1. QUALITY CIRCLE PRESENTATION
18/11/2022
Team Members:
PRODUCTIVITY IMPROVEMENT IN REC BANDED BELT
GRINDING MACHINE
Mr. N.Karthik – Technology & Development
Mr. Rajasekaran – REC Manufacturing Mr. L.Raja- Engineering Department
Mr. G.Rajesh – Technical Department
4. STEP-1
IDENTIFICATION OF WORK RELATED PROBLEM
Problem Statement
Machine adherence: Delivery adherence is poor
Rework is greater than 40% of actual coding value.
Asset utilization: Cycle time is high compare to Vertical grinding machine.
To meet the budgeted value of 2022-2023 and create capacity to failure
0
1000
2000
3000
4000
5000
6000
Qty
in
Nos.
Oct-21 Nov-21 Dec-21 Jan-22 Feb-22 Mar-22
Supply 2500 2500 2862 2132 4041 3633
Demand 3500 3500 4000 3000 5000 5000
Demand Vs Supply of Banded belt
Supply Demand
6. STEP – 2
SELECTION OF PROBLEM
Phase 1: Machine Throughput to be increase- Machine Parameters record, Machine actual
mode, Rework is high : Target : 35 % - 0% for CX & SPCX section
Phase 2: Cycle time improvement for different varieties: Target : 35 % by 2022 – 23
Phase 3: Horizontal deployment of improvements in other grinding machines
PHASE 1: REWORK TO BE REDUCE AND
ELIMINATE
35
0
0
40
Rework
Percentage
REWORK-CX Section
Existing Target
PHASE 2: CYCLE TIME REDUCTION
Target: 30%
903
589
0
150
300
450
600
750
900
1050
Cycle
time
in
CX
CYCLE TIME
Existing Target
TARGET
8. STEP – 3
DEFINE THE PROBLEM
1) Unable to achieve the current
customer demand of 60000 / annum
where our current productivity is
13000 belts per annum.
2) High rework generation: 35%
10. STEP – 4
ANALYSE THE PROBLEM
High cycle time and
Rework
WHAT is the problem?
WHERE does this problem
occur ?
Grinding Process
WHEN does it occur ? During grinding operation
WHO notices this problem ? Production department
HOW can solve this problem ?
By study and improving the
Grinding Methodology
13. STEP – 5
IDENTIFCIATION OF CAUSES
BRAINSTORMING POINTS SPECIFICATION IMPROVEMENT PLANNED RESULT
Coupling lock system Locking made on separate link Found Ok Insignificant
Cycle time in Grinding Cycle time– 903 Seconds
Grinding time can be
optimized
Significant
Pressure pad Alignment
All groove OD in pressure pad
to be equal size
Groove OD to be turned to
required size
Significant
Grinding wheel Setup change time
Setup changeover time: 12 mins
avg
Reasonable time Insignificant
Hand wheel elimination Belt Tensioning time: 33s
Time can optimize with
automated mechanism
Significant
Pulley alignment to be perfect
Pulley and belt seating area to
be align
Found Ok Insignificant
Nuts can be removed using Auto
Wrench
Using manual wrenches nut
removal happening
Found Ok Insignificant
Dead weight arrangement: Stroke
length
Stroke length of shaft: 200mm
Can be increase to some
range
Significant
Horizontal m/c to Profile grinding
machine
Loading belts in current setup
for grinding
To overcome order quantity
utilizing the asset
Significant
Grinding wheel speed Speed: 1390 rpm Reached maximum capacity Insignificant
15. STEP – 6 FINDING OUT THE ROOT CAUSES
( Why)
( Why)
COUNTER MEASURE Throughput improvement
Delay in belt delivery
High cycle time and Belt
Rework generation
Improper Pressure pad/More
number of grinding steps
( Why)
Existing method
WHY WHY ANALYSIS
19. STEP – 8: DEVELOPING SOLUTION
Act.
