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Significant Kaizen-1

AREA-CT.CLL

THEME-PRODUCTIVITY

TEAM -MOHIT

Problem Description

Problem Analysis

Rotary case RCG 01


is not working properly

.
Starting
rollers has
been broken so job
movement is not
being done easily

Counter Measure
.Roller

has been
repaired ,additional
roller has been
provided

Benefit
Problem has been
rectified

DAMAGED ROLLERS

AFTER REPAIRING

BEFORE

AFTER

Significant Kaizen-2
AREA-CT.CLL

THEME COST SAVING

TEAM -MOHIT

Problem Description
Hyd. Oil leakage
frequently happened
on SRB 06 M/C

Counter Measure

Problem Analysis
.
During
the job lifting
time hook lift the hyd.
Pipe line also .

Benefit

A protect guard has


been provided

Problem has been


rectified

GUARD NOT AVAILABLE

GUARD PROVIDED

BEFORE

AFTER

Significant Kaizen-3
AREA-CT.CLL

THEME-QUALITY

TEAM -MOHIT

Problem Description

Problem Analysis

Size variation observed


on SFB 04 M/C

.
Feed
found manually
changed on the
m/c .so feed valve to
be locked

Counter Measure

Benefit

Feed valve has


been locked

Problem reduced
under observation

FEED VALVE
NOT LOCKED

FEED VALVE LOCKED

BEFORE

AFTER

Significant Kaizen-4
AREA-CT.CLL

THEME-SAFTY

TEAM -MOHIT

Problem Description
Stair path to be
modified on
SRB 06 M/C

Counter Measure

Problem Analysis
.
Conveyor
passing
path is not safely
activity .to be
modified

Benefit

Path has been


modified

Problem has been


rectified

UNSAFE PATH

MODIFIED PATH

BEFORE

AFTER

Significant Kaizen-5
AREA-CT.CLL

THEME- PRODUCTIVITY

TEAM -MOHIT

Problem Description

Problem Analysis

Platform up down
problem on
VMD 05 M/C

.
Heavy leakage found
under platform due to
cylinder seal damage

Counter Measure

Benefit

Seal has been


replaced

Problem reduced
under observation

CYLINDER LEAKAGE

AFTER SEAL CHANGE

BEFORE

AFTER

Significant Kaizen-6
AREA-CT.CLL

THEME-QUALITY

TEAM -MOHIT

Problem Description

Problem Analysis

Facing slide jerking


problem on
SRB 06 M/C

.
Facing slide has been
jammed to be
cleaned by
disassembled

Counter Measure

Benefit

Facing slide has


been cleaned &
assembled

Problem reduced
under observation

BORING BAR
DISASSEMBLE

ASSEMBLED
BORING BAR

BEFORE

AFTER

Significant Kaizen-7
AREA-CT.CLL

THEME-PRODUCTION

TEAM -MOHIT

Problem Description

Problem Analysis

DMM 03 M/C
efficiency is decreasing

.
Break
down time
increasing therefore
control to be changed
with PLC circuit.

Counter Measure

Benefit

Control has been


changed

Now m/c effectiveness


improved

DRIVE CONTROLL
EARLIER

PLC CONTROL
CHANGED

BEFORE

AFTER

Significant Kaizen-8
AREA-CT.CLL

THEME-QUALITY

TEAM -MOHIT

Problem Description

Problem Analysis

Size variation observed


On DRM 02 M/C

.
Feed
found manually
changed on the
m/c .so feed valve to
be locked

Counter Measure

Benefit

Feed valve has


been locked

Problem reduced
under observation

FEED VALVE
OPEN CONDITION

FEED VALVE
LOCKED CONDITION

BEFORE

AFTER

Significant Kaizen-9
AREA-CT.CLL

THEME-QUALITY

TEAM -MOHIT

Problem Description

Problem Analysis

Boring bar jerking


problem on SRB 06
M/C

.
Spindle
coupling
loose due to ,key
found damaged . to
be changed

Counter Measure
.

Damaged key has


been changed

KEY DAMAGED
CONDITION

AFTER KEY REPLACED


CONDITION

BEFORE

Benefit

AFTER

Problem under
observation

Significant Kaizen-10
AREA-CT.CLL

THEME-QUALITY

TEAM -MOHIT

Problem Description
R 75 dowel Tool is
Frequently broken on
SFB 07 M/C

Counter Measure

Problem Analysis
.
Spindle
belt drive to
be changed

Benefit

Timer belt has been


provided in place
of V belt

Problem reduced
under observation

TIMER BELT
PROVIDED

NOT
AVAILABLE
A

BEFORE

AFTER

Significant Kaizen-11
AREA-CT.CLL

THEME-SAFTY

TEAM -MOHIT

Problem Description

Problem Analysis

HMC 23 M/C LEG


GUARD NOT
AVAILABLE

.
Leg guard not
available on HMC 23
M/C , to be
provided .

Benefit

Counter Measure
.

Leg support has


been provided

Now safely movement


is being done

GUARD NOT
AVAILABLE

GUARD PROVIDED

BEFORE

AFTER

Significant Kaizen-12
AREA-CT.CLL

THEME- OTHER

TEAM -MOHIT

Problem Description

Problem Analysis

Pallet not located


properly on HMC 23
M/C

.
HMC 24 M/C
material
Loading point area
not sufficient for
pallet shifting

Counter Measure
.

Platform excess
area to be cut. Stairs
to be shifted

PREVIOUS
CONDITION

AFTER EXCESS
AREA CUTTING

BEFORE

Benefit

AFTER

Now problem has


been rectified