This document summarizes a project to reduce ergonomic risks at workstations in the KV cylinder block line to facilitate greater gender diversity. The project aims to reduce ergonomic risk scores at six workstations from their current levels to below 10, allowing for an increase in the proportion of women employed from the current 7% to 14%. Key activities outlined include measuring current ergonomic risk scores, analyzing risk factors, developing solutions to reduce risks, implementing changes, and monitoring outcomes. The sponsor, process owner, and project team are identified and a timeline is laid out to complete the project in 4-6 months.
Service revamp lean six sigma black belt projectSumit K Jha
Project- Service revamp
Type- Lean Six Sigma Black Belt Project
Outline- To improve the entire process of getting purchase orders, purchasing, manufacturing, warehousing and installation
Tools/Framework- Six Sigma concepts such as SIPOC, fish bone analysis, control charts and hypothesis testing; statistical tools, Microsoft Dynamic AX
Role- Project manager
Outcome- The successful completion of the project yielded in cost savings of INR 1.61 crores
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
This slide deck will help you appreciate the application of statistics (and now data science) in the field of Quality Management and Process Improvement. And why is there a need to produce a consistent "in spec" product at 99.9997% of the time.
Service revamp lean six sigma black belt projectSumit K Jha
Project- Service revamp
Type- Lean Six Sigma Black Belt Project
Outline- To improve the entire process of getting purchase orders, purchasing, manufacturing, warehousing and installation
Tools/Framework- Six Sigma concepts such as SIPOC, fish bone analysis, control charts and hypothesis testing; statistical tools, Microsoft Dynamic AX
Role- Project manager
Outcome- The successful completion of the project yielded in cost savings of INR 1.61 crores
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
This slide deck will help you appreciate the application of statistics (and now data science) in the field of Quality Management and Process Improvement. And why is there a need to produce a consistent "in spec" product at 99.9997% of the time.
More Information:
https://flevy.com/browse/business-document/six-sigma--statistical-process-control-spc-604
DOCUMENT DESCRIPTION
The Six Sigma - Statistical Process Control (SPC) Training Module includes:
1. MS PowerPoint Presentation including 136 slides covering
- Introduction to Statistical Process Thinking,
- Basic Statistics,
- Introduction to Statistical Process Control,
- Statistical Process Control Charts,
- Sample Size & Frequency,
- Out-of-Control Action Plan, and
- Process Control Plan.
2. MS Excel Confidence Interval Analysis Calculator making it really easy to calculate confidence intervals (mean value, standard deviation, capability indices, proportion, count) and perform a Comparison of two statistics (mean values, standard deviations, proportions, counts).
"After you have downloaded the training material, you can change any part of the training material and remove all logos and references to Operational Excellence Consulting. You can share the material with your colleagues and clients, and re-use it as you need. The only restriction is that you cannot publicly re-distribute, sell, rent or license the material as though it is your own. Thank you."
Got a question about this presentation? Email us at support@flevy.com.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Failure Mode & Effects Analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with the highest-priority ones. FMEA also documents current knowledge and actions about the risks of failures, for use in continuous improvement.
In this training presentation, you can teach your employees on the proper steps to construct an FMEA for a design or process, and then implement action plans to eliminate or reduce the risks of potential failures.
LEARNING OBJECTIVES
1. Understand what an FMEA is, why it is used, and when can it be deployed
2. Understand the definitions, scoring system and calculations used in an FMEA
3. Learn the steps to developing an FMEA and the pitfalls to avoid
CONTENTS
1. Introduction to FMEA
2. FMEA: Definitions, Scoring System & Calculations
3. FMEA Procedure
4. FMEA Example
We all want to support the accomplishment of safe and trouble-free products and processes. Failure Mode and Effects Analysis has the potential to be a powerful reliability tool to reduce product design and manufacturing risk in a cost effective manner. With shorter product development times, tighter budgets and intense global competition, Design for Reliability tools such as FMEA must be applied correctly. Yet in practice, FMEA does not always achieve the expected results. Why is it that some companies have outstanding success in their FMEA application and others do not? What is the difference between well done and poorly done FMEAs? What are the essential elements of an effective FMEA process? These questions and more are answered in these three new short courses on FMEA.
