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Quality Month: Aug’11               Kaizen No                                                                        Page ...
1-   N. Centhil Kumar   1- Waste reduction from >10% to < 2% ( Saving: US$-50,000 per annum)                              ...
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WQD2011 - KAIZEN - SRF Oversear Ltd - In-house development of separator plates for TO5 twisting machines to reduce waste

Kaizen case study submitted by SRF Overseas Limited during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

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

  1. 1. Quality Month: Aug’11 Kaizen No Page No.:1 KAIZEN REPORTCompany 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 wasteCategory: [√ ] 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 TO5High 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 n1 ly1 g p Oc t1 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 n1 ly1 Ja Fe Ma Ap Ma Ju Ju Months Benefits: Participation
  2. 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 RazaStandardization: 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/058Single 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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