quality through implementation of Maruti-Suzuki production system [ MPS ]To help Tier-1 vendors to improve the quality of management of Tier-2 vendors by adopting cluster approach


Conceptual Model of Quality

Full Customer Satisfaction

World –ClassQuality forCorporate Survival

Quality

Cost

Safety

Morale

Delivery

Product Design

Conformance

Service

Cost Effective

Price Effective

Right Place

Right Time

Right Amount

In useIn production

Everyone cares

ASSURANCE

OF

QUALITY


S.NO. ITEM TARGET1 Safety : Zero Accidents2 5 S – Score 90% min.3 Quality : 3.4 ppm4 Supply to Customer 2 hourly basis5 Customer Line Stops Zero6 Inventory Turns: Min 507 Change over time < 10 min.8 OEE (Overall Equipment Efficiency) 85 - 90 %9 VA to Employee cost 510 VSM : Value stream mapping 25%11 Cost 50% less12 Absenteeism (Unauthorized) 0%13 Direct to Indirect manpower 60 : 4014 Kaizens / employee 24/emp/year

15 New Product DevelopmentAt 50% less time and

Cost16 Training Hours / Emp / Year > 5 % of working hrs

Attributes for World Class


Concept of Cluster

A group of 5 to 10 vendors ( non-competing) get together to undergo a common training session and get hand held experience.Individual attention is given to all cluster members & all queries during the session are answered.


Advantages of Cluster

Lower Cost.Group discussions & sharing of ideas.Competitiveness.Learning from one another.Exposure to best practices.Learning in a team.Exposure to benchmarking.Improved motivation.


CLUSTER MEETING IN PROGRESS


EXACTNESS

The first step in the improvement journey is Exactness. This involves three parameters:Exactness of Process: The vendor must ensure that the process is being followed exactly as per the standards, as per written down instructions. To achieve this the vendor must employ check points in Daily Work management.


EXACTNESS

Exactness of Measurement: Any process is as good as its measurement. The vendor must ensure that there is a control plan for all the instruments & measuring gauges; periodic calibrations are carried out as per the plan & all instruments /gauges are kept in good working condition.


1. Initial Problem Perception(Large , Vague, Complicated Problem)

2. Clarify the Problem

3. The “ Real “ Problem

4. POC

Direct CauseCauseCause

CauseCause

Why ?

Grasp the Situation

Why ?

Why ?

Why ?

Why ?

CauseInvestigation

Root Cause

5. Countermeasure

6. Evaluate7. Standardise

5 Why ?-InvestigationOf Root Cause

EXACTNESS of INVESTIGATION

Basic Cause and EffectInvestigation

Funnel Approach


TEAM ORIENTED PROBLEM SOLVING [ TOPS ]

We encourage Tier – 2 vendors in Quality Circle & Lean Manufacturing activities .Every Year a competition amongst the Tier – 2 vendors is held at MSIL where each vendors make a presentation about the QC & Lean Manufacturing activities [ MPS ].In order to motivate the vendors, awards are given through MSIL, the parent organization . We also encourage our Tier – 2 vendors to participate in National Competitions to understand the best practices.



Quality Circle Competition in progress



Lean Manufacturing Competition in progress



Recognition of Best Team at Lean Manufacturing Competition


TEAM ORIENTED PROBLEM SOLVING [ TOPS ] Kaizen Competition at CII – Confederation of Indian Industries


BENEFITS SO FAR .......

150TIER 2 VENDOR MEMBERS

17TIER 1 VENDORS INVOLVED

96Lean Manufacturing Projects Completed [ 09~ 10 ]

12ACTIVE CLUSTER

54 %200432No. of

Defects on Line/Month

87 %142210933Rejection PPM

Improvement2009 - 102004 -05Measure


What is Lean Manufacturing?

A systematic method to continually improve the manufacturing operation at little capital expense by involving all employees in solving problems, eliminating wasteful costs, reducing lead times, and improving quality.


History of Lean Manufacturing

Henry FordToyota Production System & Taiichi OhnoShigeo Shingo & SMEDTPM & Nippon DensoMotorola & 6 Sigma The Machine that Changed the World (James P Womack and Daniel T Jones)


Basic Lean Principles

Add nothing but valueEliminate “muda” – waste

Do it right the first timePeople doing the work add value

Team oriented

Deliver on demand“Pull” instead of push


Case Study -1 Quality Improvement

Theme: Reduction in Damping force rework.


80.4

8.8 7.13.6

10096.489.3

0

10

20

30

40

50

60

70

80

90

100

Damping Rework End cup seam leakage Vertical seam leakage Paint defects

% A

GE

0

10

20

30

40

50

60

70

80

90

100

Defect wise Rework TrendsApril’09 to June’09


Damping force Rework Trends

1.72

1.49

1.19

1.46

1.9

1.39

0

0.5

1

1.5

2

2008~09 YTD 2009~10 Apr'09 May'09 Jun'09 Jul'09

% A

GE TARGET : 1.0%


Defect wise Contribution

DF Rejection

71

147 5 1 1 0

8693 98 99 100 100

0

20

40

60

80

100

120

LowRebound

Low Comp. HighRebound

Binder High Comp. Others Lag

Type of Defect

Def

ect %

Selected for Analysis


PIE chart – Model wise contribution [ Low Rebound ]

Indica Front14%

YV-4 Front11%

Others13%

800CC Car

19%

Omni Rear43%

Case Study-1


Objective:To identify whether the Component or Assembly process is causing the problem

Technique/Tool used:

- Component Search

PART - Omni Rear


Selection of ComponentsBest of Best [ BOB ] & Worst of worst [ WOW ]

“As farther apart as possible”

BOBWOW


Sl no Trial BOB WOW

1 Initial* 65.200 45.000

2 Trial 1 65.700 44.800

3 Trial 2 66.200 45.300

65.700 45.000

1.000 0.500

* Damping Force

D/d - Ratio 27.60

20.700

0.750

Median

Range

D

d

1 BOB [ Best of Best ] and 1 WOW [ Worst of Worst ] assembly selected for study.

D/d > 1.25 and there is no overlap of readings

Components are the cause , not the Assembly process


Ranking of Components by Importance

Rank Components Label1 P.V. ASSY A2 C.V. ASSY B3 CYLINDER C4 ROD GUIDE D

Testing symbols

A-R+ A from WOW assy and Rest components from BOBA+R- A from BOB assy and Rest components from WOW


65.7 66.2

45.2

65.2

45 44.8 45.3

64.3

40.00

45.00

50.00

55.00

60.00

65.00

70.00

75.00

Initi

al

Trial 1

Trial 2 A

Reb

ound

val

ueCOMPONENT SEARCH – Graphical Plot

BOB

WOW

55.3

COMPLETE REVERSAL FOUND AFTER INTERCHANGING P.V. ASSY [ Piston Valve ]


