1. PROCESS FLOW
MODIFICATION IN
BRAKE DRUM ASSEMBLY
BY
S.DEEPANATHAN

2. PROBLEM DEFINITION
 Chamfering Operation is carried out before
machining.
 Machined components moved to the secondary
operations may damage.
 100% inspection is not done for all parameters.

3. KAIZEN THEME
 Continual Improvement
 How many places this kaizen can be deployed
horizontally?
 What modification can be done?
 How it improves the Process?

4. ACTUAL PROCESS FLOW DIAGRAM
RAW MATERIAL
INGOTS &
MELTING IN
FURNACE
CASTINGS FETTLING
DRILLING &
TAPPING
CNC
MACHINING &
BUSH
PRESSING
CHAMFERING
INPROCESS
INSPECTION
FINAL INSPECTION PACKING &
DISPATCH

5. DISADVANTAGES DUE TO THIS PROCESS:
 Castings are getting damaged.
 As defined by the customer outer diameter is the
critical parameter, it was being affected due to this
process flow.
 In-House major rejection.
 Unnecessary movement of components.
 Dust formation in machined components.
 As chamfering was a secondary operation it cannot
be included as in-process inspection.

6. Ishikawa analysis
INADEQUAT
E
TRAINING
COMPONEN
TS NOT
ARANGED
CASTINGS
DAMAGED
UNNECESSA
RY FLOW
MAJOR
REJECTION
S
UNNECESSA
RY
MOVEMENTCOMPONEN
TS NOT
ARRANGED
MISSING
OPERATION
S
CHAMFERIN
G MACHINE
BED NOT
CLEANED
CHAMFERING
MACHINE BED
NOT CLEANED
BINS
SHORTAG
E

7. P
DC
A
PLAN-DO-CHECK-ACT

8. MODIFIED PROCESS FLOW DIAGRAM
RAW MATERIAL
INGOTS &
MELTING IN
FURNACE
CASTINGS FETTLING
DRILLING &
TAPPING
CHAMFERING
CNC MACHINING &
BUSH PRESSING
INPROCESS
INSPECTION
FINAL INSPECTION PACKING &
DISPATCH

9. ADVANTAGES OVER THIS
METHOD
 Components are not damaged.
 Process flow can be much easier.
 Reduction in In-House Rejection & cost.
 In-process inspection can be done for all
parameters including chamfering.
 No dust formation in outer diameter.

10. PRODUCTIVITY
IMPROVEMENT
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Rejections PPM
Quality
Improvement
4.3
3.2
1.8
2.9
1.9
3.5
Before
After

11. CONCLUSION
 Modified process flow intimated to the customer.
 Pilot Lot submitted to the customer with proper
documents (P-PAP).
 Critical parameters are inspected and found to be
Ok.
 Improved method on Quality and reduced
rejections towards PPM.