In this 1-hour webinar you’ll learn how to select the right improvement project which will help you set yourself up for success. We’ll cover best practices, challenges you may face and a walk-through of how to use a Project Selection Tool.
Download the slides and more at: https://goleansixsigma.com/webinar-select-right-improvement-project/
Start your free Yellow Belt Training at: http://www.goleansixsigma.com/free-lean-six-sigma-training/
Get a FREE performance management kit and access to all of Victor's full videos at:
www.lifecycle-performance-pros.com
This presentation discusses the common obstacles to successfully managing organizational performance, namely aligning performance to organizational goals and objectives. This presentation discusses the 4 key alignment areas and offers techniques on how to successfully align perform to each area.
Lean six sigma and process excellence helps organisations to improve their productivity and reduce waste in the activities of management and operations. Here you can find out and learn about lean six sigma and its important aspects. Anexas Consultancy helps entrepreneurs and professional to grow their business and career in right direction. You can find more information here:http://www.leansixsigma.co.in/readmore.php?Service_Details&id=1
The ultimate guide on constructing a FMEA process for Manufacturing, Maintenance, Services and Design.
The presentation include step by step on how to determine the failure modes, failure effects, assign severity, assign occurrence, assign detection, calculate risk priority numbers and prioritize the RPNs for action. With some examples and illustrations.
Presentation contents:
1. Determing failure modes, effects and causes.
2. FMEA team & team leader.
3. Brainstorming.
4. The basic steps of FMEA.
5. Examples.
Persuasive Strategic Analysis for MTC.
Supply chain management strategy Week 6 (MTC).pptx solved.
Strategies for MTC to recover 10% of reduction in MTC’s profits
by major cost savings
PROJECT STORYBOARD: Reducing Cycle Time for Natural Disaster Response by 50%GoLeanSixSigma.com
The Federal Emergency Management Agency (FEMA) came under considerable criticism after hurricane Katrina for its slow response. GoLeanSixSigma.com Green Belt Charles White really dug into FEMA's processes and identified opportunities to make significant improvement with some common sense changes to material handling and loading.
At the time of publication FEMA has been responding to the aftermath of hurricane Florence, so the results are not in, but Charles' work looks very promising. We look forward to updating this after the Florence data has been processed.
More Information:
https://flevy.com/browse/business-document/six-sigma--statistical-process-control-spc-604
DOCUMENT DESCRIPTION
The Six Sigma - Statistical Process Control (SPC) Training Module includes:
1. MS PowerPoint Presentation including 136 slides covering
- Introduction to Statistical Process Thinking,
- Basic Statistics,
- Introduction to Statistical Process Control,
- Statistical Process Control Charts,
- Sample Size & Frequency,
- Out-of-Control Action Plan, and
- Process Control Plan.
2. MS Excel Confidence Interval Analysis Calculator making it really easy to calculate confidence intervals (mean value, standard deviation, capability indices, proportion, count) and perform a Comparison of two statistics (mean values, standard deviations, proportions, counts).
"After you have downloaded the training material, you can change any part of the training material and remove all logos and references to Operational Excellence Consulting. You can share the material with your colleagues and clients, and re-use it as you need. The only restriction is that you cannot publicly re-distribute, sell, rent or license the material as though it is your own. Thank you."
Got a question about this presentation? Email us at support@flevy.com.
[Note: This is a partial preview. To download this presentation, visit:
https://www.oeconsulting.com.sg/training-presentations]
Failure Mode & Effects Analysis (FMEA) is a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service. The purpose of the FMEA is to take actions to eliminate or reduce failures, starting with the highest-priority ones. FMEA also documents current knowledge and actions about the risks of failures, for use in continuous improvement.
