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West Bokaro Division

Introduction

SGA Circle : Tulika

West Bokaro Division

Kaizens Implemented : FY15


Kaizen ID

Kaizen Title

Tangible Saving
(Rs lakhs)

QUIKS/KZN/135808

LENS SETTING INNOVATIVELY MODIFIED IN TOTAL STATION FOR OPTIMAL VISION /CLARITY
DURING SURVEYING

0.5

QUIKS/KZN/139016

TOTAL STATION SCREEN PROVIDED WITH ADDITIONAL MAGNIFICATION LAYER FOR BETTER
READING

0.1

QUIKS/KZN/143500

DOUBLE SIDED PRINTING ON OLD PLANS TO SAVE PAPER COST

0.1

QUIKS/KZN/147831

TOTAL STATION PROVIDED WITH A INNOVATIVE TRIPOD STAND FOR BETTER STABILITY IN ALL
KIND OF ROUGH SURFACES

QUIKS/KZN/152046

LINE OF SIGHT OF OLD TOTAL STATION INNOVATIVELY FINE TUNED FOR FOSTERING ACCURACY

0.1

QUIKS/KZN/156362

GLOBAL COORDINATES UPDATED AND RECONCILED WITH LOCAL COORDINATES THROUGH


INNOVATIVE METHOD

QUIKS/KZN/161268

NEW DGPS SURVEY HANDS-ON INFORMATIVE MODULE DEVELOPED TO CREATE KNOWLEDGE BASE
FOR FUTURE

QUIKS/KZN/165478

DATABASE MIGRATED TO NEW SURVEY SOFTWARE AUTOPLOTTER FOR BETTER SURVEYING


ACCURACY

QUIKS/KZN/171180

TOTAL STATION MOUNTING BOLT MODIFIED FOR HIGH PRECISION AND FOOL PROOF JOINTING

QUIKS/KZN/174608

HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH DURABLE PLASTIC MADE
CUSTOMISED TYPE FOR LONGEVITY AND SAFETY

QUIKS/KZN/179905

INNOVATIVE VOLUME CALCULATOR MACRO PREPARED IN SURPAC TO AUTO CALUCLATE TEDIOUS


TASKS

QUIKS/KZN/184279

EXCEL MACRO DEVELOPED TO COMPARE AND POINT OUT ERRORS IN RL READINS TAKEN BY
HANDHELD GPS AND TOTAL STATION

West Bokaro Division

0.05

Weighted Average Matrix for arriving at the best Kaizens


Kaizen Title

Mithilesh Kr Singh Lakshman Singh Ramnandan Singh Mahendra Yadav Wtd. Average

LENS SETTING INNOVATIVELY MODIFIED IN TOTAL STATION


FOR OPTIMAL VISION /CLARITY DURING SURVEYING

TOTAL STATION SCREEN PROVIDED WITH ADDITIONAL


MAGNIFICATION LAYER FOR BETTER READING

4.25

DOUBLE SIDED PRINTING ON OLD PLANS TO SAVE PAPER COST

7.75

TOTAL STATION PROVIDED WITH A INNOVATIVE TRIPOD


STAND FOR BETTER STABILITY IN ALL KIND OF ROUGH
SURFACES

6.75

LINE OF SIGHT OF OLD TOTAL STATION INNOVATIVELY FINE


TUNED FOR FOSTERING ACCURACY

5.75

GLOBAL COORDINATES UPDATED AND RECONCILED WITH


LOCAL COORDINATES THROUGH INNOVATIVE METHOD

4.5

NEW DGPS SURVEY HANDS-ON INFORMATIVE MODULE


DEVELOPED TO CREATE KNOWLEDGE BASE FOR FUTURE

DATABASE MIGRATED TO NEW SURVEY SOFTWARE


AUTOPLOTTER FOR BETTER SURVEYING ACCURACY

TOTAL STATION MOUNTING BOLT MODIFIED FOR HIGH


PRECISION AND FOOL PROOF JOINTING

4.75

10

HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH


DURABLE PLASTIC MADE CUSTOMISED TYPE FOR LONGEVITY
AND SAFETY

8.75

11

INNOVATIVE VOLUME CALCULATOR MACRO PREPARED IN


SURPAC TO AUTO CALUCLATE TEDIOUS TASKS

5.75

12

EXCEL MACRO DEVELOPED TO COMPARE AND POINT OUT


ERRORS IN RL READINS TAKEN BY HANDHELD GPS AND TOTAL
STATION

4.75

West Bokaro Division

HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH


Star
Kaizen-1

DURABLE METAL ALLOY & PLASTIC MADE CUSTOMISED TYPE FOR


LONGEVITY AND SAFETY

West Bokaro Division

Before
Problem Statement :

Total Station used for Survey Measurements is a delicate and expensive instrument.
It has to be protected from exposure to inclement weather and manhandling to safeguard
the integrity of its lens and other critical components.
Any deficiency can severely compromise the quality of readings recorded.
Total Station is safely encased in a carrying case for comprehensive protection.
The handle of the carrying case gave away unexpectedly and the safety of the Total station
was at stake. Further, Total station is a cumbersome equipment that needed a case for
moving around.
Manufacturer company does not provide support for substitution of cases handle.
This implied that we had to invest in a new case, that would approx. cost around 1.5 Lakhs.
The safety of Total Station was potential threatened as it became vulnerable to damages.
West Bokaro Division

West Bokaro Division

West Bokaro Division

West Bokaro Division

West Bokaro Division

10

Fishbone analysis
Machine
Defect may set in
Lens

Component
replacement may
not be supported
by manufacturer

Critical
components may
get damaged
Inclement weather
/ elements can
corrupt sensitive
components
Lens can become
obscured/
scratchy/ spotty

Environment

West Bokaro Division

Man

Survey would be
interrupted till
replacement

Delay in Survey as
no one would be
willing to assume
responsibility of
the Total Station

Manhandling
induced damage
Unwittingly left at
site due to
overlook

Readings recorded
may be corrupted

Subjection to
harsh conditions
can result in
glitches which
becomes visible
over time

Method

Erroneous data
may lead to fatal
mistakes getting
reflected in entire
mine planning
process
11

Countermeasure

The problem was deliberated over by team members.


We could not afford much time as delay in measurement would
occur.
After brainstorming and consultation with the experts at Workshop,
an alternate solution was arrived at.
A new handle was designed in-house.

The handle is constructed out of a durable metal alloy which is


resistant to corrosion, had a coating of hardened rubber to absorb
and endure stress and finally is encased within a wooden frame for
comfortable carrying.
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12

After

West Bokaro Division

13

Tangible benefits
Amounts ( Lakhs)

Cost to be incurred for procuring new box

1.25

Material cost borne to develop customized


solution indigenously

0.15

Craftsmanship Charges

0.10

Final Savings

1.00 Lakhs

Intangible benefits

No compromise on datas accuracy and reliability

Integrity of crucial mine planning data maintained

Sustained morale of employees


West Bokaro Division

14

Next Project envisaged

Strategically altering the design of the Tripod Stand to eliminate


inadvertent errors induced due to alignment problems on field

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15

West Bokaro Division

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