Date:-24/12/13Presentation by:- Baldeep Singh Prepared by:- Amandeep Singh

We are manufacturing automobile fasteners & special items as per customer requirement.

An ISO-TS 2001:16949 Company

Before After

Comments:1)

1. Burr observed after trimming process

2. Burr found more sharp after heat treatment.

3.Customer failed the screws due to burr

4. Screws are used in aluminum compressors after tightening the screw , burr damaged the surface it increase the risk of leakage of compressor.

Comments :- 1. Quality Improved no burr observed with new designed tooling .

2. No need to trim hex at another machine.

3.Production increased.

4.Party approved the samples.

Benefits : cost pro quality time money

KAIZEN PART NAME :- Hex Screw M5×25

IDEA EXECUTE BY :- Design & Dev. Dept.

Title:- Improved Tooling Design Company name :-Perfect Industries (India)

Tooling Design by: :- Mr. Maninder Singh

KAIZEN SAVING

3

TITLE:- Improved tooling design

PART NAME :- Hex screws M5×25

Description Before After

Daily Production

100 ×8=16800 23120 ×8= 24960

Machines & tooling used for

Bolt header + trimming machine

Multi Station Bolt Forging machine

Electricity Consumed (per day)

.746×3=2.23 units per hour 2.23units×8 hours=17.90 units17.90×6=rs107/

Machine Process removed.

0 cost

Manpower Used

2 nos. 1 nos

Man hours Used

16 hours per day

8 hours per day

Rejection 5% 0.02%

Material Saved- .003gram(material saved from

one piece) .003×rs70=5250/Trimming tooling saved=1400/Electricity Saved- Daily 17.90 units saved (17 .90×rs 6.00=107/)Manpower Saved Rs.194x 7 =Rs.1358/Rejection decreased from 5% to .02%=9840/TOTAL SAVINGS FROM A LOT OF 1 LAC PIECES= 5250+1400+107+1358+9840=17955

KAIZEN INVESTEMENT Skilled Operator salary =2800/7 daysTooling =Rs.18000/ PAY BACK TIME – 1 .5 daysBENEFITS1. Customer Satisfaction & zero complaint2. QUALITY IMPROVED3. PRODUCTIVITY INCREASE 4. LESS MANPOWER 5. MACHINE PROCESS SAVED

HORIZONTAL DEPLOYMENT- YES