In this training presentation, you can teach your employees on the proper steps to construct an FMEA for a design or process, and then implement action plans to eliminate or reduce the risks of potential failures.
LEARNING OBJECTIVES
1. Understand what an FMEA is, why it is used, and when can it be deployed
2. Understand the definitions, scoring system and calculations used in an FMEA
3. Learn the steps to developing an FMEA and the pitfalls to avoid
CONTENTS
1. Introduction to FMEA
2. FMEA: Definitions, Scoring System & Calculations
3. FMEA Procedure
4. FMEA Example
We all want to support the accomplishment of safe and trouble-free products and processes. Failure Mode and Effects Analysis has the potential to be a powerful reliability tool to reduce product design and manufacturing risk in a cost effective manner. With shorter product development times, tighter budgets and intense global competition, Design for Reliability tools such as FMEA must be applied correctly. Yet in practice, FMEA does not always achieve the expected results. Why is it that some companies have outstanding success in their FMEA application and others do not? What is the difference between well done and poorly done FMEAs? What are the essential elements of an effective FMEA process? These questions and more are answered in these three new short courses on FMEA.
In this 1-hour webinar you’ll learn how to select the right improvement project which will help you set yourself up for success. We’ll cover best practices, challenges you may face and a walk-through of how to use a Project Selection Tool.
Download the slides and more at: https://goleansixsigma.com/webinar-select-right-improvement-project/
Start your free Yellow Belt Training at: http://www.goleansixsigma.com/free-lean-six-sigma-training/
Get a FREE performance management kit and access to all of Victor's full videos at:
www.lifecycle-performance-pros.com
This presentation discusses the common obstacles to successfully managing organizational performance, namely aligning performance to organizational goals and objectives. This presentation discusses the 4 key alignment areas and offers techniques on how to successfully align perform to each area.
Lean six sigma and process excellence helps organisations to improve their productivity and reduce waste in the activities of management and operations. Here you can find out and learn about lean six sigma and its important aspects. Anexas Consultancy helps entrepreneurs and professional to grow their business and career in right direction. You can find more information here:http://www.leansixsigma.co.in/readmore.php?Service_Details&id=1
The ultimate guide on constructing a FMEA process for Manufacturing, Maintenance, Services and Design.
The presentation include step by step on how to determine the failure modes, failure effects, assign severity, assign occurrence, assign detection, calculate risk priority numbers and prioritize the RPNs for action. With some examples and illustrations.
Presentation contents:
1. Determing failure modes, effects and causes.
2. FMEA team & team leader.
3. Brainstorming.
4. The basic steps of FMEA.
5. Examples.
Persuasive Strategic Analysis for MTC.
Supply chain management strategy Week 6 (MTC).pptx solved.
Strategies for MTC to recover 10% of reduction in MTC’s profits
by major cost savings
PROJECT STORYBOARD: Reducing Cycle Time for Natural Disaster Response by 50%GoLeanSixSigma.com
The Federal Emergency Management Agency (FEMA) came under considerable criticism after hurricane Katrina for its slow response. GoLeanSixSigma.com Green Belt Charles White really dug into FEMA's processes and identified opportunities to make significant improvement with some common sense changes to material handling and loading.
At the time of publication FEMA has been responding to the aftermath of hurricane Florence, so the results are not in, but Charles' work looks very promising. We look forward to updating this after the Florence data has been processed.
I have an overall 6.7 years of experience in manufacturing quality. Currently I work with Robert Bosch Chasis India , Pune as Senior Engineer. I have key work experience with OEM-Tata Motors, Pune And XLO India ltd., Nasik.
I have used SAP PP/MM module. I have knowledge in production manufacturing processes and expertise in quality control and assurance. I have experience in handling various system audits, customer complaints, use of 7 QC Tools ,8D Report, Problem solving sheet, SPC, 5’S, TPM, TQM.
I have strong evaluation, planning, and leadership skills. I consistently present a high-profile, professional demeanor, complemented by a positive, "can-do" attitude. I am both persuasive and capable of developing report and trust, as well as experienced in influencing the attitudes and ideas of others.
