kaizen in caparo

8/3/2019 Kaizen in CAPARO

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Dept. Name Weld Shop Kaizen Idea

Zone No. SUMAN

Kaizen Theme Counter Measures Trolley to be Made

Problem Status Before

Qualitative Quantitativ

AfterProblem Analysis :

Root Cause : Result

Sr. No. Where who

Plan for Horizontal Deployment

S OK

M

Cminor

D OK

PNo Proble

Q OK

Benefits:-Reduce Production Time

Completion Date:- 22th Aug;05

Lead time of the is more Bench Mark:-Nil

Target:-

Kaizen - Sheet

Team:-WELD SHOP

Idea By :-LEELADHAR THAKRE

Start Date:- 22 Jun'04

25 nos. of Components can be kept from beforeBecause Shortage of Trolley we Have

to make the Components when there is

TROLLEYS

Preventive Action

Make A Trolley

Reducing of JIT


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Dept. Name Weld Shop Kaizen Idea

Zone No. Suman

Kaizen Theme Counter Measures



After

Problem Analysis :

Result

Root Cause : Sr. No. Where who

Setting Time More

ONE FIXTURES REMOVED

One Fixture can be used instead of two

fixture as there profiles has negligibledifference

S

M

Q

Plan for Horizontal De

CSetting t

D

Changeover time more due to bring of

Fixture

Bench Mark:-Nil

Target:-

Benefits:-Reduce Set up time

TO REDUCE THE set

up time

Idea By :-Raghu Shinswar

Start Date:- 4 Aug 05

Completion Date:-

Qualitywise No Problem

Space Utilisation And

Change to reduce

Kaizen - Sheet

Team:-Weld Shop

P


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Before After

Benefits- 1.Quality improved.

2. Time save for putting the nut inthe bolt

Suggested by- Manoj

Month-may-05

Cargo body Mtg

Problem-No Fixture was there to guide the nut

for entering spatter inside the nut


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BeforeAfter

Benefits- Lead time save &

approx cost saving20,000/annum

Suggested by- MAHESH BHAGEL

Month-may-05

HSG HEAD LAMP LH /RH -- HCV

Problem- NO FOOLPROOFING WASTHERE.

Locator not there

Guage

LOCATOR PIN PROVIDED

TO AVOID HOLE MISSING


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Before

Benefits-Production Increased

without any Quality Problem.

Suggested by- Leeladhar

Month-May-05

BRACE REAR PILLAR-HCV

Problem- Gun used to be taken out inexisting fixture for four spot.

One Clamp DeletedC/Measure-

After


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Dept. Name Kaizen Idea Productivity

Zone No. 2

Counter Measures




Chances of Accidents

Result


1 u/centre R Kamal

25 secs saved per Component

Kaizen - Sheet

Team:-Weld Shop

Fixture to be

Developed

Fixture to be developed Idea By :-Kamal

Start Date:- 08 July'05

Weld ShopSuman

Completion Date:- 09July'05

Cycle time Reduced Bench Mark:-Nil

Target:-

Benefits:- Productivity Increased

C50,000 Rs

PIncreased t

Q OK

OK

SGOOD


No Fixture Available

Fixture to be developed

Kaizen Theme

M

D


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Date 20-06-05

Dept. Name Kaizen Idea

Zone No.

Counter Measures


Qualitative Quantitative


Result

Root Cause : Sr. No. Where who when status

Now working and under observation. 1 inner Suamn aug Stared

Kaizen - Sheet

Weld ShopTeam:-Weld Shop

Suman

Kaizen ThemeNew Tool to Made in

India & contingency

New Tool to Made Idea By :-Suman & makhanlal

Start Date:- 1 July'05

Completion Date:- 3rd Aug'05Tool Gets Crack every now and then Bench Mark:-Nil

Target Date :- 15 July'05

Benefits:- Cheap And easy to developed in India

Punder Obseravetion

Q OK

Loss of ProductionC

4750 Rs. Only

S


New to be developed localised

Preventive Act ion

M

D


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Dept. Name Weld Shop Kaizen Idea Preventive Action

Zone No. Suman

Kaizen Theme Counter Measures Trolley to be Made



After

Problem Analysis :

Template Fixture to be made

Result

Root Cause : No Rejection of Component Sr. No. Where who

1 FRM u/ce Raghu

2 FRM u/ce Raghu

Stacking Problem

(12 Nos.)

Due to OverLoading

Kaizen - Sheet

Team:-Quality Assurance

Idea By :-Manish Meshram

Start Date:- 4 Jun'04

Completion Date:- 7th jun '04

Chances of getting Damaged due to

Overloading

Bench Mark:-Nil

Target:-

Benefits:-Reduce Inspection time

PNo Proble

QOK

CChances

DOK


SOK

M


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Dept. Name Weld Shop Kaizen Idea 5'S activity

Zone No. Suman

Kaizen Theme Counter Measures



After

Problem Analysis :

Result


1 frm floor u Leeladhar

2 Brace Leeladhar

3 frm floor u Leeladhar

Pocket to be Made To avoid such

Problems

POCKET MADE & WHEEL

ADDED

No pocket was there to keep the

BOP & Wheels are not there.

CSearchin

DOK


Fixtures are not Designed by putting in

mind of BOP's

SOK

M

Seaching time of BOP's is ZERO

P Increased

QOK

Benefits:-Reduce Rework

Completion Date:- 7th july '05

Searching time More Bench Mark:-Nil

Target:-

Kaizen - Sheet

Team:-Weld Shop

TO REDUCE THE

CYCLE TIME OF

SEARCHING

Idea By :-Manish Meshram

Start Date:- 4 jULY'05

POCKET MADE

TO PUT THE

added

to move

freely


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BEFORE AFTER

VISUAL INSPECTION

WAS USED

USE TAMEPLATE

AS SHOWN IN FIG.

PROBLEM DEDUCTED-24/06/04 IMPLEMENTED DATE-26/06/04


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BEFOREAFTER

MIG TACK WAS DOING

HAPAZOURDLY

RACK HAS BEEN MADE TO

MINIMISE THE MATERIAL

MOVEMENT TIME


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IMPROVEMENT-1

BEFOREAFTER

CAGE NUT OFFSET

PROBLEM

DURING MIG

WELDING

STAND BY WELDING

FIXTURE MADE


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BEFORE AFTER

EML-FRM FLR UNDR FRT ASSY.

1.PROCESS UNSAFE.

2.EXTRA MANPOWER REQ.

3.HIGH CYCLE TIME.

WELDING FIXTURE MADE TO

AVOIDE THESE PROBLEM.


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BEFORE AFTER

JOB SETTING TIME VERY

HIGH AS COMP

IS SET BY C- CLAMP

WELDING FIXTURE MADE WHICH

HOLD THE COMP PROPERLY.


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NO PROPER

STORAGESYSTEM FOR

KEEPING

ELECTRODE

DURING

WORKING

HRS.

BEFORE-AFTER-

ELECTRODE STORAGE STAND HAS BEEN MADE.


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kaizen in caparo

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