Rank Components Label1 ROD NUT A12 PLUNGER A23 VALVINGS A34 REBOND STOP PLATE A4

Testing Symbols

A1 from WOW assy and others from BOBA1 from BOB assy and others from WOW

CHILD PARTS OF P.V. ASSY(ARRANGED IN ORDER OF IMPORATANCE)


65.7 66.2 65.965.2

45.4

65.3

45 44.8 45.3 44.740.00

45.00

50.00

55.00

60.00

65.00

70.00

75.00

Initi

al

Trial 1

Trial 2 A1 A2

Reb

ound

val

ue

COMPONENT SEARCH – Graphical Plot

BOB

WOW

55.3

COMPLETE REVERSAL FOUND AFTER INTERCHANGING PLUNGERNO REVERSAL FOUND

AFTER INTERCHANGING ROD NUT


SSV’s for Plunger, [Suspected Source of Variation]

• Problem statement:LOW REBOUND

• SSV’s for which Paired Comparison can be used are

• OD (25.335 – 25.360)

• ID (1.4 ±0.1 )

• LAND FLATNESS (0.1 mm Max.)

• OD (19.43 – 19.68 )

19.6

8/19

.43

FACES F1 & F2 MUST BE FLAT WITHIN 0.10


Data Collection : PAIRED COMPARISION

19.510.3101.35225.347WOW16

19.500.2501.41225.345WOW15

19.490.1751.39625.348WOW14

19.530.2401.46125.351WOW13

19.560.2201.43725.340WOW12

19.510.2901.42825.349WOW11

19.500.2101.39225.341WOW10

19.520.1001.46125.348WOW9

19.550.1001.42625.345BOB8

19.480.0501.38225.341BOB7

19.500.1001.36425.346BOB6

19.510.0401.37525.346BOB5

19.530.1001.40125.342BOB4

19.560.1001.39825.350BOB3

19.530.1201.39525.348BOB2

19.520.1001.39025.345BOB1

19.50.1 MM MAX1.4±0.125.335 ~ 25.360

O.D.LAND FLATNESSIDOD

RESPONSESR.NO


CONCLUSION:SO Dia. 19.5 IS NOT THE CAUSE FOR PROBLEM

19.48BOB7

19.49WOW14

19.50WOW15

19.50WOW10

19.50BOB6

19.51WOW16

19.51WOW11

19.51BOB5

19.52WOW9

19.52BOB1

19.53WOW13

19.53BOB4

19.53BOB2

19.55BOB8

19.56WOW12

19.56BOB3

19.5

Dia.RESPONSESR.NO

Analysis - 1

AS Min contains both BOB & WOW

TOTAL END COUNTS = 0


Dia

Res

pons

e

19.5619.5419.5219.5019.48

BOB

WOW

ResponseBOBWOW

Dotplot of Dia [ 19.5 ]

NO CLEAR DEMARCATION BETWEEN BOB AND WOW


END COUNT = 7 + 2 = 9

CONCLUSION:SO LAND FLATNESS IS THE CAUSE FOR PROBLEM

0.040BOB5

0.050BOB7

0.100BOB9

0.100WOW8

0.100BOB6

0.100BOB4

0.100BOB3

0.100BOB1

0.120BOB2

0.175WOW14

0.210WOW10

0.220WOW12

0.240WOW13

0.250WOW15

0.290WOW11

0.310WOW16

0.1 MM MAX

LAND FLATNESSRESPONSESR.NO

Analysis - 4

Upper Count = 7

Lower Count = 2


Land Flatness

Res

pons

e

0.280.240.200.160.120.080.04

BOBWOW

ResponseBOBWOW

Dotplot of Land Flatness vs Response

All Good Good + Bad All Bad


Funneling

LOW Rebound

Plunger

P.V. Assy.

DOE # 1

DOE # 2

Land flatness

DOE # 3


Land Material chip off During Drilling Operation

Drilling tool / method NG

Drilling process not capable

Variation in holes PCD

Piston Land Flatness NG

WHY-WHY ANALYSIS

Root Cause Identification – 5 Why Analysis [ Land Flatness ]


Countermeasures

BEFORE

AFTER

Drilling tool modified to avoid variation in PCDImplemented : 16thNov’09

Piston guiding from I.D.


Damping force Rework Trends

1.72

1.27

1.19

1.46

1.9

1.391.3 1.25 1.29

1.16

0.91 0.86 0.92

0

0.5

1

1.5

2

2008

~09

YTD 20

09~1

0

Apr'09

May'09

Jun'0

9

Jul'0

9

Aug'09

Sep'09

Oct'09

Nov'09

Dec'09

Jan'10

Feb'10

% A

GE

TARGET : 1.0%Project started

Project completed

Further analysis is required For bringing rejection

Level below 1 %


Case Study -2 Quality Improvement

Theme: Reduction in Burn Mark.


Defect Definition

Green Y : Burn marksType : Visual AppearanceComponent : Memory Neck Rest Process : Injection MouldingDefect Occurrence area : MouldingMachine used : 150 TonTool Used : Product Process SearchRejection % : 10~12%


DOEDefect Understanding

Good Part Bad Part


Rejection Trend For Last Six Months

Rejection Trend

280000 280357

173000143077 129583

89624

182607

050000

100000150000200000250000300000350000400000

Sep. 09 Oct. 09 Nov. 09 Dec. 09 Jan. 10 Feb. 10 Average

Months

PPM

Burn Marks Noticed ever since the development of component

Air vent provide on

Parting Line

Pin Provide to avoid air trapping

M/c Tonnage increased &

Gate Size Increased


DOE

Suspected Sources of Variation Parameter Unit

Injection Pressure BarInjection Time SecondsMould Temp. °CNozzle Temp. °CZone Temp. °CCycle Time Seconds

Data Collection Plan :Five Continuous shots every Hour


DOE

Sorting in ascending order w.r.t Injection Pressure

As Min. & Max. belong to both category

G and BEnd Count = 0

So, This is not a significant cause

105G57

105B48

105B46

105B41

105B37

105B35

105B2

100G28

100G25

100G24

100G22

100G21

100G20

100G19

100B10

100B9

Injection Pr. (105+/-10)StatusS. No.


DOE

Similarly other SSV’s were checked in the same manner through paired comparison &

only Mold temperature was found to be significant.


DOE

Sorting in ascending order w.r.t Mould Temp.

