4. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
GENERIC PROCESS OF FLOW CHART
RAW MATERIAL
MIXING PROCESS STARTS HERE
4 ROLL
CALENDER
2 ROLL
CALENDER
3 ROLL
CALENDER
BEAD
EXTRUDE
R
BIAS
CUTTER
TIRE
BUILDING
CURING FID WAREHOUSE
4
5. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
SYNOPSIS
Daily production is 55 MT , so daily we are in need of 55000 Kwh of power for
production process.
Our present power consumption is 57107.85 Kwh of production.
Our kaizen team studied different aspects where we were loosing power in process.
Our team worked and analyzed to reduce power consumption and improve power
ratio.
5
6. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
IDENTIFICATION OF PROBLEM
SR.NO. PROBLEM CATEGORY
1 WRINKLE PROBLEM B
2 KNIFE HEATER PROBLEM C
3 PNUMETIC FITTING BREAK PROBLEM C
4 DRUM BREAK PROBLEM B
5
BUILDING TREAD HEATER POWER CONSUMPTION
A
6 FLY SENSOR PROBLEM C
7 DRUM ROTATION PROBLEM B
8 TREAD VARIATION PROBLEM B
9 DRUM TRUN UP PROBLEM A
10 KNIFE POWER CONSUMPTION A
*A=MEMBERS CAN SOLVE THE PROBLEMS.
*B=NEED HELP FROM OTHER DEPARTMENT.
*C=NEED HELP FROM MANAGEMENT.
6
8. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
MILE STONE-ACTIVITY CHART 8
STEP ACTIVITY P/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1
PROBLEM
IDENTIFICATION
P
A
2
PRESENT PROBLEM
AND REASON FOR
SELECTION
P
A
3 DEFINE THE PROBLEM
P
A
4
ANALYSIS OF THE
PROBLEM
P
A
5
IDENTIFICATION OF THE
CAUSE
P
A
6
FINDING OUT THE ROOT
CAUSE
P
A
7 DATA ANALYSIS
P
A
8 DEVELOPING SOLUTION
P
A
9
FORESEEING PROBABLE
RESISTANCE
P
A
10
IMPLEMENTATION &
CHECKING THE
PERFORMANCE/RESULT
P
A
PLANNED ACTUAL DELAYED
MILESTONE ACTIVITY CHART (01.06.22 TO 15.06.22)
7
10. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
19
FINDING OUT THE ROOT CAUSE
WHY- WHY ANALYSIS
WHY CAN WE CHECK DAILY UNUSED EQUIPMENT?
No ,Due to less manpower.
WHY CAN WE OFF UN USED LIGHT & FAN?
No ,Provision for switch off unused power supply.
WHY CAN WE OFF UNUSED MACHINE?
No ,Machine readiness takes time.
WHY CAN WE OFF POWER FOR TREAD HEATER WHEN NOT WORKING?
No ,Provision for switch off tread heater supply.
10
15. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
STEP ACTIVITY P/A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 PROBLEM IDENTIFICATION
P
A
2
PRESENT PROBLEM AND
REASON FOR SELECTION
P
A
3 DEFINE THE PROBLEM
P
A
4
ANALYSIS OF THE
PROBLEM
P
A
5
IDENTIFICATION OF THE
CAUSE
P
A
6
FINDING OUT THE ROOT
CAUSE
P
A
7 DATA ANALYSIS
P
A
8 DEVELOPING SOLUTION
P
A
9
FORESEEING PROBABLE
RESISTANCE
P
A
10
IMPLEMENTATION &
CHECKING THE
PERFORMANCE/RESULT
P
A
PLANNED ACTUAL DELAYED
MILESTONE ACTIVITY CHART-COMPLETED(01.07.22 TO 15.07.22)
16
16. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
POWER CONSUMPTION DATA
16
Before Tread heater power
consumption in month for one
machine
1080Kwh
After Tread heater power
consumption saving in month for
one machine
945Kwh
Single machine tread heater in auto mode & saves total KWH unit yearly 3240 KWH &
Rs.32400 rupees yearly at 10 rupees per unit industrial cost
19. BALKRISHNA INDUSTRIES LIMITED,WALUJ,AURANGABAD.
FUTURE PLAN
Will implement for next upcoming machine of tire building. Till now
successfully implemented for 10 machine’s.
Will implement for area wise fan & light.
Will also implement for knife heater.
19
BENEFITS
REDUCED POWER CONSUMPTION.
INCREASE HEATER LIFE.
COST SAVING.
