Kobetsu Kaizen

Activities
Presented By : KK Pillar Chairman
Date :

Presentation contents
Sr.
1 Background status

Contents

AIM - KK Pillar

Target - KK Pillar

Approach

Master Plan - Master Plan

Trend Graphs

Loss Reducton Methodology

Example-Loss reduction activities

Kaizen Status

10 Result - KK Pillar Activity

11 Cost Loss Reduction activity

1. Background Status ( Dec.05 )

2. AIM KK Pillar

KK PILLAR TARGETS
Parameter

To increase Production /Hr.

Reduction in Setup and
Adjustment time (Minutes)
Reduction in Tool Change
time (Minutes)
Reduction in Start up time
(Minutes)
Reduction in Measurement &
Adjustment time (Minutes.)
Improve Output per man

Target Criteria
30 % up
Reduction by 50 % in
Minutes./Occ.
Reduction by 50 % in
Minutes./Occ.
Reduction by 50 % in
Minutes./Occ.
Reduction by 50 %
30%UP

variable conversion
cost - Model wise
1) Labour

2) Tool
3) Consumable

30% Reduction in Cost / model

4) Power
5) Fuel & water
6) Material Yield

KAIZENS /MAN/YEAR

2 KAIZENS / MAN / YR

BM-DEC 05

Target
( 31.10.07)

ACTUAL
(31.07.07)

Master Plan

KK Activity
Approach
Cost Loss
OEE Loss
Cost Loss Tree
Define loss

Loss Tree

Identify Cost Loss

Applicability loss under

Each processes
Counter Measures / Kaizens
Methodology For Loss
Reduction

Kaizens

Horizontal Deployment &

Sustenance

Horizontal Deployment &

Sustenance

Total Availability Loss T rend 39568

A v g M in s /M o n th

40000
30000

19530

20000

12349
10000

6269

5024

3822

Mar-07

Apr-07

2154

0
Bench Mark- JAN 06 TO
DEC 05
DEC 06

Jan-07

Feb-07

May-08

Month

Loss Details
S.N.

Bench JAN 06
MarkTO
Jan-07 Feb-07
DEC
DEC
05
06

Loss Desc

Tool change

KK

Setup

KK

Startup

KK

Measure / Adj

KK

Logistisc loss

KK

Jig Fix die Loss

KK

Breakdown

PM

No matl / Mgt Loss

OT

Mar-07

Apr-07

May-08

Jun-07

Loss Reduction Methodology (Kaizen Idea)

Tool Change

Set up and Adjustment

Start up

Measurement
& Adjustment

-Quick change

-Elimination of setup

-Series to parallel

-Elimination

-Auto adjustment

-Internal to external

-Speed up

-Frequency reduction

-Elimination

-Auto Adjustment

-Auto start

-Improvement in 1S/2S

-Early start

-Method change

-Improvement in 1S / 2S

-Series to parallel

-Reduction in no. of tools by

combination tools

-Speedup

-Series to parallel

-Improvement in 1S /
2S

-Presetting

-Reducing occurrences by
increasing Tool Life

-Sister tool concept

-Presetting

-Measurement
elimination

Tool Change Loss Time

Reduction

Tool Change Loss Trend 9000

7802

2000

7703

1800

7000

1600

5897

6000

1400
1200

4599

mins

5000

1000

4000
3000

2087

2000
316

1000

316

280

270

Bench
MarkDEC 05

Jan-06

Feb-06

Mar-06

2307

600
1534
950

248

11

800

2416

188

186

166

134

Oct-06
Month

Cell detail
S.N.

Cell No & Name

1 Cell No1

Total
4546- Gear Shaping min/occ
Target(min/occ)
Total
4- Cell no2
5039- Press min/occ
Target(min/occ)
Total
4- Cell no3
3927- Keyway min/occ
Target(min/occ)
Total
4- Cell no 4
5260- Keyway min/occ
Target(min/occ)
Total
Cell no 5
5411- Murata min/occ
Target(min/occ)
Cell no 6
Total
5359 - Gundrill min/occ
Target(min/occ)
Total
Total
min/occ

Target(min/occ)

Bench
MarkDEC 05
300
26
15
120
60
60
1666
36
36
1036
30
30
4680
40
40

7802
192
100

Jan-06
280
20
15

Feb-06

Mar-06

Oct-06

400

1054

768
131

95.5

200
0

M ins/O cc

8000

KAIZEN THEME : To reduce Tool Change time

per occurrence on Gear Shaping m/c.

KAIZEN IDEAS :
1)
2)
3)
4)

Combination of Tools
Speed up of activities
Inside acivities changed to outside
Elimination of activities

Work / Time Chart ( Before ) Gear Shaping M/C

S.No

Activity

Take slide back, take spanner &

loosen cutter.

Keep spanner & loosen nut fully with

hand & remove cutter.

Check cutter thickness difference betn

removed & new cutter to be mounted.

Clean adaptor,Load new cutter &

tighten nut fully with hand & spanner.

Adjust Cutter stroke position

Set size & start auto cycle.

Confirm first job produced for required

quality parameters.

Total tool change time/occ :

Activity Period

Time in minutes

4.0
4.5
2.0
5.5
6
3.0

1.0

26 mins

Stroke setting required as per

varying cutter thickness.

BEFORE :

Link bolts (4 nos) for stroke position setting

THIN shaper cutter

THICK shaper cutter

Gear to be cut

Cutter height difference

Cutter Adaptor
Cutter locating Diameter. Only one
cutter can be loaded

12 mm

AF TER :
Idea:

To preset cutter thickness .

