M&M Cost Kaizens

8/12/2019 M&M Cost Kaizens

1/11

Activity in Kaizen Idea :

KK JH QM PM HSE OTPM DM E&T

Team Members :

Problem/Present Status :

Benefits in P

1.

Sustainance Plan

S.N. Activity

Horizontal Deploy

S.N.

Different size

IMPR/TPM/F 01 Rev. 02 : Effective date 25.06.2005

2

Separate spare pulleys/belt set need to be maintained for

ASU 04

Key word :-

High Spares inventory cost

1

Analysis :

Belt tension

checking

Result :

9724

4420

KAIZEN SHEETL8 PM

Common sizeTarget

Loss :

Finish date

Bench Mark

Kaizen Theme :

To reduce spares inventory cost on ASU 04 fan & motor

pulleys & belts.

Pulley/belt of ASU 04 of different size

than that of ASU 01,02 & 03.

Pulley sizes of ASU 04 fans of different size than that of

ASU 01, 02 & 03

30.0Start date

15.0

PU

CELL

REF. NO.

New Paint Shop

Cell 04

NPS\F-06\PM\C2\TT\090

Before Sketch

1

J D Nikam, P.K.Borka

Belt replacement

2

After Sketch

Countermeasure :

Replaced ASU # 04 Fan & motor pulleys with

standard pulley, same as ASU 01,02 & 03.

Saving in electr

Area

97240

44200

25000

50000

75000

100000

Before After

SPC 5000 belt Inventory cost

Costin

Rs

V Belt Pulley V Belt Pulley


2/11

ValueBefore

replacement

After

replacement

Before

replacement

After

replacementFan RPM 690 692 689.0 693

Pulley diameter driver 410 325 410.0 325

Pulley diameter driven 810 640 810.0 640

V-belt SPC 5600 SPC 5000 SPC 5600 SPC 5000

Average Current (amps) 184.5 179 186 181.5

KWH 119.35 115.80 120.32 117.41

Units/day 2029.01 1968.52 2045.50 1996.02

Units/Year 568122.27 551186.38 572741.15 558884.51

Rs per year 1914572.06 1857498.10 1930137.69 1883440.81

Total

Net saving Rs

Saving calculation

57073.96 46696.88

103770.84

Fan 01 Fan 02


3/11

ctivity in Kaizen Idea :


aizen Theme : Countermeasure :

Team Members :

roblem/Present Status :

Benefits in P Q C D

1

2

Sustainance Plan :

S.N. Activity

Horizontal Deployment :

S.N.

High vapourisation rate.

MPR/TPM/F 01 Rev. 02 : Effective date 25.06.2005 TPM

3

Target D

2

cell leader

Resp Frequen

Cell leader weekly

01.04.05

01.05.05

6-Mar

1 Check lubrication

oil level

2

RespArea

All process

conveyors

Low evapouration rateTarget

Start date

Finish date

Bench Mark

1

NPS/F-06/PM/401

ey word :-

Afterefore

KAIZEN SHEETLoss :U

ELL

EF. NO.

New Paint Shop

Result :

High evapouration rate of lubrication oil

PM

nalysis :

High lubrication oil consumption

High lubrication cost on Sealer Oven conveyor

High lubrication frequency

Lubrication frequency reduced from w

monthly

Cleaning time of oven reduced by 8 m

during deep cleaning activity.

o reduce the lubrication cost on process conveyor

igh lubrication cost on process conveyor and buffer

hains. Yellowish stain marks oberved on insides of oven.

Use of low vapourisation rate lubrication oil.

P. K. Borkar, V. G. Ugale

TPM in

268950

178920

5000

105000

205000

305000

Before After

Cost per year per conveyor

Rs

Parameter Value

Base Oil Synthetic ester

Base Oil Viscosity 40 deg 398 cst

100 deg 29.2 cst

Evapourisation rate 0.3% per hour

Chain wetness 20 days

Carbonisation of oil No traces observed.

GI panels insidesoven

No stains observed

Parameter Value

Base Oil Not known

Base Oil viscosity 40 deg 220 cst

100 deg 9 cst

Evapouration rate 5 % every hour

Chain wetness 07 days

Carbonisation of oil Yes

GI panels insides oven Yellowish stains

OKS 352/2 Rocol chain guard 230


4/11

PU : New Paintshop Loss :

CELL : NPS/04/39 Breakdown KAIZEN SHEETREF. NO. :

Activity in Kaizen Idea : Bench Mark 6 breakdown/y

KK JH PM QM OTPM E&T SHE IFC Arrangement for re-using pump by-pass water Target 0 breakdown

Kaizen Theme : Start date

Finish dateTeam Members :

To eliminate breakdown on Paint stripping pump.

