C.P. Foundry Works is a foundry established in 1942 located in Nagpur, India. It produces cast iron products for customers like Mahindra & Mahindra and Johnson Lifts. The main processes include melting, mould making, core making, pouring, and cleaning. The company implements 5S and Kaizen for continuous improvement. Three Kaizen examples are provided: 1) Utilizing space for a fire extinguisher, 2) Arranging wires and cables systematically for safety, and 3) Disposing of unwanted material to save 5.54 square meters of space.

1. SHRI RAMDEOBABA COLLEGE OF
ENGINEERING AND MANAGEMENT
Department of Industrial Engineering
Case Study
C.P.FOUNDRY WORKS
Presented by
Ajinkya Sawarkar & Deepak Pandey
IInd Semester Mtech 2019-20
Submitted to
Dr. V.S. Deshpande

2. About Company
 NAME OF THE ORGANIZATION: C.P.FOUNDRY WORKS
 PLANT ADDRESS: P.O.UPPALWADI INDUSTRIALESTATE , KAMPTEE
ROAD, NEAR PILI NADI, NAGPUR.
 E-MAILADDRESS: foundry_ngp@bsnl.in & foundry_ngp@yahoo.com
 CONTACT PERSON: MAQSOOD ALAM
 YEAR OF ESTABLISHMENT: 1942
 Major customers :
1. Mahindra & Mahindra Ltd.
2. Johnson Lifts
MAHINDRA &
MAHINDRA
JOHNSON LIFTS

3. Company Products
CI ROLLING MILL COUPLINGS CI ROLLING MILL STAND CI GRATE STEEL ROLLING MILL PARTS
CI SANITARY GRATE CI METRIC WEIGHT CI MANHOLE COVER CI TILES
CI FLYWHEEL

4. Main Processes
o MELTING
o MOULD MAKING
o CORE MAKING
o POURING
o FOUNDRY SAND SYSTEM
o CLEANING AND FINISHING

5. 5 S Zone Wise Layout
ZONE 1 OFFICE
ZONE 2
PRODUCTION AND
PATTERN
ZONE 3 MELTING
ZONE 4 LAB
ZONE 5
STORE AND
OUTSIDE AREA
ZONE 6 INDUCTION
ZONE 7 DISPATCH

6. Kaizen
 From the Japanese words “kai-” which means “change”
and “-zen” which means “good.”
 Kaizen is defined as a continuous effort by each and
every employee (from the CEO to field staff) to ensure
improvement of all processes and systems of a particular
organization.
 Kaizen process aims at continuous improvement of
processes not only in manufacturing sector but all other
departments as well.

7. 5S
 5S represents Japanese words that describe the steps of a
workplace organization process.
 Seiri - (Sort)
 Seiton - (Straighten, Set)
 Seiso - (Shine, Sweep)
 Seiketsu - (Standardize)
 Shitsuke - (Sustain)

8.  The five S methodology helps a workplace remove items that
are no longer needed (sort).
 Organize the items to optimize efficiency and flow
(straighten).
 Clean the area in order to more easily identify problems
(shine)
 Implement color coding and labels to stay consistent with
other areas (standardize) and
 Develop behaviors that keep the workplace organized over the
long term (sustain).
 It can also referred as 7S adding Safety and Spirit to it.
5S

9. Red Tag Summary
Zone No.
Zone
Name
1st 2nd
3rd
4th
Red Tagging Campaign Red Tagging Campaign Red Tagging Campaign Red Tagging Campaign
5/7/2018 22/10/2018
Red tag
Found
Red Tag
Clear
Pending
Red Tag
Red tag
Found
Red Tag
Clear
Pending
Red Tag
Red tag
Found
Red Tag
Clear
Pending
Red Tag
Total Red
tag Found
Total Red
Tag Clear
Total
Pending
Red Tag
1 OFFICE 3 2 1
2
PRODUCTIO
N
14 8 6 3 3
3 MELTING 2 0 2 2 2
4 LAB 1 1 0
5
STORE AND
GREEN
AREA
8 0 8
6
INDUCTION
PLANT
2 2 0
7
DELIVERY/D
ISPATCH
0
8
9
Total 30 13 17 5 0 5

10. Red Tag Summary
0
2
4
6
8
10
12
14
16 Total RED TAG Captured – 35
Total Red Tag Cleared – 13
% Clearance – 37.14

11. Worst Point Photograph Zone No.2
Improvement: - SPACE UTILIZED
Shop: PATTERN ROOM Item: PATTERN
23.02.2018 11.11.2018
Before:- UNEVEN PATTERNS PLACED After:- ARRANGE PATTERN

12. Worst Point Photograph Zone No.6
Improvement: - AREA SPECIFIED
Shop: INDUCTION FURNACE Item: AREA NAME BOARD DISPLAYED
03.11.2019 03.11.2019
Before:- AREA NOT SPECIFIED After:-AREA SPECIFIED

13. Worst Point Photograph Zone No.5
Improvement: - MATERIAL STACKING
Shop: OUTSIDE AREA Item: FOOTSTEP , SURFACE BOXES
16/06/19 24/07/19
Before:- CASTINGS NOT ARRANGE
PROPERLY
After:- PAINTING AND STACKING OF
CASTINGS

14. Worst Point Photograph Zone No.6
Improvement: - CLEAN AREA
Shop: INDUCTION FURNACE Item: RACKS
31/01/2019 21/07/2019
Before:- Unwanted & wanted material kept in
mixed condition
After:-Unwanted material disposed off &
wanted material kept properly. Spaced saved
10.61sq.m.