End Count = 16So, this is a significant cause

123B2

122B41

121B37

120B46

119B35

118B48

117B10

116B9

111G57

111G19

110G21

110G20

109G28

109G22

108G25

108G24

MTC Temp. 110+/-10StatusS. No.


MTC Temp. 110+/-10

Stat

us

122120118116114112110108

B

G

StatusBG

Dotplot of MTC Temp. 110+/-10 vs Status

All Good Good + Bad All Bad

Confirmation Thru Dot Plot


Status

MTC

Tem

p. 1

10+

/-10

GB

122

121

120

119

118

117

116

115

114

113

Interval Plot of MTC Temp. 110+/-10 vs Status95% CI for the Mean

Confirmation Thru Interval Plot


DOEConclusion

After doing this exercise we concluded thatthe mould temp. is the reason for burn markin this part and this was confirmed through a series of Trials .

15/3/10

VERIFICATION DATE

ok14/3/10MouldingMTC temp. revised from

110+/-10 to 105+/-5 deg.cent.

STATUSIMPLEMENTATION DATELOCATIONCOUNTERMEASURE

Countermeasure


Rejection Trend

280000 280357

173000143077 129583

89624

21053 0 00

50000100000150000200000250000300000350000400000

Sep. 09 Oct. 09 Nov. 09 Dec. 09 Jan. 10 Feb. 10 Mar. 10 [ 1stWk ]

Mar. 10 [2nd wk ]

Apr-10

Months

PPM

Effectiveness of countermeasure

Air vent provide on

Parting Line

Pin Provide to avoid air trapping

M/c Tonnage increased &

Gate Size Increased

Counter Measure taken after DOE

Analysis

The process is under observation & some more data will be neededbefore standardization.


CASE STUDY - SMED

PRODUCTIVITY INCREASEBY

SINGLE MINUTE EXCHANGE of DIE

(SMED)AT

1000T-ISGEC PRESS LINE


Die change over time is more (12 min).

No. of Die change over are: 130 per month

Loss of time: 130X12=1560/60=26 Hrs =26 X 12 =312Hrs per year

Productivity Loss

To standardize the die change over procedure to avoid the variability from person to person

REASON FOR SELECTION


DIE CHANGEOVER TREND JULY,2009

1211.18

12 12.4711.7 12.05

13.0912 12

12.73 12 11.68 12 12.1912.1313.01

11 12 11.2512.18 12.73 11.8512.67

11.86 11.79 12 12.14

0

3

6

9

12

15

18

1st

3rd 6th 8th

10th 13th 15th 17th 20th22nd

24th 28th 30thAvg.

Dates

Tim

e (M

in.)

TARGET 7.2 MIN. [ 40 % Improvement ]


Die Change Over Activity : Break up

720 Sec= 12 MinuteTotal

20

40

165

142

18

5

35

35

30

18

5

142

10

25

10

Time (Seconds)

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Internal

Type of Activity

15

14 Bolting the die

13

Slide Adjustment12

Press's Side Gate Close11

Taking Moving Bolster (MB) down10

Outside Bolster (MB) moved in9

Inside Bolster (MB) taken out8

Taking Moving Bolster (MB) Up7

Press's Side Gate Open6

Slide up at Top Dead Center (T.D.C) 5

Unbolting the die4

Release Cushion pressure to zero3

Slide down to Bottom Dead Center (B.D.C) 2

Putting Last piece (L.O.A) into The die1

ActivityS.N.

First Of Approval (F.O.A)

Stroke Adjustment on setting blocks

16

Taking cushion up & setting required pressure 20 Internal


DIE CHANGE TIME JULY-2009

43

23

73686278 82 85 88 91 93 96 97 98.699.3100

020406080

100120140160180

14 12 4 15 8 9 7 2 13 16 11 6 3 1 10 5

S.No

Tim

e (S

ec.)

02040

6080100

CUM

%

Pareto of Die Change over

14.Bolting the die.12.Slide adjustment.4.Unboltiong the die15.Stroke adjustment on setting blocks.


KAIZEN IDEA : 1TITLE:- Reduction in cushion pins searching time

BEFORE AFTER

COMMENTS:- No proper place for cushion pins & No recording of availability of cushion pin.

COMMENTS:- Specially designed cushion pin trolley had been made & a check sheet had been made for weekly checking of the size & no. of cushion pins.

630MM-42,635-45,680-18,700-19

BENEFITS :- 1.Reduced cushion pin searching time by 60 sec.2. Now the Cushion pins of required size available on line at time of die change over


KAIZEN IDEA : 2TITLE:- Reduction in spanner searching time.

BEFORE AFTER

COMMENTS:- No place was defined for placing the spanner.

COMMENTS:- Now place has been fixed for placing the spanner near the machine Bolster.

BENEFITS :- 1. Now spanner searching time reduced by 60 Sec.2. Fatigue reduction.

No specific place for spanners


KAIZEN IDEA: 3TITLE:- No place for Nuts,bolts & washers

BEFORE AFTER

No specific Place was decided for Nuts & Bolts

COMMENTS:- There was no place for nuts, bolts & washers.

COMMENTS:- A rack made for keeping nuts,washers & bolts.

BENEFITS :-1.Searching time reduced 42 Sec. for nuts, bolts & washers.2. Reduction in fatigue

Bolt Size 165mm


KAIZEN IDEA : 4TITLE:- Reduction in Bolt tightening & Loosening time of upper die.

BEFORE AFTER

COMMENTS:- Upper die was bolted & unbolted by T bolts COMMENTS:- Now hydraulic clamps are used to clamp the upper die

BENEFITS :- 1.Bolting & Unbolting time of upper die reduced by 65 Sec.2. Fatigue Reduction & Operator Safety


KAIZEN IDEA : 5TITLE:- Reduction in Bolt Tightening & Loosening time of lower die .

BEFORE AFTER

COMMENTS:- Lower die was bolted & unbolted inside the machine. So It was an internal activity.

COMMENTS:- Bolting & Unbolting of lower die is done outside the Machine. Internal activity is converted into external activity.

BENEFITS :- 1. Bolting & Unbolting time of lower die reduced by 65 Sec.2. Safety Ensured


KAIZEN IDEA : 6TITLE:- Provided air pipe to check the cushion pin layout of draw dies.

BEFORE AFTER

COMMENTS:- No Mechanism available on outside MB [ Moving Bolster ] to check the cushion layout of draw die because bolting of lower die is done outside the machine

COMMENTS:- Now air pipe is fixed to check the cushion pin layout outside the machine.

BENEFITS :- 1. Die & Operator Safety ensured.


KAIZEN IDEA : 7TITLE:- Reduction in cushion pressure setting time.

BEFORE AFTER

COMMENTS:- Manual Cushion & Counterbalance pressure meter was available.