BE mechanical engineer with 9.7 years experience in productionJaga deesh
BE mechanical engineer with 9.7 years exp in production department ,good experience in planning,5s,kaizen,fmea,7 qc tools & story,lean manufacturing ,smed,spc techniques
BE mechanical engineer with 9.7 years experience in production
Six Sigma Final PPT - Revised
1. .
Belt : - Somrita Ghatak
MBB : - Amol Natu
Sponsor : - Parag P Pawar
Process Owner : - Sriram Srikantan
Reduction in Ergonomic Risk to facilitate Gender Diversity
Improvement from 7% workstations to 14% Work Stations in KV
Cylinder Block Line without affecting Quality & Productivity
4. Reduction in Ergonomic Risks to facilitate Gender Diversity Improvement
from 7% workstations to 14% workstations in KV Cylinder Block Line without
affecting Quality & Productivity
1. Oil Gallery SPM- Ergo Risk 27 to be reduced to 10
2. Semi Finish Cam Bore- Ergo Risk 21.6 to be reduced to 10
3. Bush Press SPM- Ergo Risk 30 to be reduced to 10
4. DMG- Ergo Risk 14 to be reduced to 10
5. MHI- Ergo Risk 12 to be reduced to 10
6. Top Deburr Work Station- Ergo Risk 12 to be 10
DefinePhase Project Title
5. 1.Define 2.Measure 3.Analysis 4.Improve 5.Control
Reduction in Ergonomic Risks to facilitate Gender Diversity
Improvement from 7% workstations to 14% workstations in
KV Cylinder Block with out affecting Quality & Productivity
Objective :
Benefits :
Project
Team :
Schedule :
5
1. Creating right environment
Belt : Somrita Ghatak
Team members : Dinesh R Kamthe, Sameer C Bhilare, Milind V
Bhagwat, Neeta N Chavan, Sandeep V Sadaphal,
Dyaneshwar J Dhamal
Sponsor : Parag P Pawar
Process Owner : Sriram Srikantan
Controller : Soma Ghosh
MBB : Amol Natu
DefinePhase Project Description
6. 6
Grow to Rs
2544.9 Cr. with
20.3% PBIT in
2015
Leverage
Complementary
Businesses
1. Become Excellent in
Customer Support
Seek Profitable
Growth
Relentlessly
Pursue Cost
Leadership
Increase
Shareholder
Value
4. Achieve Supply
Chain Excellence
1. Deliver and exceed 2015 AOP
2. Execute capital projects on time
6. Achieve Low Cost
Provider Status
1. Achieve cost savings through ACE IV(direct material savings)
2. Hit Supply Chain improvement (AsCENT) and cost reduction targets for 2015
3. Achieve zero defect processes (AMAZE)
4. Achieve operational excellence through (APEX)
Great Place
to
Work
Strategic
Principles
Common
Critical Initiatives
IEBU Critical Initiatives/ Projects
1. SBP and FPC functional excellence
2. Implement ASCP by mm/yy and WMS at PHP , evaluate mobile Supply chain
3. Deliver and develop QSK 23 for all Industrial applications, ramp up Q 23 conrod exports
4. Take gross turns to 6 for 2015, PFEP target-
1. Create excellent leaders by deploying leadership programs (BSO, LCS) & extending sponsored
education (MBA, M.Tech)
2. Create & drive high performance culture through robust PMS & ODR
3. Grow the leadership pipeline with respect to diversity
4. Functional excellence for Product planning, VPI, SCM, Manufacturing and Quality
5. Focus on resource planning for A list projects
1. Excel in PQC
2. Leverage Synergies – CSE, Integrated Account Management & End User Management
3. Defend Existing Customers by improving customer satisfaction and ensure better management of
PGU, Exports & Parts
4. Reduce warranty cost by 5% over 2014 warranty cost
5. Differentiate between process and planning for project ad product business
6. 50% reduction in BIS - , ELF ,
7. Invest in Leadership
Development and
People
2. Develop a Growth
Mindset
1. Capture Adjacent Markets- Defense- Cr & Gas- Cr
2. Excel in VPI, VPC, parts exports- Q 23, Q60, Q19 wrt timeline and cost targets