15. Sort & Set Activity done in Store
• Analysis of current situation
• Getting list of materials from Production Lines
• SDQ From Buyers (Concerned Person From Company)
• Physical verification of material (with store to production
line)
• Temporary location with coloured chalk or removable
stickers
• Labelling of Every Required items with Proper location

16. Old Store Photographs

17. New Store Photographs
New Rack Arrangement Sorting of Tools

18. CONTINUOUS
IMPROVEMENTS

19. Kaizen 1
Company: C.P. FOUNDRY
WORKS
Dept : LAB Result : FIRE EXTINGUSHER Month : 5 MAR 2019
Subject : SPACE UTILIZATION Process : SAFETY
Before Improvement
( Photo or Explanation drawing)
After Improvement
( Photo or Explanation drawing)
1. Manpower, Man hour
Saving
2. Physical Distribution
(Transporting distance)
3. Space Saving
4. Commanisation,
Unification
5. Weight Reduction
6. Energy Saving
7. Yield
8. Quality Improvement
9. 5s Yes
10. Cost Reduction.
11. Safety Yes
12. Horizontal Application
13. Productivity improved
Earlier : NO FIRE EXTINGUSHER Now : SPACE IS UTILIZED FOR FIRE
EXTINGUSHER
Cost Saving per year
Date of Implementation 26
TH
JULY 2018
Benefits :
 SPACE UTILIZED.
 SAFETY IMPROVED.
Suggested by MR. TAHIR
SIR
Approved by MR. TAHIR SIR

20. Kaizen 2
Company: C.P. FOUNDRY
WORKS
Dept : OFFICE Result : WORKPLACE 5S & SAFETY IMPROVED Month : 23
RD
FEB 2018
Subject : PROPER ARRANGEMENT OF WIRES ,
CABLES & COMPUTER EQUIPMENTS
Process : SYSTEMATIC ARRANGEMENTS OF WIRES ,
CABLES & COMPUTER EQUIPMENTS
Before Improvement
( Photo or Explanation drawing)
After Improvement
( Photo or Explanation drawing)
1. Manpower, Man hour
Saving
2. Physical Distribution
(Transporting distance)
3. Space Saving
4. Commanisation,
Unification
5. Weight Reduction
6. Energy Saving
7. Yield
8. Quality Improvement
9. 5s Yes
10. Cost Reduction.
11. Safety Yes
12. Horizontal Application
13. Productivity improved
Earlier : WIRES , CABLES & COMPUTER
EQUIPMENTS ARE TANGLLED &
UNSAFE FOR USE
Now : WIRES , CABLES & COMPUTER
EQUIPMENTS ARE ARRANGED
SYSTEMATICALLY
Cost Saving per year
Date of Implementation 26
TH
JULY 2018
Benefits :
 SAFETY IMPROVED.
 HOUSEKEEPING & 5S IMPROVED.
Suggested by MR. JOSHI SIR
Approved by MR. TAHER SIR

21. Kaizen 3
Company: C.P. FOUNDRY
WORKS
Dept : moulding
area
Result : 5S IMPROVED Month : 24 FEB 2019
Subject : SPACE SAVED Process : DISPOSED OF UNWANTED MATERIAL
Before Improvement
( Photo or Explanation drawing)
After Improvement
( Photo or Explanation drawing)
1. Manpower, Man hour
Saving
2. Physical Distribution
(Transporting distance)
3. Space Saving YES
4. Commanisation,
Unification
5. Weight Reduction
6. Energy Saving
7. Yield
8. Quality Improvement
9. 5s Yes
10. Cost Reduction.
11. Safety
12. Horizontal Application
13. Productivity improved
Earlier : MOLDING BOXES AND WOODEN
MATERIAL LYING ON AREA
Now : DISPOSED OFF MATERIAL AND CLAEA
N AREA
5.54 SQ.M. SPACE SAVED
Cost Saving per year
Date of Implementation 24
TH
FEB 2019
Benefits :
 SPACE SAVED. (5.54 SQ.M.)
 HOUSEKEEPING IMPROVED.
Suggested by MR.
MAQSOOD SIR
Approved by MR. TAHER SIR

22. Thank You