Process Improvement

2. Introduction to the team
TEAM MEMBERS
B V Mahesh Vinay A.M. Suresh T V G Reddy Vasanth
36 40 55 3 Trainee
40 27 29 52 20
20 7 11 30 2
QC QC QA PD QC
TEAM Advisor: T V G Reddy
TEAM Leader : Ravi Rao
Plant : Suma Spring
Deptt. : Production
Sect. : Winding
Circle Name : Improvement of Productivity
Theme : Productivity Improve with Operator fatigue Reduce
Member 1 Member 2 Member 3 Member 4 Member 5 Observer Observer
Name
ECode
Age
Exp
Cycle : Winter / Summer
Date of Registration :
14.05.2016.
Section

3. Activity Plan
START OF NH ACTIVITIES : Jan- 2016 Month
COMPLETION OF NH ACTIVITIES : June-2016 Month
PLAN
ACTUAL
SR.
NO.
ACTIVITIES PDCA RESP. Jan-16 Feb-16 Mar-16 Apr-16 May-16
1. Selection of Theme A N
2. Study of current situation TVG R
3 Goal / Objective setting A M S
4 Identification of Causes Team
5 Planning of C.Measures &
assigning responsibilities
Team
6 Implementation of Counter
Measures
Team
7 Countermeasure
effectiveness check
Ravi Rao
8 Prevention and
Standardization
Ravi Rao
9 Presentation Preparation Suresh
P
P
P
D
D
D
C
C
A

4. Reason for Selection
Avoid Operator Fatigue
• Doing manual operation will create more pain
on operator hand will cause to frequent Leaves
from them.
Improve productivity
• Produced Quantity Less and rejection Quantity
more with current Manual process.
Reduce Manpower
• With Manual unable to balance with the
machine produced quantity which is causing to
extra manpower.

5. Flow Diagram- Before Improvement
Received Raw
material from
Supplier
Inspection of
Raw material
Winding
Rolling Bending
(Manual)
Heat treatment
Identification
mark
Final Inspection
Surface
treatment / oiling
Packing
Despatch

6. Analysis
Before bending After bending
M/c Run Rate = 11 Pcs/Min
Operator Run Rate = 6 Pcs/Min
with operator Fatigue

7. Manual Vs. Pneumatic
Manual Tool for Hook Bending Pneumatic Tool for Hook Bending
Pneumatic Run Rate = 22 Pcs/Min
Operator Run Rate = 6 Pcs/Min
with operator Fatigue / 2 operators

8. Manual Tool for Hook Bending Pneumatic Tool for Hook Bending
Pneumatic Run Rate = 22 Pcs/Min
Operator Run Rate = 6 Pcs/Min per
operator with Fatigue
Manual Vs. Pneumatic
Before Improvement After Improvement

9. Benefits / Learning
FI.NO Before Improvement After Improvement
1 More difficult to operate with
manual which will create Hand
elbow & shoulder pain
Pneumatic piston with gear operating
tool
2 2 Manpower to balance the M/c
quantity for the Hook bending
operation.
Machine operator itself handling the
hook bending process in Pneumatic
3 12 Pcs /Min with 2 operator 22 Pcs /Min with Single Machine
Operator.
4 Unable to meet the customer
schedule with all HMSI Units
Able to meet more then scheduled
quantity with all HMSI Units.
5 Difficult to Handle & setup the tool
every time.
Easy to handle & attached with the
Machine.

10. Received Raw
material from
Supplier
Inspection of
Raw material
Winding
Rolling Bending
(Pneumatic)
Heat treatment
Identification
mark
Final Inspection
Surface
treatment / oiling
Packing
Despatch
Flow Diagram- After Improvement