COMMENTS:- Now automatic Cushion & Counterbalance control meter has been installed on line.

BENEFITS :- 1. Cushion pressure setting time reduced by 10 Sec.2. Cushion pressure remains with in the required limit . So quality improved.


KAIZEN IDEA : 8TITLE:- Reducing slide adjustment time using Automatic slide adjustment meter.

BEFORE AFTER

COMMENTS:- Earlier there was no automatic slide adjustment meter.

COMMENTS:- An automatic slide adjustment meter is now available on control panel for automatic slide adjustment.

BENEFITS :-1.Slide adjustment time reduced by 97 sec.2.One man power saved during slide adjustment.


KAIZEN IDEA : 9TITLE:- Lay out of Dies

BEFORE AFTER

COMMENTS:- No lay out for Isgec-2 dies COMMENTS:- Dies Lay out made for Isgec-2 dies.

BENEFITS :-1.Die retrieving time from Die storage to Die cart & vice-versa reduced.2. Operator fatigue reduced

No layout plan for placementOf Dies


2:102:10 -External

ActivityBefore

(Min: Sec)After

(Min: Sec)Time saved (Min: Sec)

Internal 12:00 6:11 5:49

TIME ANALYSIS : AFTER


Benefit Retainment

Countermeasure start here

Die Changeover Trends Aug.09- 8 Feb.10

0

2

4

6

8

10

12

14

Date

Tim

e (M

in.)

Series1 12.05 10.95 9.35 8.79 7.08 6.80 6.52 6.50 6.55 6.32 6.55 6.58 6.48 6.50 6.50

Jul-09Aug-09

Sep-09 Oct-09

Nov-09

Dec-09 Jan-10 1-Feb 2-Feb 3-Feb 4-Feb 5-Feb 6-Feb 8-Feb

Avg. Feb.10

Countermeasure start here


1

4

3

2

5

6

7

8

91011

12

13

15

16

14

1.Putting last piece (L.O.A) into the die

2.Slide down to bottom dead center (B.D.C)

3.Release cushion pressure to zero

4.Unbolting the die

5.Slide up at top dead center (T.D.C)

6.Press’s safety gate open

7.Taking moving bolster (MB) UP

8.Inside moving bolster (MB) taken out

9.Outside moving bolster (MB) taken in

10.Taking moving bolster (MB) down

11.Press’s safety gate closed

12.Slide adjustment

13.Taking cushion up & setting required pressure

14.Bolting the die

15.Stroke adjustment on setting blocks

16.First off approval

Standardization


CASE STUDY- Productivity

Productivity Improvement Of Assembly Rear /Back Seat Line No – 3

MODELS1.Alto Domestic LX / LXI2.Alto Export GCC / ECC


16.6

13.867868.5Productivity ( sets/ man/ day)4

5 operator6 operatorManpower2

% Improvement

390390Production sets1

445445Time (min)3

AFTERBEFOREACTIVITYS.NO

Targets


CYCLE TIME REDUCTION METHODOLOGY:

Following are the methodology adopted for Cycle time reduction

Method Activity

Measure Cycle time of all machines / stations

Define target

Identify bottleneck machines / operations

Time study

Operation redistribution.

• Operation automation.

• Activity sequence change ( Series to parallel)

• Layout optimization.

• Part commonization.Reduce cycle time

Reduce non value added work


Takt Time (Before)

30.5

12

19.5

4646.5

20.5 27

13.522

17

47.5

18

56

121

4

0

20

40

60

80

Opr-1 Opr- 2 Opr- 3 Opr- 4 Opr- 5 Opr- 6

WASTAGE

NON SELEABLE BUT REQ.

SELEABLE

TAKT TIME = 68.5 SEC / SEAT SET

PRODUCTION TARGET FOR ONE SHIFT = 390 SETS

OPERATOR

TIM

E IN

SE

CO

ND

Gap


Material close to operatorComments: Material not close to operator

BEFORE AFTER

Benefits: Operator Fatigue Reduced

Kaizen-1: Shifting Material Close to Operator


Storage tray has been provided on the working table itself to avoid the motion loss (bending angle)

Comments: Operator bends to pickup the clip from the tray below the table

BEFORE AFTER

Benefits: Operator Fatigue Reduced

Kaizen-2: Shifting Material Close to Operator


After Kaizen Work Distributed

OperationOperatorOperationOperator

1.Side C Ring fixing2. 1.Clip fixing Left & Right side

No load

1.Steaming2.C Ring fixing lower side 3.Clip fixing lower side

Before

Op- 61.Clip fixing Left & Right sideOp-6

Op-41.Steaming2.C Ring fixing lower sideOp-4

1.Clip fixing lower side2.Side C Ring fixing

Op-5

Op-5

After


Result

Before After

19.5

46 46.5

20.5 27 30.5

47.5

18 17

22 13.5 12

1 2 1

6 5 4

01020304050607080

OP- 1 OP-2 OP-3 OP-4 OP-5 OP-6

Value added work Non Value added work Wastage

Present tact time = 68.5

19.5

46 46.538

49

47.5

21 1828

13.5

0

10

20

30

40

50

60

70

80

OP- 1 OP-2 OP-3 OP-4 OP-5

Value added work Non Value added work

Time in sec Time in sec

tact time= 68.5 sec

6 Operators 5 Operators


13.86

16.6

% IMPROVEM

ENT

10 OPERATOR12 OPERATORMAN POWER TWO SHIFT02

78 SEAT SETS / OPERATOR68.5 SETS / OPERATORPRODUCTIVITY03

390 SEAT SETS / SHIFT390 SEAT SETS / SHIFTPRODUCTION01

AFTERBEFOREACTIVITYS.NO

Achievements After MPS

ACHIEVEMENTS1.Man power reduction – Two Operator / Day

2.Productivity increased – 9.5 Sets / Operator


BEST KAIZENS IMPLEMENTED BEST KAIZENS IMPLEMENTED THROUGH MPSTHROUGH MPS


Best Practices / KaizensMould / Die Set up Time

Reduction Implemented Through

MPS


Process Flow of Mould Change- Over

Move Crane Near M/c

Connect to Mold

Remove Connections

Unload Mould from the m/c

Bring Next Mould

Place in the m/c

Make the Connections

Remove Crane

Adjust Mould

PurgingTrial

1st OK Piece

Last OK Piece

Mould Set up Time = Time b/w the last OK piece to the First OK piece


Benefits :Operator Inconvenience ReducedTime Saved: 2 minutes

Comments: Tool Trolley Made to eliminate searching Time

Comments: Tools were kept in Improper Manner

AfterBefore

KAIZEN-1: TOOL TROLLEY TO ELIMINATE SEARCHING TIME

SANDEN-VIKAS


Benefits :1. Time for searching sheets to maintain die height saved ( 2 Minute )2.Operator safety ensured.3. 5-S improved .

