There are some typical Improvement activities in different - defferent Industries.

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Case Study
of
A Chassis Manufacturer

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Basic Challenges
 Too Dirty….
Inside Bins, Workstations, Components, Trolley’s, Machines & Equipment's, Ceiling
& Roof Structures , Shop Floor,
To create cleaning Culture. I make Dirty I clean. Broom Stand to every area, Cleaning
Day.
 Too Much
WIP …Careless / doesn't know the importance of material, Material Get Dropped
on Floor. Go For 01 Hrs. WIP on line…later on it will be 30 minutes.
 Too Heavy
Material Handling Bins, trolleys etc. Weight ratio of 20 (Trolley Weight) : 80
(Components)
 Poor Visual control’s.
Within one Minute Search Time.

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Work Initial Level Target
To achieve Top Class 5S-level with
maximum Audit Score
45 pt 100 pt
Reduction of Quality Defect (DMP Points)
by 50%
191pt 100pt
Improvement in Productivity by Data Not
Available
20-30%
Safer Work Environment avoiding any
Accident
2 Acc/month Zero Acc/Month
Better Inventory Management, reduction
of WIP by 50-60% Over 8-hours 2-hours
Objectives

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 Awareness Revolution & Training on Lean Tools
Formation of Teams
5S, 3-Fixed & Visual Control
Stores Reform, FIFO introduced
Deployment of Container Kanban & Water Spider
Lighter & Sleek Combination Trolleys introduced
Better line Balancing & Process Improvements
Key Steps Taken

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Improvements
In
5S & Material Handling
At
Shop Floor

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Before After
Benefits:
• Fasteners keeping racks replaced with trolleys with small bins (96 big
bins replaced with 46 smaller ones)
• 02 hours inventory for fasteners ensured
Optimization of space utilization

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Before
Benefits:
• Better looks with 02 hours inventory & free space
After
Optimization of space utilization

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AfterBefore
Damper damaged due to
improper storage
A Frame trolley designed for
Damper
Advantage – Damages eliminated
Material handling Improvement

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Subject Engine Trolley Modification
Improveme
nt
■ Before Improvement : ■ After Improvement :
1. No alignment.
2. Difficulty in loading on fixture.
3. Damaged & Strength less
1. Single piece flow.
2. Ease of loading.
3. Strengthened & Wheels replaced
Snap shots
Teflon &
Strengthen
Kaizen Improvements

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Subject Shop 02 Maintenance
Improveme
nt
■ Before Improvement : ■ After Improvement :
1. No Cleaning
2. Wanted + unwanted items
3. No Systematic Arrangement
1. Cleaning
2. Removal of unwanted
3. Systematic Arrangement of wanted items
Snap
shots
5S improvement

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5S Improvements

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Line Side all Trolleys
Made, Sub Assembly &
Rear Axle Assembly Cover
Kaizen Improvements

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Stores
Improvements

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Subject Store Small pallet FIFO system with Transparent & easy access to the stored materials
Improvement
■ Before Improvement : ■ After Improvement :
1. No accessibility inside small pallets
2. No FIFO system for the stored parts
3. Condition of the parts not visible
4. Loose material filled
1. Clear accessibility inside small pallets
2. FIFO System for the stored parts
3. Condition of the parts are visible
4. Sets of 100nos bundled
Snap shots
14
Stores Kaizen-2

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Subject Air Piping Area
Improvement
■ Before Improvement : ■ After Improvement :
1. Air pipes lying in improper condition
2. No segregation of air pipe variants
3. Stored in high rise racks with non
accessible areas
1. Air pipes arranged in proper condition
2. Segregation of different model pipes
3. New racks with low rise partitions with easy
accessible areas
Snap shots
Stores Kaizen-3

16. © torque Management Services Pvt. Ltd. 16
Area Chassis Assy – Shop II Imp. Process Shop 02
Team VC Dwivedi, Amrish, RK Sharma, Sridhaar, Aidan, Vikas Loss / Waste Type 5S/Time / Movement/Inventory
Subject Mezzanine floor racks are flooded with Fasteners in Open condition, it gets dusty , no inventory norms
Improvement
All Fasteners are packed in separate packing with minimum quantity, no dusty fasteners, pack of 100nos made
■ Before Improvement : ■ After Improvement :
Snap shots
5.Control ■ Improvement Effect :- 1) 5s 2) EEI Improved
Stores Kaizen-4

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Tool Keeping
Concept

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Another tool
keeping
arrangement
with the
similar
concept
Many types of Tool Arrangement

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Arrangement
made for
keeping
different sizes
of Torque
wrenches,
according to
the usage.
Torque Wrenches Arrangement

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Drop Box
Concept

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DROP BOX-PLAN :
A Revolutionary concept
SCALE FOR ACCUMULATION LEVEL
•Collect any tiny part
dropped on floor
•Put it immediately in
Drop box
•Analysis & clear the
items once in week

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Material Drop Trend -(4-Weeks)
22
Accounting leads to improvement----

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Time Study
&
Productivity Improvement

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Time study (Stage 1 & 2)
TOTAL ASSOCIATES ON 2 STAGES (BEFORE): 11 Nos.
STAGE 1 STAGE 2
CONVEYOR DIRECTION
OP 1 LH OP 2 LH
OP 4 RHOP 3 RH OP 4 RH OP 3 RH OP 2 RH OP 1 RH
OP 5 LH OP 4 LH OP 7 LH

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Time study (Stage 1 & 2)
TOTAL ASSOCIATES ON 2 STAGES (AFTER): 9 Nos. (Time study is going on for further stages)
STAGE 1 STAGE 2
CONVEYOR DIRECTION
OP 1 LH OP 2 LH
OP 4 RHOP 3 RH OP 9 RH OP 8 RH
OP 5 LH OP 6 LH OP 7 LHOP 2 LH
OP 4 RH

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20 % Increase in productivity achieved
at the first 2 stages. Same concept has
been planned to be deployed gradually
in all stages.

27. © torque Management Services Pvt. Ltd. 27
Shop Look – After Improvement
 WIP Reduced (01 Hrs Norms)
 Space Saved (Trolleys 130 to
60,BIN Size FPO 35 to 15, 26
Hardware Racks removed )
 Housekeeping Improved
 Effort and Time Reduced
 Better Visual
 Better Ergonomics
Customer
Speaks---

28. © torque Management Services Pvt. Ltd.
Work
Initial
Level Target Achieved
To achieve Top Class 5S-level
with maximum Audit Score 45 pt 100 pt 78 pt
Reduction of Quality Defect
(DMP Points) by 50% 191pt 100pt 100pt
Improvement in Productivity
by
To be
assessed
20-30% 20%
Safer Work Environment
avoiding any Accident 2
Acc/month
Zero
Acc/Month Zero
Acc/Month
Better Inventory
Management, reduction of
WIP by 50-60%
Over 8-
hours
2-hours 2-hours
Goals Achieved at the end of Project

29. © torque Management Services Pvt. Ltd.