This document contains a summary of a Kaizen sheet from a manufacturing plant. The Kaizen sheet describes a problem where two workers were engaged cleaning oil from center bolt cut lengths using saw dust, creating waste. The countermeasure was to use wet cotton waste instead of excess oil flow to reduce oil and eliminate saw dust cleaning, saving over Rs. 77,000 per year in expenses. The implementation was successful in eliminating the saw dust cleaning process. The document provides details on expenses before and savings achieved after the countermeasure.
This Gemba kaizen sample 30 slides is only part from the original 128 slides.
Kaizen Definition
KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination
What is MUDA?
Muda means any wasteful activity or any obstruction to smooth flow of an activity
Activity = Work + Muda
Expenditure = Cost + waste
That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!
ABOUT THE TRAINING PROGRAM :-
Kaizen is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. Kaizen was created in Japan following World War II. It comes from the Japanese words (“Kai”) which mean "change" and ("Zen") which means "good". Kaizen provides a foundation for exceeding goals, expectations and improving overall company performance.
DESIGNED FOR :-
Sr. Engineer, Engineer, Supervisor and Foreman engaged in maintenance, operation, Store, Supply chain, Quality, Safety and Engineering activities.
OBJECTIVE :-
At the conclusion of the training each Participates will be able to:-
Reduce work place stress
Increase team contribution to the company's "bottom line.
Continuous improvements in PQCDSM parameters.
Increase speed, improve quality and reduce non-value-added costs.
Creating a fun working environment
The Training is a 1 day course covering impartation knowledge of Kaizen and its associated Tools and; -application of Lean concepts to lead Kaizen Workshop/s with Innovation Projects for Change in a World Class Manufacturing Environment.
This training aims to impart a systematic review on all the critical aspects of Lean use to; lead Kaizen workshop and presentation using Standardize Kaizen form and methodology with;
Innovation to be competitive in the Global Business Environment.
COURSE CONTENT
Kaizen, its definition and Principles
Kaizen definition, Innovation Definition
Kaizen vs Innovation
Characteristics of a Lean Factory
Cellular Factory Layout
Multi-skilled Operators
6S and Visual Control
Kanban and Supermarkets
Rapid Changeover
Total Quality Approach
Right-sized, flexible equipment
Water Strider
Moving Production Lines
Total Productive Maintenance
Continuous Improvement
The 3 Pillars of Kaizen
1. 6S (5+1S) Housekeeping
2. Waste Elimination
- Types of Waste CLOSEDMITT
- Valued-added vs Non-value
added
3. Standard Operation
Three factors that accounts the 3 Pillars Activities.
1. Visual management,
2. The role of the supervisor,
3. Importance of training and
creating a learning
organization.
Innovation & Workshop Projects
Types of Innovation in Kaizen. Why Innovation?
Degree of Innovation-the act of creating new products,
processes, ideas, etc...
Examples of Types of Innovation
Innovating Process using Typical Kaizen concepts (Lean
methods)
Phase 1: Pre-Planning for Innovation
Phase 2: Execution - Innovation Week
Role of Leader, Facilitator, Participant in Innovation
Projects
Innovation Projects Implementation using Kaizen Forms for:
Daily and Weekly Report Outs
Follow-up for further Innovation
Global Manager Group has prepared presentation to provide information regarding documentation requirements for revised IATF 16949:2016 Certification. It described all primary documents like manual, procedures, plans, audit checklist, etc in details.
For further information about IATF 16949:2016 documentation requirements visit @ https://www.globalmanagergroup.com/
Overview of Lean Manufacturing types of production , comparison between Batch vs Continuous Flow , how to convert batch to continuous flow and the savings
Design of Ball Screw Mechanism for Retro Fit of External Grinding MachineIOSR Journals
Abstract: To convert the existing grinding machine into a good working machine, a ball screw mechanism is
designed and incorporated in the existing grinding machine by retrofitting process. Grinding machine removes
material from the work piece by abrasion, which can generate substantial amount of heat. Therefore a coolant
System is incorporated to cool the work piece, so that it does not overheat and go out of its tolerance. Grinding
practice is a large and diverse area of manufacturing and tool making. It can also rough out large volume of
metal quite rapidly. It is usually better suited to the machining of hard materials. Cylindrical grinding is also
called center type grinding. It is used in the removing the cylindrical surface and shoulders of the work piece.