Comments: Different sheets replaced by a single packing in the die to maintain die height above 700 mm

Comments: Sheets of different widths fixed on die one above the other to maintain die height

AfterBefore

KAIZEN-2: PROVISION OF PACKING ON DIES(HEIGHTS< 700MM)

SKH


Benefits :1. Cushion pin layout made easier & time saved 20 sec

Comments: Cushion pin template made for dies. layout become easier.

Comments: Cushion pin template not available

AfterBefore

KAIZEN-3:TEMPLATE FOR CUSHION PIN LAYOUT ACCORDING TO DIE

SKH

NO TEMPLATE FOR CUSHION PIN LAYOUT


Benefits :1. TOTAL TIME SAVING :- 21 - 8 = 13 MINS

Comments: Loading template size increased model specific and stopper position fixedTime required: 8 mins

Comments: Loading stoppers and template setting is done separately .Time Required: 21 mins

AfterBefore

KAIZEN-4: LOADING TEMPLATE SIZE INCREASED & MADE MODEL SPECIFIC

ASAHI

Stopper Loading template

Stopper

Loadingtemplate


Benefits :1.Tool change over time reduction approx. 2000 sec (33.33 mins.)2. No fine tuning required.Investment:Rs.0

Comments: Whole gathering unit assy is ready for loading.

Comments: Parts were in disassembled condition before loading on the machine.

AfterBefore

KAIZEN-5: PARTS ASSEMBLED PRIOR TO LOADING

CLIMATE SYSTEM INDIA LTD.


Benefits : Easy centeringTime saved by 1 min

Comments: Girder marked as per requirement

Comments: No girder marking for centering

AfterBefore

SUPREME

KAIZEN-6:GIRDER MARKING FOR EASY CENTERING OF MOULD


Benefits :Operator Inconvenience ReducedTime Saved: 3 minutes

Comments: Eye Bolt provided on all the Moulds

Comments: Die- Loader has to use the same eye-Bolts for next Mould to be changed

AfterBefore

KAIZEN-7: EYE- BOLT ON EVERY MOULD

JU-SHIN


Benefits :20 Seconds saved

Comments: Cover on mould provided for reducing cleaning time & safety improved

Comments: No cover on moulds; cleaning of mould at the time of loading, was time consuming

AfterBefore

KAIZEN-8: COVER PROVIDED ON MOULDS FOR REDUCING CLEANING TIME

Moulds with cover

SANDEN-VIKAS

Moulds without cover


Benefits : Homogeneous mixture obtainedNo wastage of material due to spillage

Comments: Ratio Loader ProvidedComments: Fresh & Recycled Material was mixed manually

AfterBefore

KAIZEN-9: RATIO LOADER FOR HOMOGENEOUS MIXING

ANU INDUSTRIES


Benefits :5 Minute Saved

Comments: Pneumatic air gun to be used for tightening of bolts.

Comments: During mould clamping, tightening of bolts by ring spanner takes more time.

AfterBefore

KAIZEN-10: PNEUMATIC SPANNER INSTEAD OF RING SPANNER

AUTODECOR


Best Practices / Kaizens

Productivity improvement in Molding

Implemented Through MPS


Benefits : 1. Energy cost reduction .2. Productivity enhancement 150 % .

Comments: Four cavity mould made .Comments: Earlier the component was made thru single cavity mould .

AfterBefore

KAIZEN-1: INCREASE IN NO. OF CAVITIES IN CAP COMP DASH LOWER

PRECISION TECH


Benefits : Time saved by 2 sec

Comments: Mould Opening / Closing Stroke reduced to 480 mm

Comments: Mould Opening / Closing Stroke was 620 mm

AfterBefore

AUTODECOR

KAIZEN-2: REDUCING MOULD OPENING / CLOSING STROKE

480MMSpeed: 85 %

620MMSpeed: 65 %



Comments: Safety Gate stroke Reduced to 300 mm

Comments: Safety Gate Stroke was 500 mm

AfterBefore

SUPREME

KAIZEN-3: REDUCING OPENING STROKE OF SAFETY GATE



Comments: Cooling Channel Design Changed in Parallel

Comments: Cooling Channel was in Single Loop Formation

AfterBefore

SUPREME

KAIZEN-4: COOLING CHANNEL DESIGN CHANGED TO PARALLEL

LoopingIn

Sprue bush areaIn water line

Direct coolingline

Instead ofLooping profile

1 IN

2 IN1 OUT

1 OUT

1 IN

2 OUT


Benefits : Cooling Time of Carpet Reduced by 12 sec

Comments: Cooling Channel Size Increased to 24 mm

Comments: Cooling Channel Size was 12 mm

AfterBefore

KAIZEN-5: COOLING CHANNEL DIA INCREASED TO REDUCE COOLING TIME

24 mm

12 mm

UNIPRODUCTS


Benefits : Cycle time reduced by 3 sec

Comments: Low Cycle Time in Lower Tonnage machine

Comments: High Cycle Time in Higher Tonnage Machine

AfterBefore

KAIZEN-6: SHIFTING FROM HIGH TONNAGE TO LOW TONNAGE

450 T 380 T

SUPREME


Best Practices / KaizensProductivity Improvement in

ManufacturingImplemented Through

MPSWhat you think it is... What it actually is... What it could be...


Benefits : Adjustment time reduced.

Comments: Auto wheel dressing machine installed on CNC-6 which leads to elimination of manual grinding.

Comments: Earlier Wheel repairing done manually by operator which require to pause the M/C and it took 10 minutes.

AfterBefore

KAIZEN-1: Installation of AUTO G.C stick on CNC-06

ASAHI

Manual dressing by operator

Grinding wheel

Grinding Table

Auto G.C Stick machine


Benefits : Operator no.6 relieved from his activities

Comments: Hard plastic sheet placed by the operator no. 5 to keep the bag mouth open while putting glass inside the bag.

Comments: Operator no.6 is opening the bag mouth and operator no.5 is putting the glass inside the bag.

AfterBefore

KAIZEN-2: Hard plastic sheet (Curved Shape) used to keep the bag mouth open

ASAHI


Benefits :Improvement in Productivity .

Comments: Now spring loaded ejection block provided with bending punch .

Comments: Earlier their was no provision to auto eject part after bending .

AfterBefore

K R RUBBERITE

KAIZEN-3: SPRING LOADED EJECTOR BLOCK FOR AUTO REMOVAL OF PART


Benefits :Improvement in Productivity .

Comments: Now batch code stamping & hole punching done in one stroke [ Bending tool modified ] .

