Download - Kaizen Idea new.xls
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Target
Sr. No. Who
1 NA
Kaizen Unique No: - MBU/01/10 11/1 (HORIN
DEPLOYMENT)
Kaizen Theme:- To give proper identification
to master batches.
Kaizen Idea:- Toimprove the space and proper marking of master
batches.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:- Buckets are provided for
keeping the master batches and proper
identification done on each bucket.Problem Status:- Earlier master batches are
kept in Bags without identification.
Team:- MUSAFIR BROTHERS UDYOG
Completio
Productivity 15 Min 0Min
Start Date:- 7-10-2010
Cost
Quality
After:- Env
Horizontal Deploymen
Where
Before:-
OHS
Delivery
Morale
NA
Root Cause : No proper marking and proper place
for master batches.Results:-
Problem Analysis:-
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Targ
Sr. No. Who
1
Kaizen Unique No: - MBU/01/10 11/2 (HOR
DEPLOYMENT)
Kaizen Theme:- To improve productivity at
suppliers end.
Kaizen Idea:-To improve the process with reduction in set-up
time & using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-
Mould lifting which was earlier done by Metal
Chain which require high man time due to
Nut/Bolt Assy. & being heavy in wt. Same
replaced to Synthetic Sling which is easy to fit
& operate.
Problem Status:- Less Productivity due to high
set-up time observed in Plastic Component.
Team:- MUSAFIR BROTHERS UDYOG
Start Date:- 26-9-2010 Comple
Productivity 24 Min 15 M
Cost
Quality
After:- Env
Horizontal Deploym
Where
Before:-
OHS
Delivery
Morale
NA
NA
Root Cause : Improper operations & lack of
knowledge about SMED resulted in high mould set
up time
Results:-Tool Changeover time on 180 T M/c reduced by 8 Min
with this change
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time in lifting the tool found to be 2nd
bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 24 min were for tool
lifting
Lack of proper knowledge , unutilization of
productivity improvement tools.
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Ta
Sr. No. W
1
Kaizen Unique No: - MBU/01/10 11/3 (H
DEPLOYMENT)
Kaizen Theme:- To improve productivity at
suppliers end.
Kaizen Idea:- Toimprove the process with reduction in set-up time &
using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-Conventional cooling nipples on which cooling pipe
was fitted after heating & sealed with metallic wire
replaced by push fit PU Nipples which proved to be
more productive .
Problem Status:- Less Productivity due to high
set-up time observed in Plastic Component.
Team:- MUSAFIR BROTHERS UDYO
Com
Productivity 22 Min 10
Start Date:- 05-10-2010
Cost
Quality
After:- Env
Horizontal Depl
Where
Before:-
OHS
Delivery
Morale
NA
Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set
up time.
Results:-Tool Changeover time on 180 T M/c reduced by 10
Min with this change
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time in fixing tool cooling nipples found
to be 3rd
bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 22 Min were for fixing
cooling nipples/pipes on tool
Lack of proper knowledge , unutilization of
productivity improvement tools.
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MUSAFIR BROTHERS UDYOG
Kaizen Theme:- To improve productivity atsuppliers end.
Problem Status:- Less Productivity due to high
set-up time observed in Plastic Component.
Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set
up time.
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time found to be bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 21 Min were for making
cooling battery operational.
Lack of proper knowledge , unutilization of
productivity improvement tools.
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"KAIZEN IDEA SHEET"
Result Area h i Before
Sr. No.
1
Kaizen Unique No: - MBU/01/10 1
DEPLOYMENT)
Kaizen Idea:- Toimprove the process with reduction in set-up time
& using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-Ordinary cooling battery (for Hydraulic Oil Cooling)
which had ordinary cooling pipes (heated & sealed)
replaced by quick fit cooling battery with push fit
PU nipples.
Team:- MUSAFIR BROTHERS
Start Date:- 05-10-2010
Productivity 21
Cost
Quality
After:- Env
Horizontal
Where
Before:-
OHS
Delivery
Morale
NA
Results:-Tool Changeover time on 180 T M/c reduced by 9
Min with this change
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4
Target After Verified By
Who When Status
/4 (HORINZONTAL
DYOG
Completion Date:- 15-10-2010
10 12Akash; during
supplier visit
Deployment
NA NA NA
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Targe
Sr. No. Who
1
Kaizen Unique No: - MBU/01/10 11/5(HOR
DEPLOYMENT)
Kaizen Theme:- To improve productivity at
suppliers end.
Kaizen Idea:- Toimprove the process with reduction in set-up time &
using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-
Locating Rings made w.r.t all mould/machine
dimensions & used for easy changeover. Usage
of locating rings reduced adjustment time
between M/c Nozzle & mould Sprue Bush
Problem Status:- Less Productivity due to high
set-up time observed in Plastic Component.
Team:- MUSAFIR BROTHERS UDYOG
Start Date:- 17-9-2010 Comple
Productivity 10 Min 2 Min
Cost
Quality
After:- Env
Horizontal Deploym
Where
Before:-
OHS
Delivery
Morale
Root Cause : Improper operations & lack of
knowledge about SMED resulted in high mould setup time.