The five type of cylindrical grinding are outside diameter (OD) grinding. Inside diameter (ID) grinding, plunge
grinding, creep feed grinding and center less grinding.It is used in the industries for grinding the nozzle body.
The grinding machine can be changed to automatic machine according to one of the latest technologies called
PLC’s controller. The manually operated grinding machine has some of the in-accuracies and disadvantages
compared to new modern CNC grinding machines.Based on the case study of both manual and CNC grinding
machine, the manual machine is converted into automatic machine for the better accuracy and efficiency. The
main replacement of the machine parts are hydraulic cylinder and stepper motor by ball screw mechanisms and
servo motor.
This Gemba kaizen sample 30 slides is only part from the original 128 slides.
Kaizen Definition
KAIZEN is a Commonsense Approach to Low Cost Management. It focuses on MUDA elimination
What is MUDA?
Muda means any wasteful activity or any obstruction to smooth flow of an activity
Activity = Work + Muda
Expenditure = Cost + waste
That is, for each activity there is expenditure and every work there is a cost associated. Any expenditure on the Muda is a waste!
ABOUT THE TRAINING PROGRAM :-
Kaizen is a system of continuous improvement in quality, technology, processes, company culture, productivity, safety and leadership. Kaizen was created in Japan following World War II. It comes from the Japanese words (“Kai”) which mean "change" and ("Zen") which means "good". Kaizen provides a foundation for exceeding goals, expectations and improving overall company performance.
DESIGNED FOR :-
Sr. Engineer, Engineer, Supervisor and Foreman engaged in maintenance, operation, Store, Supply chain, Quality, Safety and Engineering activities.
OBJECTIVE :-
At the conclusion of the training each Participates will be able to:-
Reduce work place stress
Increase team contribution to the company's "bottom line.
Continuous improvements in PQCDSM parameters.
Increase speed, improve quality and reduce non-value-added costs.
Creating a fun working environment
The Training is a 1 day course covering impartation knowledge of Kaizen and its associated Tools and; -application of Lean concepts to lead Kaizen Workshop/s with Innovation Projects for Change in a World Class Manufacturing Environment.
This training aims to impart a systematic review on all the critical aspects of Lean use to; lead Kaizen workshop and presentation using Standardize Kaizen form and methodology with;
Innovation to be competitive in the Global Business Environment.
COURSE CONTENT
Kaizen, its definition and Principles
Kaizen definition, Innovation Definition
Kaizen vs Innovation
Characteristics of a Lean Factory
Cellular Factory Layout
Multi-skilled Operators
6S and Visual Control
Kanban and Supermarkets
Rapid Changeover
Total Quality Approach
Right-sized, flexible equipment
Water Strider
Moving Production Lines
Total Productive Maintenance
Continuous Improvement
The 3 Pillars of Kaizen
1. 6S (5+1S) Housekeeping
2. Waste Elimination
- Types of Waste CLOSEDMITT
- Valued-added vs Non-value
added
3. Standard Operation
Three factors that accounts the 3 Pillars Activities.
1. Visual management,
2. The role of the supervisor,
3. Importance of training and
creating a learning
organization.
Innovation & Workshop Projects
Types of Innovation in Kaizen. Why Innovation?
Degree of Innovation-the act of creating new products,
processes, ideas, etc...
Examples of Types of Innovation
Innovating Process using Typical Kaizen concepts (Lean
methods)
Phase 1: Pre-Planning for Innovation
Phase 2: Execution - Innovation Week
Role of Leader, Facilitator, Participant in Innovation
Projects
Innovation Projects Implementation using Kaizen Forms for:
Daily and Weekly Report Outs
Follow-up for further Innovation
Global Manager Group has prepared presentation to provide information regarding documentation requirements for revised IATF 16949:2016 Certification. It described all primary documents like manual, procedures, plans, audit checklist, etc in details.