Comments: Earlier batch code stamping was done separately before bending .

AfterBefore

K R RUBBERITE

KAIZEN-4: MERGING OF TWO OPERATION [ BATCH CODE & HOLE PUNCHING]


Benefits :Improvement in Productivity & Hole shift problem eliminated .

Comments: New tool made & all three holes are punched in one stroke.

Comments: Earlier hole punching was done in two separate operation.

AfterBefore

K R RUBBERITE

KAIZEN-5: MERGING OF TWO OPERATION

One HolePunching

Two HolePunching

Three Hole

Punching


Benefits : 1. Time reduction in FSA Assy station by 7 secs.

Comments: Packing is modified and shroud crack chances reduced leading to checking point elimination

Comments: Packing is prone to shroud getting cracked during handling and transportation leading to checking point introduction

AfterBefore

KAIZEN-6: PACKING IMPROVEMENT TO ELIMINATE CHECK POINT ON SHROUD , RESULTING IN CYCLE TIME REDUCTION



Benefits : 1. Time reduction in final insp by 2 secs .

Comments: Marking eliminated after Dust cover is made integral part of modified motor.

Comments: Operator at Final Inspection was marking to ensure presence of Dust cover.

AfterBefore

KAIZEN-7: ELIMINATION OF MARKING FROM DUST COVER



Benefits : 1. Time reduction in fsa assy station by 2 sec

Comments: Sensor provided to check the condenser nut pocket in Radiator & Shroud assy fixture.

Comments: Operator at final inspection was checking the nut pocket in condenser

& putting mark over Condenser nutpocket.

AfterBefore

KAIZEN-8: CHECK FOR CONDENSER NUT POCKET.


Proximity sensor


Benefits : 1. Time reduction in final inspection by 6 secs2. Productivity & safety improvement (sharp edges)

Comments: Poka yoke for proper retainer clip assy made at Fan shroud assy station

Comments: Fan was pushed by operator to check retainer clip assy at final inspection station

AfterBefore

KAIZEN-9: ELIMINATING “PRESS FAN TO CHECK RETAINER CLIP ASSY” AT FINAL INSPECTION



Benefits : 1. ONE MAN POWER SAVED2. OPERATOR MOVEMENT & FATIGUE REDUCED3. SPACE SAVING ON SHOP FLOOR

Comments: Layout improved (As shown) Operator movement is reduced

by 20 Mtr. /shift

Comments: Excessive Opr. movement (40 meter/shift ) Leading to

fatigue

AfterBefore

KAIZEN-10: LAYOUT CHANGE TO REDUCE OPERATOR MOVEMENT

SUBROS

Lever pinpressing

On line stage

Damper Assy &lever pin pressing

Distance 2.2 meter Dam

per A

ssy

On line stage

Distance 0.6 meter


Benefits : 1. TIME SAVED BY 4 SEC/CYCLE

Comments: Sequence changed ,Spacefor Part placing provided, Idle time utilized

Comments:-Grinding Machine was idle during the time of inspection.

AfterBefore

KAIZEN-11: BETTER UTILIZATION OF SURFACE GRINDING MACHINE

SUBROS


Benefits : 1. Saving the changeover time of 40 minutes per shift.2. Operator fatigue reduced.3. Horizontal Deployment done in Rotor line & Condenser plant.

Comments: One cylinder pack lasts complete shift.

Comments: Average 5 times changeovers of 10 minutes each per shift.

AfterBefore

KAIZEN-12: NITROGEN CYLINDER PACK IN PLACE OF SINGLE CYLINDER

SUBROS


Benefits : IMPROVEMENT IN PRODUCTIVITY. • TAPPING MACHINE SAVED.• ONE OPERATION ELIMINATED

Comments: Unnecessary Operation (Retapping) Eliminated By Providing Bolt In M6 Nut During Powder Coating At Vendor End

Comments: Retapping Operation Done On M6 Nut After Powder Coating.

AfterBefore

KAIZEN-13: TAPPING OPERATION ELIMINATED

VICTORA


Benefits : Cycle Time Reduced by 2 sec

Comments: Spring separator providedTime Taken =1 sec

Comments: Springs entangledTime Consumed =3.0 sec

AfterBefore

KAIZEN-14: PROVISION OF SPRING SEPARATOR

MINDARIKA



Comments: Tightening done by electric screw driver hence torque consistency & Cycle Time reduced to 24 sec

Comments: Manual tightening of Lamp Holder Assy.Cycle Time: 29 Seconds

AfterBefore

KAIZEN-15: ELECTRIC SCREW DRIVER FOR TIGHTENING

PRICOL


Benefits : Time saved by 12 secOperator Fatigue eliminated

Comments: Pneumatic Clamps ProvidedTime Taken: 25 sec

Comments: Manual Clamping of Booster Bracket; Time Consumed: 37 sec

AfterBefore

KAIZEN-16: MANUAL CLAMPING CHANGED TO PNEUMATIC CLAMPING

VEE GEE


Best Practices / Kaizens

Quality / Safety Improvement



Benefits :1.Man & Machine safety ensured.2. 5-S improved .

Comments: Machine is now provided with safety guards at both ends

Comments: No Safety Guard is provided at other end of Machine

AfterBefore

KAIZEN-1: SAFETY GUARD PROVIDED ON MACHINES

SKH


Benefits : 1. Handling damage eliminated & reduction in customer complaint

Comments: Packing Improved to prevent damage to the Motor .

Comments: Earlier Material was dispatched in Bins – Some times motor gets damaged during handling – Leading to noise

AfterBefore

KAIZEN-2: IMPROVEMENT IN PACKING TO ELIMINATE DAMAGE DURING TRANSORTATION

ADITYA AUTO


Benefits : 1. Hard Movement problem eliminated

Comments: Discussed with design department center plate specification

changed 8.5+0.20 against 7.80±0.20 mm to get clearance

Comments: As per existing specification of center plate assy (YV4 Manual)-

interference observed.

AfterBefore

KAIZEN-3: CHANGE IN DIMENSION TO REDUCE HARD MOVEMENT OF WINDOW REGULATOR

ADITYA AUTO


Benefits : 1. Process Improvement

Comments: Air flow control by AC drive linked with Blower RPM.

Comments: Air flow control manually by hand valve

AfterBefore

KAIZEN-4: ELECTRONICALLY CONTROLLED AIR FLOW SYSTEM

CHANG YUN


Benefits : No delay in material feedingNo wastage of material due to spillage

Comments: centralized conveying system installed.

Comments: Earlier their was no centralized material conveying system.

