Kaizen

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

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

Facing M/Cs
BRD
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

Facing M/Cs
CFG & NT3
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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)

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

Hot Bending
UBT
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

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

38
SPG.PIN
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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

08
CBT
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

06
SBT
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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)

30.31,32
NUT-1
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

28
NUT-1
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

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

FRG. 21
Hot Forge Shop
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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
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

-
COLD FORGING
30-4-01KAIZEN SHEET
G.S.AUTO, LUDHIANA
Machine :
Unit :
Date :
Problem :
Analysis :
(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?

Kaizen

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