qcfi productivity

Laxmi Engineering

WorksPresented By:-

Mr. Nilesh R Borse

1QCFI Mini Convention- April 2015

Kaizen Theme

Productivity improvement


Problem

Higher product motion and cycle time resulting in less

output


Background

Forming 2nd piercing Tacking

Full Welding100%

Inspection on Relation

Gauge

Weld run check and palletizing


Current status of problem

5

Forming

2nd piercing

Tacking

Full Welding

100% Inspection on relation gauge

• 2 separate personnel are required for assembly of the job.

• 100% inspection on relation gauge is required due to susceptibility of job to distortionQCFI Mini Convention- April 2015

Why why AnalysisThe problem – Low productivity

• WHY?Two operators required for assembly operation

• WHY?Tacking and full welding need to be done separately

• WHY?Full welding fixture is not available

ROOT CAUSE:- Full welding fixture is not available


IdeaProvide full welding fixture


Countermeasure

Provide a full welding

fixture with accurate

dimension locators


ComparisonBefore After


Results

10

Forming

2nd piercing

Full welding

Sampling inspection

Weld run check and palletizing

QCFI Mini Convention- April 2015

• Output per man per shift increased.

• Inspection time decreased due to sampling basis inspection.

Benefits – P,Q,C,D,S & M

Area of Benefit Before After

P Output per man per shift:-240 nos

Output per man per shift:- 480 nos

Q Average 3 times per month Zero customer complaint

C Labor cost per month:- Rs 15,600/-

Labor cost per month:- Rs 7800/-

D Dispatch used to get delayed

Dispatch gets done on time

S ……. …….

M High operator fatigue and stress level

Fatigue level reduced and operator morale

boosted11QCFI Mini Convention- April 2015

Sustenance Action

• Ensure proper tightening of bolts.• Periodic lubrication during operation.• Training to operator regarding proper usage and

maintenance of the fixture.


Kaizen Idea Sheet


Thank You


qcfi productivity

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