For further information about IATF 16949:2016 documentation requirements visit @ https://www.globalmanagergroup.com/
Overview of Lean Manufacturing types of production , comparison between Batch vs Continuous Flow , how to convert batch to continuous flow and the savings
Design of Ball Screw Mechanism for Retro Fit of External Grinding MachineIOSR Journals
Abstract: To convert the existing grinding machine into a good working machine, a ball screw mechanism is
designed and incorporated in the existing grinding machine by retrofitting process. Grinding machine removes
material from the work piece by abrasion, which can generate substantial amount of heat. Therefore a coolant
System is incorporated to cool the work piece, so that it does not overheat and go out of its tolerance. Grinding
practice is a large and diverse area of manufacturing and tool making. It can also rough out large volume of
metal quite rapidly. It is usually better suited to the machining of hard materials. Cylindrical grinding is also
called center type grinding. It is used in the removing the cylindrical surface and shoulders of the work piece.
The five type of cylindrical grinding are outside diameter (OD) grinding. Inside diameter (ID) grinding, plunge
grinding, creep feed grinding and center less grinding.It is used in the industries for grinding the nozzle body.
The grinding machine can be changed to automatic machine according to one of the latest technologies called
PLC’s controller. The manually operated grinding machine has some of the in-accuracies and disadvantages
compared to new modern CNC grinding machines.Based on the case study of both manual and CNC grinding
machine, the manual machine is converted into automatic machine for the better accuracy and efficiency. The
main replacement of the machine parts are hydraulic cylinder and stepper motor by ball screw mechanisms and
servo motor.
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quantity & reducing manpower.
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We all have good and bad thoughts from time to time and situation to situation. We are bombarded daily with spiraling thoughts(both negative and positive) creating all-consuming feel , making us difficult to manage with associated suffering. Good thoughts are like our Mob Signal (Positive thought) amidst noise(negative thought) in the atmosphere. Negative thoughts like noise outweigh positive thoughts. These thoughts often create unwanted confusion, trouble, stress and frustration in our mind as well as chaos in our physical world. Negative thoughts are also known as “distorted thinking”.
Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
This presentation provides a briefing on how to upload submissions and documents in Google Classroom. It was prepared as part of an orientation for new Sainik School in-service teacher trainees. As a training officer, my goal is to ensure that you are comfortable and proficient with this essential tool for managing assignments and fostering student engagement.
Operation “Blue Star” is the only event in the history of Independent India where the state went into war with its own people. Even after about 40 years it is not clear if it was culmination of states anger over people of the region, a political game of power or start of dictatorial chapter in the democratic setup.
The people of Punjab felt alienated from main stream due to denial of their just demands during a long democratic struggle since independence. As it happen all over the word, it led to militant struggle with great loss of lives of military, police and civilian personnel. Killing of Indira Gandhi and massacre of innocent Sikhs in Delhi and other India cities was also associated with this movement.
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In Odoo, the multi-company feature allows you to manage multiple companies within a single Odoo database instance. Each company can have its own configurations while still sharing common resources such as products, customers, and suppliers.
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Welcome to TechSoup New Member Orientation and Q&A (May 2024).pdf
Kaizen
1. Straightening
Bar Drawing
16.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Two men engaged on three machines
for removing oil from Centre Bolt cut
length with saw dust.
To eliminate cleaning process of Centre
Bolt cut length with saw dust.
(Muda of process).
Oily Surface
Flow of excessive oil fed on the
straightening Rollers to save it from
friction/deterioration
Why ?
Why ?
3465
81322
0
1000020000
30000
40000
5000060000
70000
80000
Before After
Rs.
