MUSAFIR BROTHERS UDYOG Kaizen Theme:- To give proper identification to master batches.

"KAIZEN IDEA SHEET" Kaizen Idea:improve the space and proper marking of master batches.

Kaizen Unique No: - MBU/01/10 11/1 (HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1
Team Leader:- Akash

Problem Status:- Earlier master batches are kept in Bags without identification.

Counter Measure:- Buckets are provided for keeping the master batches and proper identification done on each bucket.

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 7-10-2010 Result Area Productivity h i Before 15 Min

Completion Date:- 10-10-2010 Target 0Min After 0 Min Verified By

Akash; during supplier visit

Before:-

Quality Cost Delivery OHS

Problem Analysis:-

After:-

Env Morale Horizontal Deployment Sr. No. 1 Where NA Who NA When NA Status NA

Root Cause : No proper marking and proper place for master batches.

Results:-

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

"KAIZEN IDEA SHEET" Kaizen Idea:To improve the process with reduction in set-up time & using minimum workforce.

Kaizen Unique No: - MBU/01/10 11/2 (HORINZONTAL DEPLOYMENT)

Zone/Dept Coordinator:- 1 Team Leader:- Akash

Problem Status:- Less Productivity due to high set-up time observed in Plastic Component.

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.

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 26-9-2010 Result Area Productivity h i Before 24 Min

Completion Date:- 15-10-2010 Target 15 Min After 16 Min Verified By

Akash; during supplier visit

Before:-

Quality Cost Delivery OHS Env Morale Horizontal Deployment Sr. No. 1 Where NA Who When Status

Problem Analysis:Study made on Process Flow of IM Comp. Manff. & nd high set-up time in lifting the tool found to be 2 bottleneck operation. Average tool changeover time was in the range of After:90 to 170 Min. Out of which 24 min were for tool lifting Lack of proper knowledge , unutilization of productivity improvement tools.

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
NA NA NA

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

"KAIZEN IDEA SHEET" Kaizen Idea:-

Kaizen Unique No: - MBU/01/10 11/3 (HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1 improve the process with reduction in set-up time & Team Leader:- Akash using minimum workforce.

Counter Measure:Problem Status:- Less Productivity due to high set-up time observed in Plastic Component.
Conventional cooling nipples on which cooling pipe Team:- MUSAFIR BROTHERS UDYOG was fitted after heating & sealed with metallic wire replaced by push fit PU Nipples which proved to be more productive .
Start Date:- 05-10-2010 Result Area Productivity h i Before 22 Min Completion Date:- 15-10-2010 Target 10 Min After 12 Min Verified By
Akash; during supplier visit

Before:-

Quality Cost Delivery OHS Env Morale Horizontal Deployment Sr. No. 1 Where NA Who NA When NA Status NA

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 After: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.

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 10 Min with this change

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

Problem Status:- Less Productivity due to high set-up time observed in Plastic Component.

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.

Root Cause : Improper operations & lack of knowledge about SMED resulted in high mould set up time.

Page 4

"KAIZEN IDEA SHEET" Kaizen Idea:-

Kaizen Unique No: - MBU/01/10 11/4 (HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1 improve the process with reduction in set-up time Team Leader:- Akash & using minimum workforce.

Counter Measure:Ordinary cooling battery (for Hydraulic Oil Cooling) Team:- MUSAFIR BROTHERS UDYOG which had ordinary cooling pipes (heated & sealed) replaced by quick fit cooling battery with push fit PU nipples.
Start Date:- 05-10-2010 Result Area Productivity h i Before 21

Before:-

Quality Cost Delivery OHS

After:-

Env Morale Horizontal Deployment Sr. No. 1 Where NA

Results:Tool Changeover time on 180 T M/c reduced by 9 Min with this change

Page 5

ue No: - MBU/01/10 11/4 (HORINZONTAL NT)

Coordinator:- 1

er:- Akash

SAFIR BROTHERS UDYOG

Completion Date:- 15-10-2010 Target 10 After 12 Verified By

Akash; during supplier visit

Horizontal Deployment Who When Status

NA

NA

NA

Page 6

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

"KAIZEN IDEA SHEET" Kaizen Idea:-

Kaizen Unique No: - MBU/01/10 11/5(HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1 improve the process with reduction in set-up time & Team Leader:- Akash using minimum workforce.

Problem Status:- Less Productivity due to high set-up time observed in Plastic Component.