AfterBefore

KAIZEN-5: CENTRALIZED RAW MATERIAL CONVEYING SYSTEM

PRECISION TECH


Benefits : 1. Dust in clean room is controlled. 2. Better atmosphere for injection Molding .3. Better product quality & reduction in customer complaint

Comments: Clean room made for prevention of dust .

Comments: Earlier there was no provision of Clean room

AfterBefore

KAIZEN-6: PROVISION OF CLEAN ROOM TO PREVENT DUST

AUTODECOR


Benefits : 1. Weld spatter & distortion problem eliminated .

Comments: Welding of latch has been replaced with riveting process.

Comments: Earlier the latch was welded with latch bracket

AfterBefore

KAIZEN-7: PROCESS CHANGED FROM WELDING TO RIVETING TO ELIMINATE DISTORTION

IFB


Benefits : 1. Reduction in scratch problem .

Comments: Sleeves of curing trolley are covered with fabric.

Comments: Earlier Sleeves of curing trolley were not covered with fabric.

AfterBefore

KAIZEN-8: MODIFICATION OF TROLLEY TO AVOID SCRATCHES

KRISHNA MARUTI- DTD


Benefits : 1. wrong Fitment of Fuel Gauge Eliminated

Comments: Plate is introduced & used as a separator for differentiation between

two

Comments: TG Assy was fixed instead of FG Assy in the Board

AfterBefore

KAIZEN-9: POKA YOKE TO AVOID WRONG FITMENT OF FUEL GAUGE

PRICOL


Benefits : 1. Reduction in Crease defect ( 25000 PPM to 90 PPM )2. Operator safety ensured

Comments: Nail provided to avoid Manual Holding

Comments: Manual holding of carpet during moulding

AfterBefore

KAIZEN-10: NAIL PROVIDED ON TOOL TO PREVENT MANUAL HOLDING OF CARPET

UNIPRODUCTS


Benefits : 1. Glue mark problem reduced in roof headliner2. Standard decided for various ranges of density

Comments: Colour coding from top to bottom for density variation. Bottom- Red

, Middle- Green, Top-Yellow

Comments: No identification from Bottom to Top

AfterBefore

KAIZEN-11: MARKING FROM TOP TO BOTTOM FOR DENSITY VARIATION IN PU BLOCK

KRISHNA GRUPO ANTOLIN


BRIEF ABOUT THE PROBLEMPart: Battery Retainer

MODEL :- Alto & WagonR

Bending Ht, Reqd.4.5 ±.0.3mm. Observed up to 5.5 mm.


ROOT CAUSELOCATING PIN WAS NOT HARDENED

COUNTER MEASURE

1. HARDENED PIN PROVIDED TO LOCATE THE BLANK

2. PROFILE LOCATING GAUGE PROVIDED TO CHECK THE COMPONENTS TO PREVENT RECURRENCE.

STANDARDIZATIONHARDENED PIN PROVIDED IN ALL OTHER

BENDING TOOLS ALSO AS HORIZONTAL DEPLOYMENT.


RECEIVING GAUGE FOR RETAINER BATTERY

Slider provided to check Dim.

4.5 mm.


PROJECT

REDUCTION IN CASE NOISE IN ALTO

TECHNICO INDUSTRIES LTD.


CASE NOISE REJ PPM TREND ( AUG’08 TO OCT’08)

Rej PPM trend of Case Noise Alto

62387894

12198

0

2000

4000

6000

8000

10000

12000

14000

Aug'08 Sep'08 Oct'08

PPM

TECHNICO


PROBLEM ANALYSIS PHASE-1

Contributing Components ( Child parts )

CASE SPRING

SERRATION PIN BASE PLATE

PINION PLATE ASSY

TECHNICO


FUNNELING USING 7 QC TOOLS

All components

1. Process not standardized 2. No proper oiling3. Punch wear out

Cause & Effect diagram

5 Why analysis

1. Spring fitment process 2. Line mark on surface

3. Taper in ID

TECHNICO


POTENTIAL CAUSES & COUNTERMEASURES SUMMARY SHEET

TECHNICO

3. DRAW PUNCH MATERIAL CHANGED FROM HSS TO CARBIDE

& TOOL MODIFIED

3. TAPER IN CASE ID

2. OILING STARTED & ADDED IN WORK INSTRUCTION.

2. NO PROPER OILING B/W DIE & PUNCH

1. WORK INSTRUCTION MADE & DISPLAYED

1. SPRING FITMENT PROCESS NOT STANDARIZED

COUNTERMEASURESROOT CAUSE


ALTO CASE NOISE REJECTION PPM( AUG’08 TO DEC’08)

62385129

2423

0

7894

12192

0

2000

4000

6000

8000

10000

12000

14000

Aug'08 Sep'08 Oct'08 Nov'08 Dec'08 Tgt

After MPSBefore MPSPROJECT

EXTENSION TO ACHIEVE ZERO

DEFECT BY USING DESIGN OF

EXPERIMENTS

TECHNICO


PROBLEM ANALYSIS PHASE-1

PROBLEM : CASE NOISE IN ALTO

SSV : 1. CASE ID 2. SERRATION PIN O. D.3. CLEARENCE B/W CASE & PIN

CASE SERRATION PIN

TECHNICO


FUNNELING THROUGH DOE

Case ,serration pin , Clearance or assembly process

Case Clearance

Clearance b/w Pin OD & case ID

Component search

Paired comparison

TECHNICO


PAIRED COMPARISON – CLEARANCE

Bottom count = 5

Top count = 7

Total Count = 7+ 5= 12

CONCLUSION : CLEARANCE IS THE ROOT CAUSE OF THE PROBLEM

Clearance RESPONSEBetween case I.d & Pin O.D

0.11 GOOD 0.11 GOOD 0.11 GOOD 0.12 GOOD 0.12 GOOD 0.13 GOOD 0.13 GOOD 0.15 GOOD 0.15 BAD0.15 BAD0.15 BAD0.16 BAD0.16 BAD0.16 BAD0.16 BAD0.16 BAD

TECHNICO


CONCLUSION : After paired comparison , CLEARANCE was filtered as the

reason for the problem.

CONTROL : Clearance to be controlled within 0.13 mm max.