Cleaning with Saw Dust
Wet waste cotton used
instead of flow of oil
Excessive flow of oil
To reduce oil flow & to
eliminate saw dust cleaning
process
StatusMachine Target Date Resp
RS,GS,PS,AS,AS,JS
To eliminate saw dust cleaning process
by 18.07.2001
01 (ZONE-1)
.
OIL PIPE
OIL
Straightening Roller
Straightening RollerWork Rest
Straightening Roller
Wet Sponge/Cotton Pc.
Work Rest
Elimination of Cleaning with Saw Dust
Saving of 16 Man Hours/ Day
Saving Rs.77857.00 / Year
(SHEET ENCLOSED)
17
18
20.07.01
20.07.01
GS Implemented
ImplementedGS
2. BEFORE
1. OIL (DIESEL) CONSUMPTION / DAY : 5 LITRES
PRICE / LITRE (RS.) : Rs.16.66
COST OF OIL/DAY (16.66 x5) : Rs. 83.30
COST OF OIL/MONTH (83.30 x26) : Rs. 2165.80
COST OIL OIL / YEAR (2165.80 x12) : Rs.25989.60
2. SALARY OF 2 PERSONS/ YEAR : Rs.48000.00
3. SAW DUST CONSUMPTION / DAY : 23.3 KGS
SAW DUST COST/BAG : Rs.21.00
MONTHLY EXPENSES OF SAW DUST (21.00x26) : Rs.546.00
YEARLY SAW DUST EXPENSES (546.00x12) : Rs. 6552.00
4. MONTHLY ELECTRICITY EXPENSES : Rs.65.00
YEARLY ELECTRICITY EXPENSES : Rs. 780.00
TOTAL EXPENSES PER YEAR (25989.60 + 48000+6552+780) : Rs. 81322.00
AFTER
YEARLY EXPENSES OF OIL (0.7 LTR/DAY x26 x 12) : Rs. 3465.00
TOTAL SAVING/YEAR (81322.00 -3465.00) : Rs. 77857.00
ANNEXURE: KAIZEN-1
3. Facing M/Cs
BRD
01.08.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Extra movement of Facing Operators
To eliminate the movement of operator at
Centre Bolt cut length facing machines
(Muda of movement & Muri)
Distance between facing &
Straightening M/c was 14’ & 11’
respectively
Why ?
0
386
0
100
200
300
400
Before After
Operator goes to Straightening M/c
to pick up cut length for facing (80
times in a day)
2 Facing machines shifted
near Straightening M/Cs
Improper Layout
To eliminate Muda of Movement
& Muri
StatusMachine Target Date Resp
GS, AK, PS, AS
To eliminate operator movement & Muda
before 07.08.2001
03 (ZONE-1)
01
03
02
01
02
03
Straightening
Machines
Facing
M/Cs
14 Feet
5 Feet
11 Feet
Tray
Facing
M/Cs
Straightening
M/Cs
01
02
03
01
02
03
3 Feet
5 Feet
3 Feet
Operator Movement :386 Km/Year
Man Hours Saved (386/5) : 77 Hours
Wages saved / Hour : Rs. 10.00
Wages/Year (77x10) : Rs. 770.00
(Total cost reduction)
Operator Fatique Reduced
Why ?
Improper Layout
Picking & operation within operator’s arm distance
4. Facing M/Cs
CFG & NT3
07.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Extra movement of Material
To reduce Muda Of Transportation
from Cold Forging to Nut-3 Sec.
Facing & Chamfering M/Cs are not
available in Cold Forging Section (M/c
Layout constraint)
Why ?
