case study of productivity and yield improvement of a single part using kaizen … · 2020. 5....
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Case Study of Productivity and yield Improvement of a Single Part Using Kaizen and Best Practices at n S InternationalKeywords: Productivity, yield, Slide Bolt, Traub, Cold forging, Kaizen.
AbstrAct
This case study deals with a single part improvement in Yield Saving and Productivity Improvement. Problems and ideas eliminating those problems through Kaizen and best practices are described and the benefits achieved by the organization and sharing the same with customer are shown.
Introduction: Productivity & yield Improvement
Productivity & Yield Improvement inSLIDE BOLT
OPERATION : TROUBMODEL : BOHD018
Problem (Reason for Selection)
1. Productivity was 1200 Nos./Shift with multiple machine
2. Yield was 13.39%
3. customer order increasing but not adhered
4. Selling price was lower than the Quotation cost
5. High Process cost
6. Delivery failure
7. customer complaints were increasing
Problem Understanding
Slide bolt-Focus on Process for Productivity Improvement
Traub-1Part off
andTurning
CLG-1TRD
GrindingRuff
Troub-2Under CutMilling Dia
Turning
CLG-2TRD
GrindingFinish
Milling-1 Rolling
PlatingInspectionPacking
End
Start1=44 Nos.
1 2 3 4 5
11 10 9
1=333 Nos. 1=145 Nos. 1=125 Nos. 1=167 Nos. 1=167 Nos. 1=417 Nos.
Milling-2 Deburing
= Focus in process to be improved or eliminated
= Freeze Process
44 N 333 N 45 25 N 67 N 67 N 17 N
Productivity and Yield Improvement of a Single Part Using Kaizen and Best Practices 105
Productivity-Nos./Man/Hr
44
333
125
Taub
-1 P
art
off a
nd T
urni
ng
CLG
-1 T
RDG
rindi
ng R
uff
Milli
ng-1
Milli
ng-2
Debu
rring
CLG
-2 T
RDG
rindi
ng F
inish
Machine
450400350300250200150100500
Nos.
GOOD
Nos./Man/Hr.
167 167
417
yield loss
Yield Loss
Bar used Dia 18.5 (56 g/pc), Material Cost 60 Rs./Kg.Material Cost Per pc 3.37 Rs. Yield was 13.39%
Yield% used
Yield% Loss13.39
86.61
Loss1
61
List of Kaizens Implemented
S.No. Before After Benefit Target Date1 Troub-1, CLG-1,
Troub-2, Mil-1, Mil-2, Deburing, CLG-2, Processes were very low production
Forging Developed for the part. Troub-1, Mil-2, Deburing, CLG-2, has been eliminated
32000 Nos. Produced in Single Shift. Process Cost reduce 4.4 Rs. to 1.53 Rs.
02.12.2014
2 Bar Dia 18.5 used. Raw material cost was 3.37 Rs./pc, Weight 56 gms/pc, Yield-13.39%
Wire size 8.88 used. Raw material Cost 0.82/pc., Weight 14 gms/pc, Yield-53.57%.
Yield improved 13.39% to 53.57%, where Per pc cost reduce 3.37 Rs. to 0.82 Rs.
02.12.2014
106 N S International
Kaizen No. 01Company: Deptt.: Result: Month of Report Dec-14N.S. International Production-Troub Implemented
Subject: Productivity improvement through process change Process: Productivity Improvement
Before
Why-Why Analysis Horizontal Deployment
Benefits:
Comments: Comments:
ProductivityQuality
CostDeliverySafetyMorale
EnvironmentOthers
Saving/YearDate of Imple.Suggested by
Approved by
YesYesYesYesYes
Yes
20.1 Lac12.12.14Dayal Singh
PraveenSharma
Troub-1, CLG-1, Troub-2, Mil-1, Mil-2, Deburing, CLG-2, where the production was 1200 pcs/shift
� Production increased by 28800 Nos./shift (288000/mpnth)� Process Cost reduce 4.4 Rs. to 1.53 Rs./pc (Monthly-1435000
Forging Developed for the part. Troub-1, CLG-1, Troub-2, Mil-1, Mil-2, Deburing, CLG-2, has been eliminated, where production is 30000 Nos. per shift
Bolt Maker-1Cold Forging
1=30,000 Nos.
