2. WHY was it required?
Objectives:
To make the traceability process 100%
To make worker more accountable of its work.
To track the history and causes of a problem.
To differentiate In-house Part from Vendor’s Part.
Muhammad Ahsan
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3. WHAT used to happen?
Manual Punching with Hammer
Punch letter Z Placing of Punch at desired
location.
Hammering on the punch to
have its impression on Case
Bottom.
Disadvantages in this Process
1. Very Dim Impression of the punch. 2. Operator’s tasks were increased.
3. Probability of missing a piece 4. Possibility of damages due to hammer.
Muhammad Ahsan
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4. WHAT did we Innovate?
Automatic Punching with Modified Die
Punch placed in the modified
part clamping jig.
Cylinder of Part holder moves
forward, both clamping and
punching the part at the same time.
Part placed for clamping in the
part holder.
Muhammad Ahsan
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5. HOW did we do?
Manufacturing Process
Cylinder of Part holding Jig The new cylinder with punch
assembled it.
New Cylinder formed, with a
hole to place the punch
Advantages after Innovation
1. Dark Impression of the punch. 2. No Fatigue for Operator
3. No chance of Missing a Piece 4. No Possibility of damage on parts.
Muhammad Ahsan
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6. Achievements and Results
Sr. No. Objective Status
1. To make Traceability process 100%.
(100% Traceability achieved as every part that is machined will be punched)
2. To make operator more accountable for his work.
(A punch for each operator; One can now trace the operator of problematic part.)
3. To track the history and causes of a problem.
(As per planned laser printing after painting, a problem may be monitored)
4. To differentiate In-house Part from Vendor’s Part.
(The part with punch mark is AAL In house; while without punch is Al-Badar)
Muhammad Ahsan
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