1297
5100
0
1000
2000
3000
4000
5000
Before After
Material movement from Cold Forging
after cutting & One side reducing to
Nut-3 for Chamfering & Facing, then
again comes back to Cold Forging for
2nd side reducing, then again
returned to Nut-3 for stamping &
threading
Facing M/Cs installed in
Cold Forging Section
Due to non-availability
of facing M/Cs in Cold
Forging Section
Install S.P.M. Facing machines
in Cold Forging Section
StatusMachine Target Date Resp
AK, GS, PS, AS, JS
To reduce material movement by 10.07.01
04 (ZONE-1)
Cold Forging
Nut-3
Cold Forging
Nut-3
Auto Black
Packing
195.5 m
195.0 m
195.0 m
154.95 m
94.0 m
Total : 834.45 m
COLD FORGING
AUTO- BLACK
PACKING
118.0 M
94.0 M
TOTAL : 212.0 M
SAVING/YEAR :
Rs. 5100.00-1297.00 = 3803.00
(SHEET ENCLOSED)
5. ANNEXURE : KAIZEN-04
BEFORE COUNTER MEASURE
Distance covered/Day : 834.45 M
Distance covered/Year : 2553.4Km
(834.45x306 Days)
Average distance
covered by man/Hr : 5.000 Km
Man Hrs(2553.4/5) : 510
Wages/Hour (Rs.) : 10.00
Total Wages/Year : 5100.00
(510Hrs x Rs.10.00)
AFTER COUNTER MEASURE
Distance covered/Day : 212 M
Distance covered/Year 648.72Km
(212 M x 306 Days)
Average distance
covered by man/Hr : 5.000
Km
Man Hrs(648.72/5) : 129.74
Wages/Hour (Rs.) : 10.00
Total Wages/Year : 1297.00
(129.7 Hrs x Rs.10.00)
SAVING/YEAR : 3803.00
6. Hot Bending
UBT
02.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Gap controlled manually
M/c is not capable to control the gap
Why ?
Why ?
208320
312480
0
1 0 0 0 0 0
2 0 0 0 0 0
3 0 0 0 0 0
Before After
Rs.
Material Overheating
M/c to be modified by
Machine design error
To avoid overheating during
Bending
StatusMachine Target Date Resp
BS,JS,RS,BS,DS
30% Electrical Energy saving at Hot
Bending process by 30.07.2001
01 (Zone-2)
Why ?
Machine Design error
Saving of Electrical Energy on Hot
Bending Process
More Electric Energy consumed for
Induction Heating the U.Bolts e.g.
Rs.26,040.00/ Month
providing taper attachment to control the gap
Heating Time : 15 Seconds for 20mm dia
Heating time : 10 Seconds for 20mm dia
SAVING/YEAR (Rs) : 1,04,160.00
(SHEET ENCLOSED)
Taper attachment
Follower
Adjusting
Screw
Bending Die
Bending Roll
7. ANNEXURE: KAIZEN-01 (ZONE-2)
BEFORE
ELECTRIC LOAD /HOUR : 40 AMPS
ENERGY COST/HR.(40 x Rs.3.90) : 156.00
ENERGY COST/SEC(Rs.156/60x60)Rs. : 0.0434
HEATING TIME/PIECE : 15 Seconds
ENERGY COST/PIECE (15x0.0434)Rs. : 0.651
MONTHLY PRODUCTION : 40,000 PCS
MONTHLY ENERGY COST(40000x0.651): 26,040.00
YEARLY ENERGY COST(26040.00x12) : 3,12,480.00
AFTER
ELECTRIC LOAD /HOUR : 40 AMPS
ENERGY COST/HR.(40 x Rs.3.90) : 156.00
ENERGY COST/SEC(Rs.156/60x60)Rs. : 0.0434
HEATING TIME/PIECE : 10 Seconds
ENERGY COST/PIECE (10x0.0434)Rs. : 0.434
MONTHLY PRODUCTION : 40,000 PCS
MONTHLY ENERGY COST(40000x0.434): 17360.00
YEARLY ENERGY COST(17360.00x12) : 2,08,320.00
SAVING/ YEAR (312480.00-208320.00) : 1,04,160.00
8. 38
SPG.PIN
20.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Operator moves 4 meters to unload
the Bar & places it on the floor
Reduce Operator Movement at Bar
Turning Process (M/c No.31)
(Muda of Movement)
Operator has to hold 5 meter long bar
from the end
Bar stand not available
Why ?