No
ACTIVITY
Cycle Time in
Secs
(Existing)
1
Setting the parameters in
HMI 10
2 Belt Loading Time 20
3
Closing the lid and press
RUN in HMI 3
4 Step 1-2 95
5 Step 2-3 92
6 Step 3-4 79
7 Step 4-5 79
8 Step 5-6 66
9 Step 6-7 69
10 Step 7-8 62
11 Step 8-9 62
12 Step 9-10 61
13 Step 10-11 60
14 Step 11- 12 51
15 Step 12-Grinding complete 35
16 Reversal-End 43
17 Unloading Time 16
Cycle time, seconds 903
HORIZONTAL GRINDING MACHINE
20. STEP – 8: DEVELOPING SOLUTION
BEFORE AFTER
HAND WHEEL
Belts are Loaded in machine and belt
tension given to belt with hand wheel for 4
belts.
Cycle time 33 secs
Simple mechanism provided by eliminating
the hand wheel with Motor mechanism-Easy
tensioning.
Cycle time 3 Sec
Simplify
Action : 1 HAND WHEEL ELIMINATION
21. STEP – 8: DEVELOPING SOLUTION
KAIZEN IDEA - SHEET
22. STEP – 8: DEVELOPING SOLUTION
BEFORE AFTER
Stroke length
increased to
meet the
correct Belt
Tension
The dead weight is not arranged properly
Tension variation is high due to stroke
length deviation
Dead weight- 240 Kg
Action : 2 DEAD WEIGHT ARRANGEMENT: STROKE LENGTH
23. STEP – 8: DEVELOPING SOLUTION
BEFOR
E
AFTE
R
Equal
surface
achieved
Tape
removed
AFTER
BELT CODING NOT OK
BELT CODING OK
BEFORE
35% THROUGHPUT
IMPROVED
Action : 3 UNEVEN PRESSURE PAD
RESULT IMPACT: THROUGHPUT IMPROVEMENT
24. STEP – 8: DEVELOPING SOLUTION
Action : 4 REDUCTION IN GRINDING STEPS
35% Reduction time for Target, From 903 Sec to 589 Sec – Reduction 314 Sec.
The Reduction plan is based on idea generation in brain storming points identified through SCAMPER
approach
VA – Value
Added Activity,
NVA –Non Value
Added Activities
Act. No. Activities
Actual
Time taken
(sec)
Time
Reduction
plan(Sec)
Saving
time in
(Sec)
Category
VA NVA
4 Grinding Step 1-2 95 94 1
1
5 Grinding Step 2-3 92 86 6
6 Grinding Step 3-4 79 70 9
7 Grinding Step 4-5 79 66 13
8 Grinding Step 5-6 66 62 4
9 Grinding Step 6-7 69 60 9
10 Grinding Step 7-8 62 55 7
11 Grinding Step 8-9 62 0 62
12 Grinding Step 9-10 61 0 61
13 Grinding Step 10-11 60 0 60
14 Grinding Step 11- 12 51 0 51
16 Reversal-End 43 22 21
2
15 Grinding Step 12-Grinding complete 35 55 -20
17 Belt Unloading Time 16 3 13 3
2 Belt Loading time 20 3 17 4
1 Setting parameters in HMI 10 10 0 5
3
Closing the lid and press RUN in
HMI
3 3 0 6
Total time in secs 903 589 314
90%
10%
VA NVA
27. STEP – 9 FORSEEING PROBLEM OF RESISTANCE
Sl.