Traub-1Part off
andTurning
CLG-1TRD
GrindingRuff
CLG-2TRD
GrindingFinish
Milling-1
Start1=44 Nos.
11
2 4 5
1=333 Nos. 1=125 Nos. 1=167 Nos. 1=167 Nos. 1=417 Nos.
Milling-2 Deburing
44 N 333 N 25 N 67 N 67 N 17 N
After
Kaizen No. 02Company: Deptt.: Result: Month of Report Dec-14N.S. International Production-Troub Implemented
Subject: Yield improvement through process change Process: Cold Forging
Before
Why-Why Analysis Horizontal Deployment
Benefits:
Comments: Comments:
ProductivityQuality
CostDeliverySafetyMorale
EnvironmentOthers
Saving/YearDate of Imple.Suggested by
Approved by
YesYesYesYesYes
Yes
20.1 Lac12.12.14Dayal Singh
PraveenSharma
Slide Bolt fully machining at troub section by using of Bar Dia 18.5 (Slide Bolt fully machining at troub section by using of Bar Dia 18.5 (56 Grams) Operation-Part turning and total length, Groove Turning, OD Turning, Milling1 2, Deburring, CLG Threading, Plating, Inspection, Yield% 13.39, per pc cost-3.37Rs.
� Yield Saving–Rs. 2.55/pc (129000/month),� Quality Complaints reduced
Slide Bolt developed at forging process by using Bar Dia 8.88 (14 Grams) Operation-Forging, Traub, Milling, Deburring, CLG, Yield improved 53.57 Per pc cost 0.82 Rs./pc.
After
Productivity and Yield Improvement of a Single Part Using Kaizen and Best Practices 107
Benefits and Achievements
Traub-1Part off
andTurning
CLG-1TRD
GrindingRuff
Troub-2Under CutMilling Dia
Turning
CLG-2TRD
GrindingFinish
Milling-1
Start
Start
End
1=44 Nos.
1
1 2 3
456
2 3 4 5 6 7
1=333 Nos. 1=145 Nos. 1=125 Nos. 1=167 Nos. 1=167 Nos. 1=417 Nos.
Milling-2 Deburing
444 N 333 N 455 25 N 677 N 677 N 177 N
6 Machining Processes Eliminated
Slide Bolt – Productivity Improvement – After
Bolt Maker-1Cold Forging
1=30,000 Nos.
RollingTraub-1Turning
PlatingInspection
= Process After Improvement= Freeze Process
Packing
OperationBefore After
Manpower Nos./Man/Hr.
ManPower Nos./Man/Hr.
Traub-1 Part off and Turning 1 44
1 2500
CLG-1 TRD grinding Ruff 1 333Milling-1 1 125Milling-2 1 167Deburring 1 167CLG-2 TRD Grinding Finish 1 417
Benefit – 1 Man makes 2500 Nos./Hr. instead of 5 Men where productivity was 125 Nos. to 417 Nos./Man/Hr. Max.
13.39
86.61
Yield Loss – BeforeBEFORE
AFTER Yield Improved – After
Yield% used
Yield% Loss
Yield% Loss
Bar used Dia 18.5 (56 g/pc), While finish Pc. Wt.was just 7.5 gms.
Yield was 13.39%
Wire used Dia 8.88(14g/pc), against finish Pc.Wt. 7.5 gms.
Yield was 53.53%
46.47
53.53
Yield% used
108 N S International
1. Productivity was 1200 Nos./Shift with multiple machine – Increased by 30000/Shift with Single Machine
2.Yield was 13.39% – Increased by 53.57%
3.customer order increasing but not adhered – Adhered
4. High Process cost – Process Improvement done. Cost Reduced
5.Delivery Failure – no Delivery Failure
6. customer complaints were increasing – no. Customer Complaint after Process Improvement
Benefits Sharing with Customer
Cost
in R
s./P
c.
GOOD
Benefit Sharing with Customer
9876543210
Previous Cost/Pc. Present Cost/Pc.
5.6.
8.5
Team: Group Leader - Shri Dayal Singh, manager (operations), Team Leader – Shri rajinder Saini, In-charge (Production), Team Members – Shri Waseem ahmad, engineering (Qa), Shri Satish thakur, assistant In-charge (tool room) & Shri madan, Die Setter (Production).
s
Productivity and Yield Improvement of a Single Part Using Kaizen and Best Practices 109