Why ?
Operator movement & placing
on the floor
Rack provided at machine
height level
Bar stand not available
To eliminate muda of movement
& Muri
Status
12.08.01
Machine Target Date Resp
SS35
JS, GS, DS, SS
Reduce the operator movement & fatique
50% before 05.08.2001
(HOW MANY)
5000
Before After
1008
4032
0
1000
2000
3000
4000
Rs.
02 ( Zone-02)
36 12.08.01 SS
Implemented
Implemented
Turning Bars
BAR TURNING M/C
Support
Turning Bars
BAR TURNING M/C
Rack
Time Consumed(Unloading) Time Consumed
Daily (20x4) = 80 Min. Daily(20x1)= 20 Min.
Monthly(80x25) = 2000 Monthly(20x25)=500
Monthly Cost (2000x0.168) Monthly Cost(500x0.168
=Rs.336.00 = Rs. 84.00
Yearly Cost (336x12) Yearly Cost(84.00x12)
=4032.00 =1008.00
SAVING/YEAR(4032.00 - 1008.00) = 3,024.00
9. 08
CBT
04.08.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
One extra worker being used for filing
operation, who removes the burr
(Burr developed at the head milling
operation).
Save one worker at Filing operation
(Muda of Waiting)
Material received from milling m/c
having burr
Milling operator was overlooked the
burr
Why ?
Why ?
6000
8000
0
2000
4000
6000
8000
Before After
Rs.
Milling operation is done by one
worker & developed burr is removed
by second worker by filing operation
Worker used for filing
Awareness/ Training given
to operator to utilize his idle
time for filing
Lack of awareness/
Training
To eliminate Muda of Waiting
Milling & filing operations will be
performed by one worker ( During
waiting time for milling process, same
worker removed the burr) so, the
second worker to be saved
Status
25.08.01
Machine Target Date Resp
PS29
H.S., R.P., B.S., P.S.,B.S.
One worker will be saved by 05.08.2001
01 ( ZONE-03)
Why ?
1000 Pcs made by 3 Milling +1 Filing operator
Salary of 4 Operators (2000x4) : 8000.00 (Rs)
Salary of 3 Operators (2000x3) : 6000.00 (Rs)
Saving/ Month (8000-6000) : 2000.00 (Rs)
Saving/ Year (2000x12) :24000.00(Rs.
Milling operator not used his idle time
for filing the burr
Why ?
Lack of awareness/ training
10. 06
SBT
26.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Wastage of electric power (when the
process is completed) but the 2 motors
of M/c & Coolant Pump run continuously
during idle time
To save electric power by installing limit
switch on m/c no.06 (Milling M/c)
Power consumed by 2 Motors in idle
time
No provision available to stop the M/c
in idle time
Why ?
Why ?
220
393
0
200
400
Before After
Rs.
Wastage of power on machine
Limit switch provided
No provision to stop the
m/c when m/c is not
carrying out the process
Save electric power by installing
limit switch on the machine
StatusMachine Target Date Resp
H.S., R.P., B.S., P.S.,B.S.
Save electric power on m/c No.06 up to
28.07.2001
Earlier power consumption/shift : 4.77 Units
Price for the same (4.77 x Rs.3.30) : 15.74
Cost / Month (Rs.15.74 x 25 Days) : 393.00
Now Power consumption/Shift : 2.67 Units
Price for the same (2.67 x Rs.3.30) : 8.81
Cost / Month( Rs.8.81x 25 Days) : 220.00
Saving/Month (Rs.393-200) : 173.00
Saving/Year (Rs.173x12 months) : 2076.00
2 MOTORS ARE RUNNING REGULARLY
(MAIN MOTOR OF M/C & MOTOR OF
COOLANT PUMP) IN IDLE TIME ALSO.
SO THE WASTAGE OF ELECTRIC POWER
IS OBSERVED
THE 2 MOTORS STOPPED IN IDEL TIME
BY PROVIDING LIMIT SWITCHES
( SAVE OF ELECTRIC POWER) 05 20.07.01 HS,RP Implemented
21
22
25.08.01
26.08.01
HS,RP
HS,RP
Why ?