Results:-Tool Changeover time on 180 T M/c reduced by 8
Min with this change
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time found to be bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 7-8 Min were for tool
adjustment in absence of locating ring.
Lack of proper knowledge , unutilization of
productivity improvement tools.
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Targ
Sr. No. Wh
1 NA
Kaizen Unique No: - MBU/01/10 11/6 (HOR
DEPLOYMENT)
Kaizen Theme:- To improve productivity at
suppliers end.
Kaizen Idea:- Toimprove the process with reduction in set-up time &
using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-
Mould moved on a make shift arrangement
requiring 2 people to do the job instead a pallet
lifter deployed which does the job more
effeciently requiring only a single person.
Problem Status:- Less Productivity due to high
set-up time observed in Plastic Component.
Team:- MUSAFIR BROTHERS UDYOG
Comple
Productivity 10 Min 7 Mi
Start Date:- 29-09-2010
Cost
Quality
After:- Env
Horizontal Deploy
Where
Before:-
OHS
Delivery
Morale
NA
Root Cause : Improper operations & lack of
knowledge about SMED resulted in high mould set
up time
Results:-Tool movement time to M/c reduced by 3 Min with
this change
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time found to be bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 10 Min were for Mould
Movement to M/c.
Lack of proper knowledge , unutilization of
productivity improvement tools.
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Result Area h i Before Ta
Sr. No. W
1 N
Kaizen Unique No: - MBU/01/10 11/7 (H
DEPLOYMENT)
Kaizen Theme:- To improve productivity at
suppliers end.
Kaizen Idea:- Toimprove the process with reduction in set-up time &
using minimum workforce.
Zone/Dept Coordinator:- 1
Team Leader:- Akash
Counter Measure:-Allen Key replaced by ratchet spanner Allen key
which proved to be more handy & productiveProblem Status:- Less Productivity due to high
set-up time/labour shortage observed in Plastic
Component.
Team:- MUSAFIR BROTHERS UDYO
Com
Productivity 7 Min 5
Start Date:- 23-10-2010
Cost
Quality
After:- Env
Horizontal Deplo
Where
Before:-
OHS
Delivery
Morale
NA
Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set
up time
Results:-Tool Changeover time on 180 T M/c reduced by 2
Min with this change
Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &
high set-up time found to be bottleneck operation.
Average tool changeover time was in the range of
90 to 170 Min. Out of which 7 Min were for
operations involving searching & usage of allen key
Lack of proper knowledge , unutilization of
productivity improvement tools.
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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"
Root Cause : No arrangement of tools Results:-5-10 min saved in searching of tool.
Problem Analysis:- there is no
proper place for tools, which give rise
to wastage of time in searching of
tools.After:-
Before:-
Kaizen Theme:- To save time insearching of tools.
Kaizen Idea:-To develop a tool box for tools.
Counter Measure:- Spanner & other
tools are arranged on shadow board
and near to machines.
Problem Status:- As the tools are not
arranged and at proper place,
workers has to waste there time in
searching tools.
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Result Areah i
Before Target After Verified By
Sr. No. Who When Status
1 NA NA NA
Horizontal Deployment
Where
NA
Morale
OHS
Delivery
Env
Cost
Quality
Productivity 10 Min 0 min 0 Min Akash; during supplier visit
Kaizen Unique No: - MBU/03/10 11/8 (HORINZONTAL
DEPLOYMENT)
Zone/Dept Coordinator:- 3
Team Leader:- Akash
Team:- MUSAFIR BROTHERS UDYOG
Start Date:- 10-10-2010 Completion Date:- 17-10-2010
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MUSAFIR BROTHERS UDYOG
Kaizen Theme:- To Save time For searching
Dies.
Problem Status:- Worker has to search for dies
since not arranged and marked.
Root Cause : No arrangement & numbering of dies
accordingly.
Problem Analysis:-Since Dies are not arranged or marked, lots of time
is waste in searching of dies,which reduces the
production and manpower.
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"KAIZEN IDEA SHEET"
Result Area h i Before
Sr. No.
1
Kaizen Unique No: - MBU/03/10 1
DEPLOYMENT)
Kaizen Idea:-
To develop die stand & give numbers to each
die.
Zone/Dept Coordinator:- 3
Team Leader:- Akash
Counter Measure:-
Now die stand is made for arrangement of dies
and they are arranged on stand according to
there number.
Team:- MUSAFIR BROTHERS
Productivity 22 Min
Start Date:- 17-9-2010
Cost
Quality
After:- Env
Horizontal
Where
Before:-
OHS
Delivery
Morale
NA
Results:-Tool Changeover time on 180 T M/c reduced by 10
Min with this change
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Target After Verified By
Who When Status
NA NA NA
/9 (HORINZONTAL
DYOG
Completion Date:- 20-10-2010
10 Min 12 MinAkash; during
supplier visit
Deployment
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