3. Product Planning for new Emissions (Industrial– 2016; Powergen – 2017) – Engine and Emission
Solutions ; Launch Fit for Market products on time
4. Drive growth in Marine - Cr & construction- Cr and defend rail- Cr and compressor- Cr
5. Plan and deliver IEBU WIN initiatives of 5-1-0
Objectives
5. Meet Long Term
Financial Targets
1. Execute Safety and environment initiatives to deliver world class performance
2. Improve safety behaviors at all low performing sites
3. Improve contractor safety
4. Achieve safety target – and Enviroinment target -
5. Foster an open, safe & inclusive environment
8. Become World Class
in HSE
Create the
Right Work
Environment
9. Embed Corporate
Responsibility into our
Business
1. Support and measure leadership teams on engagement in community leadership
projects (through 5 IEBU leader led projects)
2. Drive company-wide initiatives: CCEW, Zero Garbage, etc.
3. Move from
Multinational to Global 1. Ramp-up the Q60 production for exports
2. Leverage India sourcing and low cost production for global markets
First Choice of
Customers
Achieve Zero Defect
Lead in Critical
Technologies
DefinePhase IEBU Goal Tree
7. Cummins Operating System - 10
Practices
Put the
customer first,
and provide
real value
Synchronize
flows (material,
physical and
information)
Design quality in
every step of the
process
Involve people
and promote
teamwork
Ensure equipment
and tools are
available and
capable
Establish the
right
environment
Create
functional
excellence
Treat preferred
suppliers as
partners
Follow common
problem solving
techniques
Use Six Sigma as the
primary process
improvement method
DefinePhase
8. 1. Does the Sponsor have responsibility for the problem
being addressed ?
Yes No
2. Is the Process owner involved in Project definition
and evaluating Baseline ?
Yes No
3. Can the project be completed in 4 to 6 months? Yes No
4. Will the belt be able to spend @ 20% of time on this
project ?
Yes No
5. Which is/are the key Business Goals that the project
impacts the most ?
Elaborate, in brief –
Recruit & develop Diverse
high Caliber work force
6. What is the likelihood of success? High Low
7. Impact of this project on Customer satisfaction
(Customer for the process being improved)
High Low
8
DefinePhase Project Selection Filters
9. 9
•.One of Shop operation’s key initiatives aligned with
IEBU critical initiatives
“Facilitate gender diversity improvement in Shop
operations”
•Scope of this Project shall be work stations in KV
cylinder block line
DefinePhase
1. Oil Gallery SPM- Ergo Risk 27 to be reduced to 10
2. Semi Finish Cam Bore- Ergo Risk 21.6 to be reduced to 10
3. Bush Press SPM- Ergo Risk 30 to be reduced to 10
4. DMG- Ergo Risk 14 to be reduced to 10
5. MHI- Ergo Risk 12 to be reduced to 10
6. Top Deburr Work Station- Ergo Risk 12 to be 10
Why this Project?
10. • Project Scope
Identification
• Baseline
Calculation &
Target setting
• Belt, Sponsor
& Team
formation
• Establish
stake holders
for VOC
Define
• Risk
assessment
verification
• VOC
• Types of m/c
data collection
Measure
• Machine
categorization
• Top Risk score
• Proposal
Evaluation and
development
• Ergo
requirements
• Idea
generation on
selected
machine
Analysis
• Develop
solution design
• Implementatio
n on identified
machines
• Pilot
implementatio
n
Improve
• Update work
instruction &
RA with
improvements
• Maintenance
• Training
Control
Jan,15 Feb,15 Mar,15 Apr,15
p p p p
Road map for Reduction in Ergonomic Risks to facilitate
Gender Diversity Improvement from 5% workstations to 14%
workstations.