Lack of awareness / training
02 (ZONE-03)
11. 30.31,32
NUT-1
16.07.01KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Nut Tapping machines 30,31,32 are
being operated by 3 operators ( one
operator for each machine)
Manpower reduction and space recovery
in Nut-1 Section
Distance between m/c is 5 Feet
Improper layout
Why ?
Why ?
73260
24420
0
20000
40000
60000
Before After
Rs.
3 Operators at 3 Machines
LAYOUT CHANGED
Distance between M/Cs
is too large & improper
layout
Layout of M/Cs to be changed
StatusMachine Target Date Resp
JS,CS, RC, GS & HS
One operator will operate 3 machine
by 21.07.01
01 (ZONE-4)
31 30
32
5 FEET 5 FEET
3 MACHINES, 3 OPERATORS
31
30
32
31
2 Feet
2 Feet
3 MACHINES, 1 OPERATOR
3 Operators Salary/ Year (Rs) : 73260
1 Operator salary / Year (Rs) : 24,420
Net Saving / Year:
73260-24420 (Rs) : 48840
12. 28
NUT-1
05.07.2001KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Operator fatigue is more on Tapping M/c No.28
After tapping oily Nuts are kept in trolley on wire
mesh and oil from these Nuts is collected into
trolley which is again re-filled in the M/c oil tank
by lifting the trolley manually 3-4 times in a
shift.
Time wastage = 30 Minutes/Shift
Oil Wastage = 200 ML/Shift= Rs.7.80
Operator fatigue is more on Tapping M/c
No.28 (MURI & Muda of Movement)
Trolley is being lifted by Operator 3-4
times in a shift to re-fill the oil in M/c
oil tank through drum
Absence of direct oil passage
from trolley to oil tank
Why ?
Why ?
0
8280
0
2500
5000
7500
10000
Before After
Rs.
Operator fatigue/ time wastage/ Oil
wastage
Oil Passage provided
Absence of oil passage
To eliminate Muri & Muda of
Movement
Status
18.07.01
Machine Target Date Resp
CS,GS25
CS,RC,GS,HS
Trolley & oil tank to be connected with
plastic pipe for direct oil passage by
10.07.2001
02 (ZONE-4)
Oil wastage eliminated
Oil re-filling time saved
Operator Fatigue eliminated
Net Saving/Year/Shift:2340+1800 = Rs.4140.00
Net saving/year/day: 4140.00x2 =Rs.8280.00
Implemented
MACHINE
OIL TANK
NUTS
TROLLEY
DRUM
MACHINE
OIL TANK
NUTS
TROLLEY
PIPE
PLASTIC
30
31
32
20.07.01
26.07.01
28.07.01
CS,RC
CS,GS
CS,RC
Implemented
Implemented
Implemented
13. ANNEXURE: KAIZEN NO. 02 ( ZONE-4)
BEFORE COUNTER MEASURE
OIL REFILL QUANTITY = 20 LITRES/SHIFT
OIL WASTAGE/MONTH/Shift (Rs) = 195.00
(Rs.7.80 x 25days)
OIL WASTAGE/YEAR/Shift (Rs) = 2340.00 (A)
(Rs.195.00 X 12 months)
TIME WASTAGE/MONTH/Shift (Rs) = 150.00
(30 Min x 25 = 750 Min(12.5 Hrs)
Time wastage/Year/Shift (Rs.) = 1800.00 (B)
(150.00x12)
Total Wastage/ Year/Shift (A+B) Rs. = 4140.00
Total Wastage/Year/Day(4140x2) Rs. = 8280.00
AFTER COUNTER MEASURE
• OIL WASTAGE ELIMINATED
NET SAVING/ YEAR/Shift (Rs) = 2340.00
• TIME WASTAGE ELIMINATED
•NET SAVING /YEAR/Shift (Rs) =1800.00
•TOTAL SAVING/YEAR/SHIFT (2340+1800.00)(Rs) =4140.00
•TOTAL SAVING/YEAR/DAY(4140x2) (Rs.) =8280.00
14. FRG. 21
Hot Forge Shop
27.07.01KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
Muda of Movement & counting
process.
