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Quality Month: Aug’11               Kaizen No                                                                        Page No.:1

                                                                                                  KAIZEN REPORT
Company logo                                                              Company Name                                                             Department:                         Section/Process:
                                                                          SRF OVERSEAS LIMITED                                                     Manufacturing Team                  Engineering.



Improvement Title:                       In-house development of separator plates for TO5 twisting machines to reduce waste
Category: [√ ] Quality improvement [ ] Health & Safety [] Environment [√ ] Productivity [ ] Office processes
                                        Before Situation                                                        Root Cause Analysis                  Improvement Measures                                                                                 After Situation
                                                                                                                                             Sl.    Problem Root           Solution
                                                                                                                                             No              cause         proposed
                                                                                                               ‘Why –Why’ Analysis                           identified
                                                                                                                                                       HB    Since         To put
                                                                                                                                             1        waste  there is no   separator
                                                                                                               Why waste is generated?              is > 10% provision     plates in
                                                                                                                                                             for any       between
                                                                                                                                                             kind of       two
                                                                                                                                                             separation    spindles.
                                                                                                                                                             between
                                                                                                                                                             two
                                                                                                               Waste is generated due to                     spindles it                                                                                                                                            Separator
                                                                                                               higher half bobbins in in                     is                                                                                                                                                     plates added
                                                                                                                        TO5 m/c                              resulting                                                                                                                                              between the
                                                                                                                                                             into                                                                                                                                                   spindles
                                                                                                                                                             generation
                                                                                                                                                             of half
                                                                                                                                                             bobbin
                                                                                                                                                             waste.
                                                                                                                  Why half bobbin
                                                                                                               generation is high in TO5
High half bobbin waste generation in TO5 machines ( twisting                                                           twisters?                                                                                                           New separator plate fixed .
machines)

                                                                                                                                                                                                                                               TO5- MONTHWISE HALF BOBBIN% TREND
                             TO5- MONTHWISE HALF BOBBIN% TREND
         18.00
                                                                                                                  In TO5, if cord in one                                               18.00
                                                                                                                                                                                       17.00
         17.00                                                                                                   spindle breaks, it also                                               16.00                                                            Befo                                                                       Afte
                                                                                                                                                                                       15.00                                                            re                                                                         r
         16.00                                                                                                 breaks the cord in adjacent                                             14.00
                                                                                                                                                                                                                                                        14.60
         15.00
         14.00
                                                                  14.60                                           side due to slashing.                                                13.00
                                                                                                                                                                                       12.00                                12.20         11.90                         11.87
         13.00                                                                                                                                                                         11.00                  10.90
                                       12.20                                                                                                                                           10.00
         12.00                                     11.90                       11.87                                                                                                    9.00
         11.00            10.90                                                                                                                                                         8.00
         10.00                                                                                                                                                                          7.00                                                                                                          7.01
  HB %




          9.00                                                                                                  Why does slashing take                                                  6.00
                                                                                                                                                                                        5.00                                                                                            5.33
          8.00
          7.00                                                                                          7.01
                                                                                                                         place?                                                         4.00
                                                                                                                                                                                        3.00
                                                                                                                                                                                        2.00                                                                                                                        2.51          2.16
          6.00                                                                                                                                                                                                                                                                                                                                 1.69
                                                                                           5.33                                                                                         1.00
          5.00                                                                                                                                                                          0.00
          4.00
                                                                                                                                                                                                          1             1             1            11               1               1             1           '11           '11            1          '11       '11
          3.00                                                                                                                                                                                      n-1          b- 1             r-1         r-              y-1             n'1             ly'1        g             p          Oc
                                                                                                                                                                                                                                                                                                                                     t'1           v           c
                                                                                                                                                                                               Ja              Fe            Ma            Ap            Ma              Ju              Ju            Au            Se                         No          De
          2.00                                                                                                 Since there is no provision
          1.00                                                                                                 for any kind of separation
          0.00
                                                                                                                 between two spindles.
                      1            1           1              1            1           1            1
                   n-1          b-1         r-1         r-1            y-1          n'1         ly'1
                 Ja          Fe           Ma          Ap             Ma           Ju          Ju
                                                           Months