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

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 17-9-2010 Result Area Productivity h i Before 10 Min

Completion Date:- 17-10-2010 Target 2 Min After 2 Min Verified By

Before:-

Quality Cost Delivery OHS Env Morale Horizontal Deployment Sr. No. 1 Where Who When Status

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 After:adjustment in absence of locating ring. Lack of proper knowledge , unutilization of productivity improvement tools.

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

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

"KAIZEN IDEA SHEET" Kaizen Idea:-

Kaizen Unique No: - MBU/01/10 11/6 (HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1 improve the process with reduction in set-up time & Team Leader:- Akash using minimum workforce.

Problem Status:- Less Productivity due to high set-up time observed in Plastic Component.

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.

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 29-09-2010 Result Area Productivity h i Before 10 Min

Completion Date:- 16-10-2010 Target 7 Min After 7 Min Verified By

Akash; during supplier visit

Before:-

Quality Cost Delivery OHS Env Morale Horizontal Deployment Sr. No. 1 Where NA Who NA When NA Status NA

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 After:Movement to M/c. Lack of proper knowledge , unutilization of productivity improvement tools.

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

MUSAFIR BROTHERS UDYOG Kaizen Theme:suppliers end. To improve productivity at

"KAIZEN IDEA SHEET" Kaizen Idea:-

Kaizen Unique No: - MBU/01/10 11/7 (HORINZONTAL DEPLOYMENT)

To Zone/Dept Coordinator:- 1 improve the process with reduction in set-up time & Team Leader:- Akash using minimum workforce.

Counter Measure:Problem Status:- Less Productivity due to high set-up time/labour shortage observed in Plastic Component.
Allen Key replaced by ratchet spanner Allen key which proved to be more handy & productive
Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 23-10-2010 Result Area Productivity h i Before 7 Min

Completion Date:- 29-10-2010 Target 5 Min After 5 Min Verified By

Akash; during supplier visit

Before:-

Quality Cost Delivery OHS Env Morale Horizontal Deployment Sr. No. 1 Where NA Who NA When NA Status NA

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 After:Lack of proper knowledge , unutilization of productivity improvement tools.

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 2 Min with this change

MUSAFIR BROTHERS UDYOG Kaizen Theme:- To save time in searching of tools.

"KAIZEN IDEA SHEET" Kaizen Idea:To develop a tool box for tools.

Counter Measure:- Spanner & other Problem Status:- As the tools are not tools are arranged on shadow board arranged and at proper place, and near to machines. workers has to waste there time in searching tools.

Before:Problem Analysis:- there is no proper place for tools, which give rise to wastage of time in searching of tools.

After:-

Root Cause : No arrangement of tools

Results:5-10 min saved in searching of tool.

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 Verified By

Akash; during supplier visit

Result Area h i Before Target After Productivity Quality Cost Delivery OHS Env Morale Sr. No. 1 Horizontal Deployment Where Who When NA NA NA 10 Min 0 min 0 Min

Status NA

MUSAFIR BROTHERS UDYOG Kaizen Theme:Dies. To Save time For searching

Problem Status:- Worker has to search for dies since not arranged and marked.

Problem Analysis:Since Dies are not arranged or marked, lots of time is waste in searching of dies,which reduces the production and manpower.

Root Cause : No arrangement & numbering of dies accordingly.

Root Cause : No arrangement & numbering of dies accordingly.

"KAIZEN IDEA SHEET" Kaizen Idea:To develop die stand & give numbers to each die. Counter Measure:Now die stand is made for arrangement of dies and they are arranged on stand according to there number.

Kaizen Unique No: - MBU/03/10 11/9 (HORINZONTAL DEPLOYMENT)

Zone/Dept Coordinator:- 3 Team Leader:- Akash

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 17-9-2010 Result Area Productivity h i Before 22 Min

Before:-

Quality Cost Delivery OHS

After:-

Env Morale Horizontal Deployment Sr. No. 1 Where NA

Results:Tool Changeover time on 180 T M/c reduced by 10 Min with this change

Results:Tool Changeover time on 180 T M/c reduced by 10 Min with this change

MBU/03/10 11/9 (HORINZONTAL

or:- 3

sh

ROTHERS UDYOG

Completion Date:- 20-10-2010 Target 10 Min After 12 Min Verified By

Akash; during supplier visit

Horizontal Deployment Who NA When NA Status NA