Kaizen case study submitted by SRF Overseas Limited during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

1. Quality Month: Nov-10 Kaizen No Page No.:TEX/Nov/04
KAIZEN REPORT
Company logo Company Name Department: Manufacturing Team Section/Process: Textile
SRF OVERSEAS LIMITED
Improvement Title: Reduction in damages in rewound-yarn in twisting machines ( Direct – Cabler )
Category: [√ ] Quality improvement [ ] Health & Safety [] Environment [√ ] Productivity [ ] Office processes
Before Situation Root Cause Analysis Improvement Measures After Situation
Why there is more damage in case of In order to make cheese winder operation to the
rewound-cheese? desired level, following three ideas were tried  Quality Benefits: Half bobbins (defects) reduced from
and verified through PDCA methodology. 7.3% to 3.4 % level.
 This in-turn reduced the waste level from 0.40% to
Action 1:
When rewound cheese are made the yarn 0.22 %
gets entangled in machine part, where as To reduce the gap on the right- side we used  Butts stock reduced from 23.2 MT. To 15.3. MT level
incase of virgin cheese this entanglement rubber O-ring which is equivalent to one inch.
is very minimal
This helped in slight reduction in number of
damages.(20% reduction )
Why yarn entanglement is high in case of
rewound cheese?
Action 2:
Earlier, while making rewound-cheese we were
Rewound cheeses are made with 10 inch
winding from rewinding machine where as using empty paper-tube as base.
our twisters are designed for 12 inch Instead of this paper tube, we experimented with
cheeses. So there is additional gap in case
left over (12-inch) cheese which reduced the gap
of rewound cheeses( on both sides)
on both the sides and therefore entanglement
was reduced significantly.(50% reduction )
In our manufacturing process we use yarn (virgin
Cheese) to make fabric. Why we cannot get 12 inch cheese from Data : Break bobbin % reduced from 7.3% to
our rewinding machine?
5.2 %
These virgin cheeses will generate left over yarn
which is collected and then converted into re- Action 3 :
usable yarn called ‘rewound-cheese’.
Earlier Yarn or cheese loading did either 100%
Due to machine design
We were facing the issue of higher no of damages virgin cheese or rewound cheese on twisters.
in case of re-wound cheese. Instead of 100% virgin or rewound we
Data: Target for Break bobbins* reduction: 7.3 % experimented with 50% virgin plus 50% rewound
to 2.0% cheese which will gave remaining 20% reduction
in our break bobbins % in direct cablers.
*For internal use, these damages are called Data : Break bobbins % reduced from 5.2 to
‘BREAK-BOBBINS’ 3.4%
(We used why why analysis method for
find out the route cause of the problem)
This led to substantial reduction in damages
( or break-bobbins)

2. Benefits: Participation
Textile team: M.R. Palani / MN Ratnam / Pankaj Singh / Ajay Laroia / Pothiappan
 Quality Benefits : Half bobbins (defects) reduced from 7.3 to 3.4 % level.
 This in-turn reduced the waste level from 0.40% to 0.22 %
 Butts stock reduced from 23.2MT. To 15.3. MT level
 Cost saving : US $ 51,840 /- annum
 Shop floor operators were happy to operate the machines ( Earlier machine stopped frequently
due to this operators were unhappy to restart the machine but now they are happy due to machine
stoppages time reduced by 50% )
 Rework time reduced by 50% since break bobbins % reduced by 50%

The same improvement is horizontally deployed to other 6 units of similar operation across globe (4 in
India, 1 unit in Thailand and 1 unit is South Africa).
Standardization: Horizontal Deployment Opportunities (Replication):
WI/TEX/64 Issue no 2 The same improvement is horizontally deployed to other 6 units of similar operation across globe (4
in India, 1 in Thailand.)
WI/TEX/65 Issue no 2
Single Point Lesson: Remark / Management Comments:
It is a really simple innovative kaizen WITHOUT ANY INVESTMENT.
We always believe that our employees are main asset to the company
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
1.TQM cell 20thJuly 2010 ( First 2 project ) 31st July 2011
2.Cheese winder display board 10th Jan 2011 (3rd project ) (inclusive of 3
3.IMS Record file improvement projects)
4.Copy to Management representative
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_______