                                                                          Benefits:                                                                                                      Participation
1-   N. Centhil Kumar
   1- Waste reduction from >10% to < 2% ( Saving: US$-50,000 per annum)                                   2-   Biswajit Mallick
   2- Increase is machine efficiency                                                                      3-   T.B. Singh
                                                                                                          4-   Ahmed Raza



Standardization:                                                                                       Horizontal Deployment Opportunities (Replication):

Technical Standard developed for specification of separator plate and the process of fixing it on      The stated improvement has been deployed in 4 out of 12 machines.
the Twisting machines                                                                                  Machine nos: TO5-2, TO5-3, TO5-4 and TO5-10,

Ref: MECH/TS/058
Single Point Lesson:                                                                                   Remark / Management Comments:
-
                                                                                                       This is a very innovative solution, where in-house modification has been done by the engineering team
                                                                                                       and which this improvement has given us lot of savings.
Copy Distribution:                                                                                     Date of Starting:                     Date of Completion:      Control No. (by DQG)

                                                                                                      15th July 2011                           2nd August 2011
        Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
        community at large to promote Continual Improvement and good practices.

        Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT
        _________________________________ Date: _07___/_10___/_2011_______

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WQD2011 - KAIZEN - SRF Oversear Ltd - In-house development of separator plates for TO5 twisting machines to reduce waste

  • 1. Quality Month: Aug’11 Kaizen No Page No.:1 KAIZEN REPORT Company logo Company Name Department: Section/Process: SRF OVERSEAS LIMITED Manufacturing Team Engineering. Improvement Title: In-house development of separator plates for TO5 twisting machines to reduce waste Category: [√ ] Quality improvement [ ] Health & Safety [] Environment [√ ] Productivity [ ] Office processes Before Situation Root Cause Analysis Improvement Measures After Situation Sl. Problem Root Solution No cause proposed ‘Why –Why’ Analysis identified HB Since To put 1 waste there is no separator Why waste is generated? is > 10% provision plates in for any between kind of two separation spindles. between two Waste is generated due to spindles it Separator higher half bobbins in in is plates added TO5 m/c resulting between the into spindles generation of half bobbin waste. Why half bobbin generation is high in TO5 High half bobbin waste generation in TO5 machines ( twisting twisters? New separator plate fixed . machines) TO5- MONTHWISE HALF BOBBIN% TREND TO5- MONTHWISE HALF BOBBIN% TREND 18.00 In TO5, if cord in one 18.00 17.00 17.00 spindle breaks, it also 16.00 Befo Afte 15.00 re r 16.00 breaks the cord in adjacent 14.00 14.60 15.00 14.00 14.60 side due to slashing. 13.00 12.00 12.20 11.90 11.87 13.00 11.00 10.90 12.20 10.00 12.00 11.90 11.87 9.00 11.00 10.90 8.00 10.00 7.00 7.01 HB % 9.00 Why does slashing take 6.00 5.00 5.33 8.00 7.00 7.01 place? 4.00 3.00 2.00 2.51 2.16 6.00 1.69 5.33 1.00 5.00 0.00 4.00 1 1 1 11 1 1 1 '11 '11 1 '11 '11 3.00 n-1 b- 1 r-1 r- y-1 n'1 ly'1 g p Oc t'1 v c Ja Fe Ma Ap Ma Ju Ju Au Se No De 2.00 Since there is no provision 1.00 for any kind of separation 0.00 between two spindles. 1 1 1 1 1 1 1 n-1 b-1 r-1 r-1 y-1 n'1 ly'1 Ja Fe Ma Ap Ma Ju Ju Months Benefits: Participation
  • 2. 1- N. Centhil Kumar 1- Waste reduction from >10% to < 2% ( Saving: US$-50,000 per annum) 2- Biswajit Mallick 2- Increase is machine efficiency 3- T.B. Singh 4- Ahmed Raza Standardization: Horizontal Deployment Opportunities (Replication): Technical Standard developed for specification of separator plate and the process of fixing it on The stated improvement has been deployed in 4 out of 12 machines. the Twisting machines Machine nos: TO5-2, TO5-3, TO5-4 and TO5-10, Ref: MECH/TS/058 Single Point Lesson: Remark / Management Comments: - This is a very innovative solution, where in-house modification has been done by the engineering team and which this improvement has given us lot of savings. Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG) 15th July 2011 2nd August 2011 Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business community at large to promote Continual Improvement and good practices. Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT _________________________________ Date: _07___/_10___/_2011_______