PDC DEEP DIVE – PRODUCTIVITY IMPROVEMENT

Part Name : GEAR BOX HOUSING

40 1 3 36
1 1 33
35 30
Shots per hour

30
25
20
15
10
5
0
Baseline Optimize Robot sprayer Internal and Shots to be As per NADCA Achieved
Machine Optimization External spray increased to Output
Parameter optimization meet NADCA
Ideas
1. To increase the effectiveness of heat transfer at bottom/side core by modifying the internal cooling design in CFT.

2.Reduce heat check mark in high temp. spots by introducing loose pieces wherever required.

NADCA STANDARD.
 NADCA Cycle time =26.90 + (0.0365 * Machine Locking Force in Tons)
=26.90+(0.0365*2000)
=100 sec 36 shots/Hour
 Considering 90 % Of NADCA Cycle time we should achieve 33 shots/Hour
 We Planning to achieve Cycle time by New Innovation and ideas In Future

Inference : We have improved 10 %from the baseline.

 Kaizen No. & Date : 19.02.2019
KAIZEN IDEA - SHEET
Department : HPDC
Category P Q C D S M Team Members

Kaizen Theme: Kaizen Start : 23.01.2019 M.Gopi, Sivanesan, Raymond furdato, Srinath,
Praveen, Aravind, Dharani Babu
To Improve Productivty in Gear Box housing Kaizen Finish : 19.02.2019

Problem / Present Status Countermeasure/ After improvements Benefits

1) Cycle time of auto sprayer is around 55sec.
1. Machine Parameter Optimised.
2. Auto spray lubrication on both the dies at same time and
program optimised according to the requirements.
3. External Spray position modified for effectivness.
4. Die temp. attained to 180±30°c rapidly, by this activity at
after spray condition.
1) Productivity improved 30 nos to 33 nos.
2) Cycle time reduced 120 sec to 109 sec.
3) Auto spray is given in required area.
4) Auto spray and Die life increased

Sep'18 Before After

*
40
30 This Kaizen is
30 Ir-reversible
Reversible
20 If reversible updated in
10 Process sheet
JH Check sheet
0
Timer cooling given at 7 different PM Check sheet
shots/Hour Timer cooling given at 5
spots of the die at less volume and
locations of Die at High
Eqpt/ fixture Drawing
pressure pressure and volume. QM check sheet
Analysis Results
Auto Sprayer Cycle time high 1) Less No.of interpolations in Auto sprayer. Scope & Plan for Horizontal Deployment:
2.Cycle time reduction from 55sec to 48sec.
S.No. Item Target Date Responsibility Status
More spray required to cool and lubricate the die 3) Ouptut per hour increased from 30 to 33 No's.
Ladder
shots/Hour 1 March '19 M.Gopi on Going
Before spray temperature of the die is high Frame
34 33
Differnence of Die temp. at specific spots 32
30
30 IF IT IS POKA YOKE WHAT TYPE & FUNCTION
Use forced extermal cooling at specific spots 28
Sep'18 Feb'19
Prevention Shutdown

1. To increase the effectiveness of heat transfer at bottom/side core by modifying the Detection Warning
New Ideas to reach 100 internal cooling design in CFT. Control
% Nadca Cycle time 2.Reduce heat check mark in high temp. spots by introducing loose pieces wherever
1
required.