To eliminate the movement & counting of
material from trolley to tray on m/c no. 21
trimming
Wheeled trolley size is big &
Height is less from reqd size
Generic trolley not suitable for
trimming m/c
Why ?
Material moves from Trolley to tray ?
TWO WHEELED
TROLLEYS PROVIDED ON
MACHINE & COUNTER TO BE INSTALLED
Fixed tray is with m/c
Fixed tray to be replaced with
wheeled trolley of same size
& Counter to be installed on m/c
StatusMachine Target Date Resp
Hamir Singh, Lakhwant Singh,
Rattan Singh
Moveable trolley to be made
Before 30.07.01
04 ( V)
TIME Saving = 1.5 Hour/Day/M/c
= 450 Hour/Year/M/c
=56Man Days/M/c
Time saving on 2 Machines = 112 Man days/year
= 3.7 Months
Yearly Saving = 3.7x2500=Rs. 9250/-
FRG. 22 13.08.01 ImplementedH.S, S.S
2300
2700
2000
2200
2400
2600
2800
BEFORE AFTER
PRODUCTION
PERM/C
Why ?
Why ?
Lack of awarenes/training
COUNTER YET
TO BE
INSTALLED
15. -
COLD FORGING
30-4-01KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Kaizen Theme : Target & Target date :
Problem :
Before Counter Measure :
Benefits/Results after Implementation :
Analysis :
After counter measure : Scope & plan for horizontal deployment :
(WHAT& WHICH) (HOW MUCH & WHEN)
(WHERE)
(HOW MANY)
Implemented by :
(WHO)
Kaizen no. :
(HOW)
Root Cause :
Idea :
Counter measure :
PRODUCTION OF STEP TURNING
IS LESS AS COMPARED TO STEP
REDUCING OPERATION & TURNING
IS FOLLOWD BY GRINDING
OPERATION & CYCLE TIME MORE
e.g.62 HOURS FOR TURNING & GRD
OPERATION
TO ELIMINATE THE GRINDING PROCESS IN
MBJT-228 (MUDA OF PROCESS)
TURNING IS DONE TO MAINTAIN ANGLE 30
DEG & TURNING OPERATION IS NOT
CAPABLE TO MEET REQD THE PRE THRD
ROLL DIA
.
Why ?
1 BLANK CUTTING
2 HEAD FORGING
3 STEP TURNING
4 STEP GRINDING
5 THREADING
THREADED R.D.IS BEING MADE BY
TURNING AND THEN BY GRD OPERATION
NON THREADED DIA TO BE CHANGED SAME AS OF PRE
THREAD ROLL DIA
END APPLICATION HAS
NO MEANING OF ANGLE
30 DEG
CUSTOMER TO BE APPROACHED
FOR REVIEW OF SPECIFIACTION
1 BLANK CUTTING
2 STEP REDUCING
3 HEAD FORGING
4 THREADING
Status
20.9.01
PART No Target Date Resp
A.K./JSMBJT-226
HAMIR SINGH,ASHOK KUMAR,
JATINDER SINGH,PARAMJIT SINGH
DRAWING WITH ANGLE 15 DEG TO BE
SENT TO CUSTOMER FOR APPROVAL
05 (V)
REDUCTION IN WT/PC=11 gms
MAT.SAVING = 33 Kg/MONTH
REDUCTION IN OPERATION COST=Rs 0.42/PC
MONTHLY SAVING IN 3000PCS=690+1260
YEARLY SAVING = Rs 23400/-.
16230
14280
13000
13500
14000
14500
15000
15500
16000
16500
BEFORE AFTER
COSTINRs
CYCLE TIME IS MORE
WHY?