This document summarizes a Kaizen improvement where two separate tools for drilling and tapping were replaced with a single drill cum tap tool. This reduced machine cycle time by 11.67 minutes per shift and tool costs by 20.15%. The new tool combines drilling and tapping into a single process, eliminating gaps between steps for tool changes and rapid positioning motions. As a result, the company gained increased machine capacity and reduced cycle times.

1. Break Through Kaizen
(Drilling & Tapping)
By: Mr Suchit Singh
Industrial Engineer (IIT Roorkee)

2. BEFORE AFTER
Modification / Improvement : Two different Tools got replaced by Single Drill cum Tap Tool
Modification Benefits : M/C time reduced by 11.67 min./Shift & Tool Cost reduced by 20.15 %
Drill Dia. 5 &Tap M6*1.0 Used
Separately
Drill & Tap together in Process
KAIZEN: DRILL CUM TAP

3. 3
GAP OBSERVED
(6 Sec) (3.5 Sec)
Tool Change, Rapid Motion
& Go to Home Position
Drilling & Tapping

4. 4
BASIC TOOL STRUCTURE

5. 5
TOOL COMBINATION STRUCTURE

6. 6
Process Parameters
Drill cum Tap M6*1.0
Drilling
S = 1500 RPM
F = 350 mm/min.
Tapping
S = 1000 RPM
F = 1.0 mm/rev.
Cutting Length
7.6 mm/Job

7. 7
RESULTS : GAIN TO COMPANY
181
175
172
174
176
178
180
182
BEFORE AFTER
140
144
138
139
140
141
142
143
144
145
BEFORE AFTER
M/C Cycle Time M/C Capacity
CycleTime(inSec)
No.ofJobs/Shift

8. 8
GOLDEN POINTS