No
Implemented actions Resistance
Raised
by
Corrective
actions
Status
1 Hand wheel elimination Hand wheel -
Introduced motor
mechanism
Completed and
implemented
2 Rework elimination Pressure pad -
Even Surface finish
achieved through
lathe operation
Completed and
implemented
actions are
followed
3 Stroke length Adjustment Dead weight -
Stroke length
increased to meet the
correct belt tension
Completed and
implemented
actions are
followed
4
Grinding steps reduced
for CX section
More steps in
grinding
-
Performed Load and
temperature study
and reduced the
grinding steps
Completed and
implemented
actions are
followed
29. STEP – 10
TRAIL IMPLEMENTATION & CHECK PERFORMANCE
After
Act.No ACTIVITY
CycleTime in
Secs (Existing)
1 Setting the parameters in HMI 10
2 Belt Loading Time 20
3
Closing the lid and press RUN in
HMI 03
4 Step 1-2 94
5 Step 2-3 86
6 Step 3-4 70
7 Step 4-5 66
8 Step 5-6 62
9 Step 6-7 60
10 Step 7-8 55
11 Step 8-9 0
12 Step 9-10 0
13 Step 10-11 0
14 Step 11- 12 0
15 Step 12-Grinding complete 55
16 Reversal-End 22
17 Unloading Time 03
Cycle time, seconds 589
30. STEP – 10
TRAIL IMPLEMENTATION & CHECK PERFORMANCE
S.No Activities
Before
(In
Secs)
After
(In
Secs)
%Reduction
in time
Action taken
1 VA 854 570 33.25%
1. Pressure pad outer diameter turned
to achieve even surface
2. Stroke length increased with simple
mechanism to withstand the dead
weight in proper way
3. Introduced Load, frequency meter
and modified the rpm. Performed
temperature simulation study on
machine
2 RNVA 49 19 61.22%
Introduced Motor feed mechanism by
eliminating manual hand wheel
operation
Total
time in
secs
903 589 34.78%
95%
5%
VA RNVA
97%
3%
VA RNVA
BEFORE CYCLETIME
AFTER CYCLETIME
31. STEP – 11: REGULAR IMPLEMENTATION
1
REGULAR IMPLEMENTATION
NO DEFECT - NO WASTE - NO DELAY
32. STEP – 11
REGULAR IMPLEMENTATION
Results
1000.00
1080.00
0
200
400
600
800
1000
1200
1400
Jun-22 Jul-22 Aug-22 Sep-22 Oct-22 Plan Avg.
Belt
Numbers
Qty
REC Grinding m/c– ProductionTrend Avg Plan Actual
PHASE 1: REWORK ELIMINATED
35
0
0
40
Rework
Percentage
REWORK-CX Section
Existing Target
PHASE 2: CYCLE TIME REDUCTION
Achieved: 35%
903
589
0
150
300
450
600
750
900
1050
Cycle
time
in
CX
CYCLE TIME
Existing Target
33. STEP – 11
REGULAR IMPLEMENTATION
P - PRODUCTIVITY
Q - QUALITY
C - COST
D - DELIVERY
S - SAFETY
M - MORALE
Achieved the daily production Norms and
No loss due to implemented action
34. STEP – 11
REGULAR IMPLEMENTATION
P - PRODUCTIVITY
Q - QUALITY
C - COST
D - DELIVERY
S - SAFETY
M - MORALE
Cost Savings :
1500000/- per annum Cost savings
Expected by reducing the cycle time of
Grinding process in CX Section
Investment Cost : 10000
Return Of Investment : 1 Months
35. STEP – 11
REGULAR IMPLEMENTATION
P - PRODUCTIVITY
Q - QUALITY
C - COST
D - DELIVERY
S - SAFETY
M - MORALE
100% Internal customer and External Customer
delivery improved
36. P - PRODUCTIVITY
Q - QUALITY
C - COST
D - DELIVERY
S - SAFETY
M - MORALE
100% Internal customer and External Customer
delivery improved
STEP - 11
REGULAR IMPLEMENTATION
FENNER SUPER KINGS 36
15-Sep-23
40. CONCLUSION
Communication skills
Inter Personal Relations
Team Spirit
Product Knowledge
200
195
190
185
180
175
170
165
160
155
150
M
ill
io
n
s
o
f
D
o
lla
r
s
1992
1991
1990
Pr oduc t i
on C
os t s
U
ni
t Pr i
c e
Pr of i
t s
Self Confidence
Computer Skills Improved