Before Sketch

Problem / Present Status :

Cavitation of pump due to entrapped air in feed water

Heavy vibration and knocking in pump head

7-Nov-04

Counter Measure : Connecting by-pass water to tank Benefits in P, Q, C, D, S, M

12-Nov-04

P. K. Borkar, A. M. Khond

After Sketch

Discharge ventil and sleeve broken

Feed water line directly connected to plant supply line

1) 96 manhours saving/year

2) Spares cost saved 1.2 lac

3) Water saving 15000 m3/ye

(Rs saved 1.87 Lac/year)

Horizontal Deployment :ResultsAnalysis : Paint stripping pump not working

Nil

TPM

F04

06

Nov 04Breakdownincidences

0

To spray lance

Feed waterBy-pass waterSpray lance water

Feed waterBy-pass waterSpray lance water

Waste water tank To spray lance Waste water tank

Overheadtank

Mar 05

TPM Secretariat - Nasik


5/11

Activity in Kaizen Idea :


Team Members :

Benefits in P Q C D

1.

2.

Sustainance Plan :

S.N. Activity

Horizontal Deployment :

S.N.

2

Inefficient equipment

Analysis :

Sealer oven

holding fanCell 02

1

Targ

Ma

High power consumption at Surfacer oven ciruclation fan

Fan Motor drawing higher current

Ma

Key word :-

After SketchBefore Sketch

Result :

Less overall efficiency of blower/motor.

High power required to deliver required output.

Energy

Kaizen Theme :

To reduce energy consumption on Surfacer Oven

circulation fans.

Cell-02

NPS\F-06\PM\C2\KAIZEN SHEET

Loss :PU

CELL

REF. NO.

New Paint Shop

119819 Electical units

60000 Electrical units

10.04.05

20.05.05

Countermeasure :

To change 45kw motor to 37kw motor.(Heat up 01, Holding

01 and Holding 02 circulation fans.)

Bench MarkEfficient motor.

Target

Start date

Finish date

Problem/Present Status :

High power consumption on Hot Air Circulation fan

V. G. Ugale P. K. Borkar.

Elimination of Soft starter 03 nos

outflow Rs 1.00 lac

Pm time reduction by 30 minutes

tobetter mountings of motor.

Check motor

current

Cell 02

1

Sealer oven Heat

up fan

Area Resp

2

Resp Freq

cell 02 Mo

TPM in

500000

1000000

1500000

Before After

units

3,61,363Electrical units/year

2,01370Electrical units/year

Savings


6/11

Holding 02

Motor capacity 45 KW Motor capacity 37 KW

RPM 2910 RPM 1465

Flow rate 150 m3/hr Flow rate 150 m3/hr

Head 35 mtr Head 37 mtr

Average current 37.27 Average current 20.13

KWH 24.11 KWH 13.02

KWH per day 433.98 KWH per day 234.40

Rs per day 1462.51 Rs per day 789.92

Rs per Year 409504.17 Rs per Year 221178.40

KWH per year 121514.59 KWH per year 65631.57

Holding 01 UnitMotor capacity 45 KW Motor capacity 37 KW Rs

RPM 1440 RPM 1440

Discharge 45000 m3/hr Discharge 45000m3/hr Average current 37.27 Average current 20.13

KWH 24.43 KWH 13.54






7/11

Heat UP 01Motor capacity 45 KW Motor capacity 37 KW

RPM 2910 RPM 1465

Flow rate 150 m3/hr Flow rate 150 m3/hr

Head 35 mtr Head 37 mtr

Average current 35.80 Average current 20.60KWH 23.16 KWH 13.33





361363.61 201037.13 160326.49


8/11

Before After

361364 201037

1217795 677495


9/11

641305.9433


10/11

Saving Per Year ( Rs. In L

Sr Area

1 Electrical Energy

2 LPG

3 Other


11/11

cs)

Saving / Year( In Lac)

52.3

37.19

9.65

Documents

M&M Cost Kaizens