Prepare

AKAU OMATICS KAIZEN IDEA SUMMARY SHEET TPM

Plant Name: AKA- Rohtak Area: SHAFT COMP OIL PUMP Machine Name: Drilling Machine Department: Calibration
Kaizen Result Area: Loss No. Pillar wise Kaizen Category
JH PM QM
P 1. Productivity Improvement Q 2. Product/Process Quality Improvement C 3. Cost/Energy Saving Kobetsu Kaizen Jishu Hozen
Planned Quality
Maintenance Maintenance
ET SHE OTPM DM
D 4. Delivery Improvement S 5. Safety Improvement M 6. Morale/ 5S Improvement Safety Health &
Education & Training Office TPM Development Management
Environment

Kaizen Theme: To Improve Productivity and Quality at Drill Kaizen Idea: Implemetation of automatic clamping fixture
Kaizen Detail AKA-18.12.06-K-KK-calibration-drill machine
Machine .

Kaizen Start Date: 4.01.2019

Problem/Present Status Before Kaizen: Countermeasures: Kaizen Finished Date: 11.01.2019

Loading & unloading time is more Automatic clamp & declamp the component Benchmark:
Quality issue
Target:
Team Leader: Sunil Kumar, Vikash dhankar
Before Kaizen Photo: After Kaizen Photo: Team Members: Investment Cost
1. Suresh Labour 0
2. jasvinder Material 0
3. manjeet Total Cost
4. in Rs 0
Benefit After Kaizen:

1.Improve Quality
2.Reduce Customer complained
3 One piece cycle time .
4 total save upto

Manual Clamping Fixture Auto Clamping Fixture

Analysis: Result:
Problem: Cycle time and quality issue in manual clampinng fixture. Kaizen Sustenance

Why-1 Operator clamp the component manualy. What to do: Verification of Kaizen Dec,18 Jan,19

Why-2 Fixture design for sample basis . 1.Improve quality. How to do: Kaizen Monitoring Sheet 5 0

2.Increase production .
Why-3 Quality issue due to loosen clamping 3. Save upto .......... Frequency: Daily

Why-4 Scope & plan for Horizontal Deployment

Sr. No. M/c No. Target Date Resp. Status

Root
Cause

Scope & Plan for Horizontal Deployment in Other MT Plants

MT-1 MT-2 MT-3 MT-4 MT-5 MT-6 MT-7 AK-1 AK-2 AK-3
Checked By: Prod. Head Quality Head Maint. Head Engg. Head HR Head TPM Coordinator GM-Operation Approved by: Mr. Ajay Girwan
Document for Evidence and Verification: Cost Calculation sheet
 Prepare
AKAU OMATICS KAIZEN IDEA SUMMARY SHEET TPM
Plant Name: AKA- Rohtak Area: Spindle Comp Kick Starter Machine Name: Round Welding M/c Department: Calibration
Kaizen Result Area: Loss No. Pillar wise Kaizen Category
JH PM QM
P 1. Productivity Improvement Q 2. Product/Process Quality Improvement C 3. Cost/Energy Saving Kobetsu Kaizen Jishu Hozen
Planned Quality
Maintenance Maintenance
ET SHE OTPM DM
D 4. Delivery Improvement S 5. Safety Improvement M 6. Morale/ 5S Improvement Safety Health &
Education & Training Office TPM Development Management
Environment

Kaizen Theme: To Improve Productivity at Round Welding Kaizen Idea: Implemetation of Automatic clamping fixture
Kaizen Detail AKA-K-KK-calibration-Round Welding machine
Machine .

Kaizen Start Date: 4.01.2019

Problem/Present Status Before Kaizen: Countermeasures: Kaizen Finished Date: 11.01.2019

Clamping time is more due to L-Key bolt tightinig provision An pnuematic cylinder provision provided for autoclamping Benchmark:

Target:
Team Leader: Sunil Kumar, Vikash dhankar
Before Kaizen Photo: After Kaizen Photo: Team Members: Investment Cost
1. Suresh Labour 0
2. Sanjeev Material 0
3. Total Cost
in Rs 0
Benefit After Kaizen:

1. Clamping time reduce.

2. Productivity increase .
3. Operatoar Fatigue less.
4. Quality improvement .
5 Save 82200 Rs per year.
Manual Clamping Fixture
Auto Clamping Fixture

Analysis: Result:
Problem: Clamping time is more (35~45 sec.) Kaizen Sustenance

Why-1 Operator clamp the component manualy. What to do: Verification of Kaizen Dec,18 Jan,19
Welding shift rate =1259
Why-2 L-Key bolt tightning provision was there at welding m/c fixture Total working hours=8 How to do: Kaizen Monitoring Sheet 5 0
Save upto 0.043 Rs per sec.
Why-3 Inadequate Fixture design Per part save = 1.37 Frequency: Daily
Save 5000*1.37=6850 per month
Why-4
During initial development stange autoclamping provision not Save 6850*12=82200 per year Scope & plan for Horizontal Deployment
considred
Sr. No. M/c No. Target Date Resp. Status
Root
Cause

