cultural change in amm factory - alfa laval india
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Lean Kaizen Mela 2013
5S… Cultural change in AMM factory.
What is it?5S is one of the cornerstones of Lean
Basis of a visual factory Fundamental to Total Productive Maintenance
Sort
Set
Shine
Standardise
Sustain
“Lean is doing the right thing at right time, in right quality and right quantity with using minimum resources.”
Messy Factory 5 S Manufacturing Laboratory
Lean Kaizen Mela 2013
A global company…
Alfa Laval is a leading global provider of specialized products and engineered solutions. Creating the best heat transfer, separation and fluid handling technologies in the world for a 130 years, Alfa Laval's products and solutions are used in such areas as food and water supply, energy, environmental protection and pharmaceuticals.
Lean Kaizen Mela 2013
We serve most industries…
BiofuelsBiotech and pharmaceutical
ChemicalsCrude oil refinery
Engine and transportFluid power
Food and beverages HVAC
Industrial fermentation Latex
Machinery
Marine and dieselMetal workingMining and mineral processingOil and gas Power Pulp and paperRefrigeration and air-conditioningSemiconductor systemsSteel and coke oven gasSugarWastewater treatment
Lean Kaizen Mela 2013
AMM Product Folio…
We are specialized in CIP SOLUTIONS (CIP200,CIP400,CIP800,CIP1800,CIP2800)
CLARA MODULES (CLARA 15, CLARA 20, CLARA 80, CLARA 200, CLARA 250)
BREW (80,BREW 250,BREW 301)
PX (PX30,PX55,PX65,AFPX810)
MIXERS (MX 60,MX80,MX90,MX100)
STERILISERS
PASTURISERS & PREHEATERS
ALDOX & CARBOBLEND,
VISCOLINE (VLA/VLM/VLC)
Lean Kaizen Mela 2013
CIP modules & mixers
CIP MODULE
MIXER MODULE
Lean Kaizen Mela 2013
Sterilizers & Aldox and Carboblend
Sterilizers
Aldox and Carboblend
Lean Kaizen Mela 2013
Separator Modules…
CLARA 20 MODULE
CLARA 80 MODULECLARA 200 MODULE
MBPX 810 MODULE
PX MODULE BREW MODULE
Lean Kaizen Mela 2013
Vision!! Operations India is the 2nd manufacturing region, by 2013 the first in establishing the ALPS to achieve World Class Performance
5S is the core of the system.
Objective!! 5S Implementation through
Cultural Change.
Lean Kaizen Mela 2013
Journey started…in Nov 2010
Lean Kaizen Mela 2013
Methodology…
Awareness & Training Workshops Zones
FormationDaily 10 min 5S
Weekly 1 hour 5S
Internal weekly Audit
Gap Analysis Action Implementation Reward & Recognition
Lean Kaizen Mela 2013
Working zones…
Lean Kaizen Mela 2013
Gap Analysis…
13
Before Kaizen After Kaizen
Problem Action Result
Unsafe gang way and unwanted material lying on
shop floor
Unwanted material removed and Place For Everything And Every useful
thing in Its Place
Safe gang way for manual movement no unwanted material
on shop floor
Kaizen Improvement
14
Before Kaizen After Kaizen
Problem Action Result
While operating corrugation m/c one extra man needed for start
& stop m/c & also wasting extra time & motion
By fixing remote switch for corrugation m/c
Using remote switch only one man operating m/c which saving time man
power & motion
Kaizen Improvement
15
Before Kaizen After Kaizen
Problem Action Result
To much time to search the tools like
grinders,hammers,faceshield
Systematic arrangement done As shown
Kaizen Improvement
16
After Kaizen
Problem Action Result
To much time to search the tools like
grinders,hammers,faceshield
Systematic arrangement done As shown
Kaizen Improvement
After Kaizen
17
Before Kaizen After Kaizen
Problem Action ResultHeavy water spillage on shop
floor during testingDischarge sump fabricated As shown, hoses connected to drainage
directly.
Kaizen Improvement24/08/2012 OWNER:-S CHOUGULE, S KAMBALE
18
Before Kaizen After Kaizen
Problem Action Result
Dust & burr goes on face because so much gape between face & shield from downside also
shield goes upWhen operator saw down
By making changes on unbreakable shield fix downside
guard & also fix ribbon to downside guard
Face shield proper fitted so no dust & burr goes on face also extra ribbon fitted to new down guard because of this face shield not
moving from face
Kaizen Improvement OWNER:-Mahendra Chougule21/01/2013
19
Before Kaizen After Kaizen
Problem Action ResultFor VLC,VLM jobs no proper
arrangement for testing, grinding flaring, assembly ,pickling &
transporting which occurs scratch mark, wastage of time & bad quality of
jobs
By making multipurpose trolley By using of trolley easy for testing, grinding flaring, assembly ,pickling & transporting which reduced wastage of time & good quality of jobs
because no scratch mark found on jobs
Kaizen Improvement
20
After Kaizen
Problem Action Result
VLA mala foods one job needs six bends & twelve weld joint to
one couple
By bending a pipe saving cost & manpower
By bending a pipe saving six bends & twelve weld joint to one couple. we are
making three couple like this which save manpower welding joints & also good
looking
Kaizen Improvement
21
Before Kaizen After Kaizen
Problem Action ResultNo Specific arrangement for storage of
CIP200L Tank.Tanks getting scratch mark & also
getting damagedNot safe for handling & travelling
By making a fixture By making a fixture reduces wastage of place also improve in quality because not tanks not getting
damaged & not found any scratch mark on itSafe for handling & travelling
Kaizen Improvement
22
Before Kaizen After Kaizen
Problem Action Result
Hand injury occurs while tungsten rod grinding on bench
grinder
By providing safety guard for bench grinder
No hand injury occurs because of latest adjustable guard for bench grinder
Kaizen Improvement OWNER :- Mahendra Chougule & prakash salunkhe
02/03/1013
23
Before Kaizen After Kaizen
Problem Action ResultShell tapping was risky because no
specific arrangement for holding shell. Shell was holding by hands
Chances of hand injury is more wastage of time is more wastage of manpower
found
By making a fixture Safe because shell not needed to hold & chances of injury is less wastage of time is less
No extra manpower needed fixture make in a base frame which not needed extra space
Kaizen Improvement
Lean Kaizen Mela 2013
Improvement photographs…
Lean Kaizen Mela 2013
Who benefits…
Earlier 5S only workshop activity It is not possible in fabrication line
Later
Improves health and safety• Creates a better environment• Items are easier to find, saving time• Less irritation when you can find items easily• Less conflicts with colleague’s because items can be found easily• Improve morale and teamwork• Gives ownership to us• Puts tools at point of use• Less tired at the end of the day
Employees Statements from Alfa Laval 5S Sites
Lean Kaizen Mela 2013
Celebrations…
Lean Kaizen Mela 2013
Appreciation news on Share…
Lean Kaizen Mela 2013
Appreciation news on Share…
Lean Kaizen Mela 2013
THANK YOU…