DefinePhase
11. 11/18/2015 Cummins Confidential11
Solution Strategy
• Ergonomic Job Hazard Survey to identify improvement opportunity on
20% Work stations to deploy female operator to achieve at least 14%
Woman-Friendly Work Stations in KV Block, BU-01 by Q3 2015
• Calculation of Ergonomic Job Hazard Score on the Machines/ Work
Stations identified by Ergonomic Job Hazard Survey
• Certify Work Stations/ Machines to be woman-friendly on the basis of
BRIEF/BEST/NIOSH Study
• Find out the Key contributors to Ergo hazard for the work stations
showing high Ergo Risk (>20)
• Conduct various trials to reduce Ergo Risk
• Implement action to reduce Ergo Risk at identified points
• Budgetary proposal for points where trials have not resulted in the
reduction of Ergo risk
• Approval of Budget
Initiate procurement of Final solution and implement
DefinePhase
13. 13
Brief Details of Ergo Risk Score Measuring Tool
• Human-Tech is a Cummins Authorized System to evaluate Job
Ergonomic Hazard Score
• Brief-Best Score evaluation records 5 Types of causes (Posture, Force,
Duration, Frequency & Physical Stressors) of Ergonomic Risk to
Operator
• Final Job Hazard Score is calculated on the basis of Time Exposure on
Job per Week and it indicates Ergo Risk associated with the Job
BRIEF & Best Survey Data Collection Sheet
MeasurePhase
14. 11/18/2015 Cummins Confidential14
Base Line Data
Scope of the Project
Work Stations with Lower Job Hazard Score is having lesser
Ergonomic Risk
i.e. Easily convertible to Woman-friendly work stations
MeasurePhase
Machine Name Ergo Risk Score Target
Oil Gallery SPM 27 <10
S/F Crank Bore SPM 21.6 <10
Bush Press SPM 30 <10
DMG 14 <10
MHI 12 <10
Top Deburr W/S 12 <10
• Total number of work stations in
KV Block, BU-01- 44
• Currently woman friendly- 7% (Top
Milipore, Inspection, Clearance)
25. Objective – To understand the requirements of stake holders
with respect to ergonomics while ensuring Safety, Quality and
productivity.
The KJ was performed on GEMBA to understand the
requirements in details through a questionnaire.
Internal Stake holders
Production associate
Quality manager
Production manager
Process Manager
11/18/2015
Requirement KJAnalyzePhase
27. Wrist aches after tightening cartridge in S/F
Stress felt after Insert change on S/F Cam Bore
Issue in horizontal reach for switched of spindle
on S/F Cam Bore.
Bush Press Machine Bar doesn’t work in
Auto, until a certain distance.
Pain on shoulder for carrying Alignment Bar on
shoulder
No Material handling provision for Functional
Gauges on Oil Gallery
Very risky to climb stairs while too change on Oil
Gallery. No proper support.
Material handling difficult as very heavy functional
gauge on Oil Gallery
Bending causes discomfort while lifting
alignment bar
Heavy Gauges are to lift for every job
Single person can’t handle functional
gauges on Oil Gallery
Very Heavy Alignment Bar causing Back
Pain on Bush Press
11/18/2015
Requirement KJ
Forklift thrashes with the Machine platform,
difficult to stand, no railings
Alignment bar is too heavy to carry
Bush Pressing bar in machine doesn’t go
inside without manual pushing
Storage of alignment bar is below waist level,
causing uncomfortable bends
Person may fall down if forklift thrashes with
platform of S/F Cam Bore
Wrist aches after tightening cartridge in S/F
Bush Press Machine Bar doesn’t work in
Auto, until a certain distance.