Scope & Plan for Horizontal Deployment in Other MT Plants

MT-1 MT-2 MT-3 MT-4 MT-5 MT-6 MT-7 AK-1 AK-2 AK-3
Checked By: Prod. Head Quality Head Maint. Head Engg. Head HR Head TPM Coordinator GM-Operation Approved by: Mr. Ajay Girwan
Document for Evidence and Verification: Cost Calculation sheet
 Prepare
AKAU OMATICS KAIZEN IDEA SUMMARY SHEET TPM
Plant Name: AKA- Rohtak Area: Spindle Comp Kick Starter Machine Name: Round Welding M/c Department: Calibration
Kaizen Result Area: Loss No. Pillar wise Kaizen Category
JH PM QM
P 1. Productivity Improvement Q 2. Product/Process Quality Improvement C 3. Cost/Energy Saving Kobetsu Kaizen Jishu Hozen
Planned Quality
Maintenance Maintenance
ET SHE OTPM DM
D 4. Delivery Improvement S 5. Safety Improvement M 6. Morale/ 5S Improvement Safety Health &
Education & Training Office TPM Development Management
Environment

Kaizen Theme: To Improve Quality at Round Welding Kaizen Idea: Implemetation of Automatic clamping fixture
Kaizen Detail AKA--K-KK-calibration-Round Welding machine
Machine .

Kaizen Start Date: 4.01.2019

Problem/Present Status Before Kaizen: Countermeasures: Kaizen Finished Date: 11.01.2019

Opposite site welding can be done due to part od size same from both A sensor is provided at grooving area, if part loading from opposite Benchmark:
end. side is done, sensor dectect and inter lock with m/c so that m/c
welding cycle not run . Target:
Team Leader: Sunil Kumar, Vikash dhankar
Before Kaizen Photo: After Kaizen Photo: Team Members: Investment Cost
1. Suresh Labour 0
2. Sanjeev Material 0
Total Cost
in Rs 0
Benefit After Kaizen:

1.Improve Quality
2.poka yoka implemented .
3. opposite side welding rej. zero.

Welding Fixture without sensor Component Modified Fixture with senor

Analysis: Result:
Problem: Welding position incorrect (shaft reversly loaded in welding fixture) Kaizen Sustenance

Why-1 Shaft od size same from both end . What to do: Verification of Kaizen Dec,18 Jan,19

Why-2 No guiding / locking provided for avoide reversly loading of shaft . 1. Quality improve. How to do: Kaizen Monitoring Sheet 5 0

2. Poka yoka implemented .

Why-3 Inadequate Fixture design 3. Opposite side welding rejection zero. Frequency: MONTHLY

During initial development stage reversly loading of shaft not

Why-4 Scope & plan for Horizontal Deployment
considred
Sr. No. M/c No. Target Date Resp. Status
Root
Cause

Scope & Plan for Horizontal Deployment in Other MT Plants

MT-1 MT-2 MT-3 MT-4 MT-5 MT-6 MT-7 AK-1 AK-2 AK-3
Checked By: Prod. Head Quality Head Maint. Head Engg. Head HR Head TPM Coordinator GM-Operation Approved by: Mr. Ajay Girwan
Document for Evidence and Verification: Cost Calculation sheet
 Prepare
AKAU OMATICS KAIZEN IDEA SUMMARY SHEET TPM
Plant Name: AKA- Rohtak Area: Spindle Comp Kick Starter Machine Name: Round Welding M/c Department: Calibration
Kaizen Result Area: Loss No. Pillar wise Kaizen Category
JH PM QM
P 1. Productivity Improvement Q 2. Product/Process Quality Improvement C 3. Cost/Energy Saving Kobetsu Kaizen Jishu Hozen
Planned Quality
Maintenance Maintenance
ET SHE OTPM DM
D 4. Delivery Improvement S 5. Safety Improvement M 6. Morale/ 5S Improvement Safety Health &
Education & Training Office TPM Development Management
Environment

Kaizen Theme: To Improve Quality and improve checking Kaizen Idea: Implemetation of combine dimension
Kaizen Detail AKA--K-KK-calibration-hobbing m/c
method by using runout checking gauge checking root dia checking .

Kaizen Start Date: 7.02.2019

Problem/Present Status Before Kaizen: Countermeasures: Kaizen Finished Date: 9.02.2019

Root dia Gauge can check only receving and other gauge check runout A combine gauge implement in place of receving and dial gauge . Benchmark:

Target:
Team Leader: Sunil Kumar
Before Kaizen Photo: After Kaizen Photo: Team Members: Investment Cost
1. Suresh Labour 0
2. Sonu Material 0
3 Ranbir Total Cost
in Rs 0
Benefit After Kaizen:

1.Improve Quality
2.Save one gauge cost .
3. Easy checking method

Runout Gauge Root dia Gauge Runout Gauge with root dia master

Analysis: Result:
Problem: Gauge detact only max dia Kaizen Sustenance

Why-1 gauge was only receving type What to do: Verification of Kaizen Dec,18 Jan,19

Why-2 diffecut checking method . 1. Quality improve. How to do: Kaizen Monitoring Sheet 5 0

2. Save 1 gauge cost.

Why-3 Inadequate gauge design Frequency: MONTHLY

Why-4 operator check Scope & plan for Horizontal Deployment

Sr. No. M/c No. Target Date Resp. Status

Root
Cause

Scope & Plan for Horizontal Deployment in Other MT Plants

MT-1 MT-2 MT-3 MT-4 MT-5 MT-6 MT-7 AK-1 AK-2 AK-3
Checked By: Prod. Head Quality Head Maint. Head Engg. Head HR Head TPM Coordinator GM-Operation Approved by: Mr. Ajay Girwan
Document for Evidence and Verification: Cost Calculation sheet