1. The document summarizes a Kaizen report from SRF Limited's manufacturing department that aimed to reduce process scrap in their CTC dipping machine from 800kg to 400kg per month. 2. The root cause of high scrap was identified as the accumulation of transferred dipping solution in the baffle box, which was made of mild steel and contaminated the solution. 3. To address this, the team modified the material of the baffle box from mild steel to stainless steel, allowing the excess solution to be reused rather than becoming scrap.

1. Quality Month: November 2008 Kaizen No Page No.:1
TTBV/Dip/Jan 10/05.
KAIZEN REPORT
Company logo Company Name Department: Manufacturing Section/Process: Dipping
SRF Limited, Technical Textile Business, Trichy
Improvement Title: To reduce the process scrap from 800kg per month to 400kg per month in CTC dipping machine
Category: [√ ] Quality improvement [ ] Health & Safety [√ ] Environment [√ ] Productivity [ ] Office processes
Before Situation Root Cause Analysis Improvement Measures After Situation
Blockage in Baffle Box Sno Root Idea Solution
Why 1? Cause Proposed
Accumulation of transferred identified
solution from de-webber to
baffle box 1 Material To To
Why 2? of the provide modify
Solution transferred from de- baffle a the
webber cannot be sent to dip box no suitable material
tank suitable material from mild
Why 3? for for steel to
As the material of the baffle reusing baffle stainless
box is made up of Mild Steel, it the box so steel
will change the property of dip solution that
solution, preventing from reuse reusing
of the solution. the
Why 4? excess
Material selection carried out solution
by supplier during installation is
possible
Benefits: Participation
Dipping and Mechanical Team
1. Process scrap reduced from 800kg to 200 kg per month leading to a cost saving of
Rs 6000 /Month, leading to annualized saving of Rs 72000
2. Machine cleaning time has been reduced from 8 hrs to 3 hrs per month
3. Due to reduced scrap and re-usage dip solution consumption has been reduced
from 105 Kg/MT to 102 Kg/MT leading to a saving of Rs 9600/month getting a
annualized saving of Rs 1,15,200.
4. Operator morale improved due to fatigue in cleaning reduced.
5. Operator confidence improved on machine quality as excess solution can be reused
(Previously due to contamination it cannot be reused).
Approx US $ 4000 per annum
Standardization: Horizontal Deployment Opportunities (Replication):
1. Baffle box material standardized through CTC/BB/01 Rev No:03 in the machine
manual Nil
2. Machine cleaning time has been standardized from 8 hrs per month to 3 hr per
month
Single Point Lesson: Remark / Management Comments:
OPL on MATERIAL MODIFICATION has been displayed in department
Process scrap has been reduced by 75% through this kaizen
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
SEP 2009 DEC 2009
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.

2. Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT
_________________________________ Date: _07___/_10___/_2011_______