Conclusion & Control

TECHNICO


Cpk COMPARISON BEFORE & AFTER

Cpk Ppk Cpk Ppk

CASE 0.83 0.67 1.14 1.3

SERRATION PIN 0.25 0.2 0.87 0.77

SERRATION PIN ( SHIROKI )

COMPONENT BEFORE AFTER

Cpk = 1.40 & Ppk = 1.04

AS THE Cpk & Ppk OF SERRATION PIN WAS COMING LOWER THAN SHIROKI PINS IT WAS DECIDED TO ADD GRINDING PROCESS

AFTER FORGING TO IMPROVE CAPABILITY

TECHNICO


ALTO CASE NOISE REJECTION PPM( AUG’08 TO MAR’09)

62385129

2423989 783

074

7894

12192

0

2000

4000

6000

8000

10000

12000

14000

Aug'08 Sep'08 Oct'08 Nov'08 Dec'08 Jan'09 Feb'09 Mar'09 Tgt

After MPS

Before MPS

TECHNICO


Best Practices / KaizensReduction In Energy Consumption



WORKING FOR INJ. MOLD. HYD. PUMPWORKING FOR INJ. MOLD. HYD. PUMP

• ENERGY SAVING DEVICE CONTROLS THE POWER (Ampere) SUPPLY OF HYDRAULIC PUMP MOTOR ACCORDING TO LOAD CONDITION, THUS DECREASING THE POWER CONSUMPTION DURING “NO LOAD”CONDITION.

KAIZEN 1: INSTALLATION OF VFD ON INJECTION MOULDING M/C

KML - DTD


KAIZEN 1: INSTALLATION OF VFD ON INJECTION MOULDING M/C

KML - DTD

37.66

26.63

20.23

%, SAVING

28.17

%, AVG. SAVING

10543.67

5015.67

2709

UNIT, SAVED

1067613385450 TON, IMM-01

1382218837.67650 TON, IMM-06

M/C TONNAGE

BEFORE,UNIT CONSUMED (AVG. JAN,FEB,MAR’09)

AFTER,UNIT CONSUMED,

MAY’09

1400 TON,IMM-11

27999.67 17456

ENERGY SAVING BY VFD(SIEMENS)


KAIZEN 2: SHIFTING MOULD FROM HIGH TONNAGE TO LOW TONNAGE

KML - DTD

POWER CONSUMPTION MACHINE & MOLD WISE

S.NO COMPONENT

CONSUMPTION

450 T M/C 360 T M/C

Kwh / KG Kwh / KG

1 ORNAMENT , FR. MODEL- A

0.93 0.74

Saving ( Kwh / Kg) 0.19

% Saving/Kg 20.43


Benefits : 1. Energy cost reduction .

Comments: Insulation Jackets put around the heaters to reduce energy consumption for maintaining the temperature inside the heater

Comments: Earlier the heat was getting dissipated due to lack of insulation .

AfterBefore

KAIZEN-3: INSTALLATION OF JACKET ON BARREL. [ Energy Consumption Reduced by 19 % ]

PRECISION TECH


Benefits : State power to Generator - < 20 SecGenerator to state power – Instant [ Approx saving of one lakh /year ]

Comments: Now auto change over installed with alarm .

Comments: Earlier the change over was manual resulting in high change over time

AfterBefore

KAIZEN 4: INSTALLATION OF AUTO CHANGE OVER

PRECISION TECH


Benefits : 1. POWER SAVING OF RS. 2.0 LACS / ANNUM

Comments: NATURAL DRAFT COOLING TOWER WITHOUT COOLING FAN RESULTING 7.0 HP ENERGY SAVED

Comments: MECHANICAL DRAFT COOLING TOWER WITH 7 H.P FAN MOTOR

AfterBefore

KAIZEN 5: NATURAL DRAFT COOLING TOWER

SUBROS


Benefits : 1. Annual Saving of 21.24 Lacs/ year

Comments: New Latest Energy efficient Motor Screw Compressor (3 Nos X 630 CFM) installed.(90kW for 630 CFM)

Comments: Traditional Old type of Screw Compressor. (Motor Rating 90kW for 520 CFM)

AfterBefore

KAIZEN 6: INSTALLATION OF NEW COMPRESSOR WITH ENERGY EFFICIENT MOTOR

JBML


Benefits : 1. 30 % Energy cost reduction .2. Productivity enhancement 15 % .

Comments: All electric injection moulding M/C installed .

Comments: Earlier their was no all electric injection M/C.

AfterBefore

KAIZEN-7: INSTALLATION OF ALL ELECTRIC INJECTION MOULDING M/C

PRECISION TECH


Benefits : Energy Consumption reduced from 1,44,000 KWh/year to 1,32,000 KWh/year

Comments: VFD with pressure transducer installed for continuous loading

Comments: No variable frequency drive (VFD) & pressure transducer on compressor to avoid unloading

AfterBefore

KAIZEN 8: INSTALLATION OF VFD[ SAVING OF 8 % IN KWh ]

MINDA RIKA


Benefits :Energy Consumption reduced from 1700 to 1200 KWh/year

Comments: LED Indicator InstalledComments: Filament type Indicator

AfterBefore

KAIZEN 9: REPLACING FILAMENT INDICATORS WITH LED INDICATOR[ SAVING OF 29 % IN KWh ]

MINDA RIKA


Benefits :Energy Consumption reduced from 36,000 to 30,000 KWh/year

Comments: Timer Installed to switch off the lights automatically during Lunch Time & after Shift Closing

Comments: Assembly Lights Remained on During Lunch Time

AfterBefore

KAIZEN 10: INSTALLATION OF TIMER CONTROL IN ASSEMBLY AREA[ SAVING OF 16 % IN KWh ]

MINDA RIKA


Benefits :Scissors Lift Movement Reduced to Half

Comments: Trolley Width Increased. 4 Trolleys per Loading

Comments: 2 Trolleys are carried / loading

AfterBefore

KAIZEN 11: REDUCTION IN MOVEMENT OF SCISSORS LIFT[ Saving of 2730 KWh / Year ]

KRISHNA MARUTI- DTD


Don’t Forget

It is not the person doing the work that is ugly, It is the Waste that is ugly.We are not attacking peopleWe are attacking Waste

WasteMonster


Small Things Count [ Benjamin Franklin ]For want of a nail a shoe was lost,

for want of a shoe a horse was lost,for want of a horse a rider was lost,

for want of a rider an army was lost,for want of an army a battle was lost,

for want of a battle the war was lostfor want of the war the kingdom was lost,

And all for the want of a little horseshoe nail.“We are as Strong as our weakest link”

A defective part that costs a few Dollars can make a final assembly nonconforming or, even worse , result in a field failure.

To Conclude


References

ACMA , http://www.acmainfo.com/six-sigma/six-sigma-tools.htm

Keki R. Bhote & Adi K. Bhote ( 2008 ). World Class Quality 2nd ed.. Jaico Publishing House

Stefan H. Steiner & R. Jock Mackay ,( 2005 ). Statistical Engineering . Quality Press , ASQ

Davis R. Bothe ( 2002 ). Reducing Process Variation , Volume II , Landmark Publishing Co.


Thank YouThank YouThank You

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