Bending causes discomfort while lifting
alignment bar
Single person can’t handle functional
gauges on Oil Gallery
Very Heavy Alignment Bar causing Back
Pain on Bush Press
Forklift thrashes with the Machine platform,
difficult to stand, no railings
Alignment bar is too heavy to carry
Bush Pressing bar in machine doesn’t go
inside without manual pushing
AnalyzePhase
Tools weight is too heavy to carry to
machine
Very heavy tools to be carried to machineHeavy tool changing activity
32. 32
Key Contributor:
1. Tool Change Activity- Step 3 Action: To be done by CSE
Point Leader
Key Contributor: No Major Finding of Ergonomic Risk
Key Contributor:
1. Tool Change Activity- Step 3 Action: To be done by CSE
Point Leader
Requirement KJ
Modify Oil Gallery SPM, S/F SPM, Bush Press SPM, DMG, MHI, Top
Deburr Work Station in such a way that employees will not face
any ergonomic issue while working.
AnalyzePhase
DMG
MHI
Top Deburring Work Station
1. Machine Training required of Female Operator
33. AnalyzePhase
Fitness to Standard
Fitness to UseFitness to Latent Requirements
“Taken for
Granted”
Types of Needs:
1 – Fitness to Standard (Must Be)
2 – Fitness to use
3 – Fitness to Latent Requirements
Condition
Dissatisfied Feeling
Physically
Fulfilled
(Need is met)
“Competitive”
the more the better
(Need is not met)
“Surprise &
Delighters”
Satisfied
Feeling
Weight To be reduced of
Gauges used in Inspection in
Oil Gallery
Bush Pressing Bar very tight
for movement
Bush Press Alignment Bar
handling provision to be done
& weight to be reduced
Horizontal reach issues on S/F
Cam Bore
Material handling
provision to be made
for Functional Gauges
of Oil Gallery
Alternative option for Tool
Change
Training of the female
operator
KANO Model
34. 34
Sr. No. Machine Name Actions Identified Responsibility Target Date Status
1 S/F Cam Bore SPM
Switch Position to be changed to improve
horizontal reach
Somrita 15-07-2015
Planned on
5/07/2015
3
Jib Crane & Air Balancer assembly to be
provided for handling of Functional Gauge
Somrita 31-07-2015
Quotation
received
4 Weight reduction of Functional Gauges Somrita 31-07-2015
Design In
Progress
6 Weight Reduction of Alignemnt Bar Somrita 31-07-2015
TDR released
to Tool Room
7 Easy handling provisioin of Alignment Bar Somrita 31-07-2015
Quotation
received
8 Modify Bush Pressing Bar Somrita 31-07-2015
Feasibility to
be checked
9 Arrange alternate plan for Heavy Tool Change activitySomrita 30-06-2015 Completed
10 CNC Machine Training of the female opertaor Somrita 31-07-2015 In Progress
11 Arrange alternate plan for Heavy Tool Change activitySomrita 30-06-2015 Completed
12 CNC Machine Training of the female opertaor Somrita 31-07-2015 In Progress
13 Top deburr Work StationTraining of the female operator Somrita 31-07-2015 In Progress
Oil Gallery SPM
Bush Press SPM
DMG
MHI
AnalyzePhase Action Plan to achieve 20% Woman-friendly Work stations to deploy
female operator against target of 14% Woman-friendly Work Station
in KV Block, BU-01 by Q-3 2015
38. 38
Why Yellow Closure?
Late receipt of Quotations
from Various Suppliers
Delay in Raising RFA
Delayed Procurement of
Materials required
• Major Reason: Delay in submission of RFA
• Required Budget Summary: ~11 Lacs Against AOP approval of 25
Lacs for Human-Tech deployment
• RFA Raised on: 07/08/2015
• Current Status of RFA: RFA Approved on 18/08/2015
• Target Date for Green Closure- Q1, 2016
Root Cause Analysis for Yellow Closure
Please follow next Slide for machine wise
Details of delayed implementation of action
plan
Improvement
Phase
Why?
Why?
39. 39
Machine Wise Details for Delayed Implementation of Action
Plan
Improvement
Phase
Target Completion Date for Green Closure: Q1, 2016