The document describes how the manufacturing team at SRF Overseas Limited developed an in-house cot roller inspection machine to automatically inspect cot rollers for defects, which improved inspection accuracy from manual inspection and saved 36 man-hours per machine by reducing inspection time from 15 minutes to 3 minutes. The new inspection machine eliminated defective cot rollers from being installed on twisting machines, reducing defective cord production.

1. Quality Month: Jun’11 Kaizen No Page No.:1
KAIZEN REPORT
Company logo Company Name Department: Manufacturing Team Section/Process: Engineering .
SRF OVERSEAS LIMITED
Improvement Title: In house design & development of Cot-Roller inspection machine
Category: [√ ] Quality improvement [ ] Health & Safety [] Environment [√ ] Productivity [ ] Office processes
Before Situation Root Cause Analysis Improvement Measures After Situation
Why- Why Analysis 1. During the shop-floor brainstorming
session one senior operator
Why defective cord is generated on suggested that if we can buy or design
twisting machine? a machine where inspection can be 1. After the machine was developed it was tested
done automatically, this problem can and found that we are getting 100% accuracy.
be resolved.
Due to usage of defective cot rollers
2. Finally, it was decided to develop the No gap observed
Cot-Roller inspection machine in-house. between the Gap observed
Used to create Why defective cot rollers are used delivery roller and between the
twist in the yarn cot roller delivery roller
and cot rollr.
After rectification of grooving, we are not
able to inspect the surface of cot roller
properly
Over a period of time, grooves are formed in cot
Why we cannot inspect the cot roller
roller due to which it is not able to hold the cord
properly
properly.
To rectify this, we buff the cot roller. After this it is
manually inspected with the help of vernier
calliper. Inspection is carried out manually Cot Roller inspection
machine ( made
Due to manual inspection, there is lack of inhouse)
accuracy in measurement. Besides, approx 15
minutes gets wasted each time for carrying out
the inspection.
As a result the defective cot rollers gets cleared in
manual inspection and is installed on the
machine.
Finally, it leads to generation of defective cord on
twisting machine.
Manual inspection

2. Benefits: Participation
1-N.Centhil Kumar
1. Cot roller inspection done with inspection machine (developed in house) , we are able to 2-Biswajit Mallick
reduce time (15 MINS TO 3 MINS )upto 36 Man-hours of Saving per machine 3-M.R. Palani
2. Inspection accuracy increased to 100% 4- T.B. Singh
3. Reduction in defective cord generation.
4. It eliminated chances of safety incidents (manual inspection is not carried out)
Standardization: Horizontal Deployment Opportunities (Replication):
WI made ‘How to use the m/c’
Ref: MECH/WIL/057 - We are using this machine for more than 10, 000 cot rollers (180 cot roller per machine x
56 Machines).
- This improvement has been done in other 4 Tyre Cord Fabric plants of SRF ( 3-India; 1-
Thailand)
Single Point Lesson: Remark / Management Comments:
This as an extremely wonderful improvement done by engineering team. It has substantially reduced
defects and has been implemented across TCF plants.
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices.
Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT
_________________________________ Date: _07___/_10___/_2011_______