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4.1.1 Background
4.1.2 Aim
4.1.3 Target
4.2 Approach
4.4 Result
1
4.2.3 Definition of 18 Major losses (Contd.)
8b Production adjustment Losses that arise from equipment stoppages at the production
loss planning level in order to adjust production requirements
9b Manpower Waiting losses that are caused by management, such as waiting for
Shortage operator
9c WIP Shortage Waiting losses that are caused by management, such as waiting for
WIP
10 Operating Motion Man-hour losses arising due to m/c run by non-regular operator
loss
11 Line organization Idle time losses when waiting for material to come from previous m/c
loss
2
4.2.5d Result of Startup Loss
Total Factory
Section No. of
Kaizens 4500
4000
4065
3,872 BM
Plate Parting 1
3500
3,431
Better
Indl Filling 1 Actual
1000
0
BM 04-05 05-06 06-07 YTD 07-08 Target
Year
350
400
300
250 300
200
200 176
139
150
100 100
50
5 3 6 3
0 0
BM 04-05 05-06 06-07 YTD 07-08 Target BM 04-05 05-06 06-07 YTD 07-08 Target
Year Year
3 Back
4.2.6.2 Stratification of Operating motion loss - Total Factory – during Bench Mark period
During the benchmark period Operating Motion Loss was one of the Loss that was contributing towards lower
amount of production. All Operating Motion Losses were studied machine wise and corrective actions taken. This
graph shows the stratification of this loss sectionwise and machine wise for the total factory
897
900
Section wise
800
700
Loss Time (in Minutes)
600
477
500
426
400
300 268
200
100 53
26 13 586
0
13
Machine wise
600
Assembly(Auto)
Assembly(indl)
Parting(Auto)
Casting(Auto)
Filling(indl)
Pasting(indl)
Gride Casting(indl)
Spine Casting(indl)
500
400
311
300
200
100
0
Aiken2
Aiken1
4
4.2.4.5.1 Kaizen Example Of Operating motion Loss
Physical Phenomenon : More time taken by the operator to switch ON / OFF blower, light
etc. Cause : Switches located away from the
Root
operator
BEFORE AFTER
Switches located away from the operator Switches brought near to the operator
Switches
Operator Operator
Switches
Result : Operating motion Loss reduced from 30 Minutes to Zero Minutes in a shift
Result : Operating motion Loss reduced from 20 Minutes to Zero Minutes per m/c per shift
Total Factory
Section No. of
Kaizens 4500
4000
4065
3,872 BM
Plate Parting 2
3,431
3500
Indl Filling 1 Better Actual
1000
0
BM 04-05 05-06 06-07 YTD 07-08 Target
Year
350
400
300
250 300
200
200 176
139
150
100 100
50
5 3 6 3
0 0
BM 04-05 05-06 06-07 YTD 07-08 Target BM 04-05 05-06 06-07 YTD 07-08 Target
Year Year
7 Back
4.2.4.5.1 Kaizen Example Of Cycle Time Reduction
BEFORE AFTER
High air pressure filling time Solenoid valves provided
Manufacturing Cost & Loss in individual areas has been identified and corrective actions have been
Initiated. Matrix of the Cost Loss is shown below.
07-08
Q4
Dross
Metal 0.11 0.10 0.11 0.08 0.07 0.06
8.91 8.73 12.05 14.83 17.17 15.16
20.41
Oct -
0.15
Nov
Sump Paste
07
Raw Material
07-08
23.80
ORM
0.15
Q2
12.88 12.23 16.12 18.91 21.62 18.03 0.18 0.18 0.22 0.16 0.15 0.09
07-08
21.08
0.16
Q1
3.79 3.33 3.85 3.93 4.31 2.78 0.03 0.02 0.02 0.02 0.02 0.02
2006-
18.34
0.17
07
Energy Power
2005-
15.23
0.23
Spares
Q4
Job Charges
0.14 0.16 0.17 0.17 0.19 0.17
Loss
9
4.2.7.2 KAIZEN EXAMPLE OF YIELD LOSS REDUCTION
BEFORE AFTER
Excess lead in group bar where Modified group bar with reduced
there is no plate lead
BEFORE AFTER
Brushes wear out Tool developed to grind the worn out
brush
Benefit :
11