Providing required thickness

spacer above the cutter back-face.
COUNTERMEASURE :

SPACER provided to make e qua l cutte r thickne ss

THICK shaper cutter

THIN shaper cutter

Cutte r he ight same . No nee d

to set stroke position.

Cutter Adaptor
Modified Cutter locating
step to accommodate
spacer.

20 mm

Work / Time Chart ( After ) Gear Shaping M/C

S.No

Activity

Take slide back, take spanner &

loosen cutter.

Keep spanner & loosen nut fully with

hand & remove cutter.

Check cutter thickness difference

betn removed & new cutter to be
mounted.

Clean adaptor,Load new cutter with

Spacer tighten nut fully with hand &
spanner.

Set size & start auto cycle.

Confirm first job produced for

required quality parameters.

Total tool change time/occ :

Activity Period

Time in minutes

4.0
4.5
2.0
5.5

3.0
1.0

20 mins

RESULTS:

BENIFITS:
8%

Dec-05
Aug -07

Cell No 1

Cell No 2

Cell No3

Cell No 4

Result- Tool Change Time - Plant

RESULTS
Summary of the Results Plant Tool Change time reduction
2000

BM-Feb01
BM Dec 05
Actual Jun 07
Mar.05

1800

Total time
BM-Feb01 1800
1500 Mar.05
620

68 %
6.3 %

1000

237

620
223

500
0
Total time

Production / hour

Tool Change change Time

250
200
150
100
50
0

Nos.

Pressing
19

Machining

Fabrication

Painting

113

11

191

13

Total 42 Kaizens

11
Cell No-1

Cell No-2

Cell No-2

9
Cell No-4

Set up Change Time

Loss Reduction

Set up Change Loss Trend

120

200
10

KAIZEN THEME : To reduce Set up Change

time per occurrence on Press Machine.

Work / time sheet of Set up & adjustment activity.- MC NO 4692

Time In Minutes
ACTIVITY
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

REMOVE
Last produce componant
Take press on micro inch
Take Ram at BDC on inch
Unclamp blank holder & bed.Ensure it
Removing blank feeding conveyor
Take ram at TDC.
Take blank holder up by 130 mm
Take ram at BDC.
Unclamp punch manually
Take ram at TDC.
Lift moving bolster
Take moving bolster out
FIX
Take second moving bolster in
Position outer/ inner slide for new die
Take moving bolster down
Take ram at BDC.
Check gap between punch & inner slide
Take ram at TDC.
Position Inner slide shut height
Position centering of Die
Take ram to BDC
Clamp punch manually.
Take ram to TDC.
Position shut height of Outer slide.
Take ram at BDC.
Center adoptor plate.
Clamp blank holder / Outer plate
Clamp Inner slide & ensure
Clamp Outer slide & ensure
Take ram at TDC.

9 10 11 12 13 14 15 16 17 18 19 20

21

22

23

24

25

26

27

28

29

30 31

32

33

Actual Die setting Time

Kaizen

31 Change press operation (Micro to Run)

32 Place material stand
33 Place material stack on stand

ADJUST
34 Run one stroke idle.

Produce New Component by Trial &

Adjust with setting Oil Patter &
35 appling Oil to Part or Die
36 Inspect it visually.

Actual Time of Activities

Inside to Outside
Series to Parallel
Speed Up

45.15
Minutes
45.15
Minutes - - 36
36 Activities
Activ ities
40.75 Minutes (4.4 Minutes Reduction)
39.5 Minutes (1.25 Minutes Reduction)
09.05 M inutes (30.45 Minutes Reduction) - 15 Activities

34

43

44

45

Kaizen / Idea summary sheet - M/C BA 4294

Sr. Activity
No.
1 REMOVE
2
3
4
5
6
7
8
9
10
11
12

Element

T ime Before Kaizen T ime After

( Mins )
No.
Mins.
Last produce component
0
---0
Take press on micro inch
0.6
---0.6
Take Ram at BDC on inch
0.6
---0.6
Unclamp blank holder & bed.ensure it
1
---1
Removing blank feeding conveyor
1
---1
Take ram at TDC.
0.4
---0.4
Take blank holder up by 130 mm
1.5
49
0
Take ram at BDC.
0.25
49
0
Unclamp punch
2.6
49
0
Take ram at TDC.
0.4
49
0
Lift moving bolster
0.2
---0.2
Take moving bolster out
1.25
---1.25
T otal remove activity time
9.8
5.05
13
FiX
Take second moving bolster in
1.25
13399
0
14
Position outer/ inner slide for new die
1.8
49
0
15
Take moving bolster down
0.2
---0.2
16
Take ram at BDC.
0.4
---0.4
17
Check gap between punch & inner slide
1.6
13603
0
18
Take ram at TDC.
0.4
13603
0
19
Position Inner slide shut height
2.2
13603
0
20
Position centering of die
1.3
45
0
21
Take ram to BDC
0.4
49
0
22
Clamp punch.
2.6
49
0
23
Take ram to TDC.
0.4
49
0
24
Position shut height of outer slide.
1.5
13603
0
25
Take ram at BDC.
0.4
13603
0
26
Center adoptor plate.
1.5
46
0
27
Clamp blank holder / outer plate
1.6
---0
28
Clamp Inner slide & ensure
1.4
---1.4
29
Clamp outer slide & ensure
1.3
13605
0
30
Take ram at TDC.
0.5
---0.5
31
Change press operation (Micro to Run)
0.4
---0.4
32
Place material stand
1.5
13604
0
33
Place material stack on stand
1
13604
0
Total fix activity time
23.65
2.9
34 ADJUST Run one stroke idle.
0.4
---0.4
35
Produce new component by trial & error,
11
13604
0.4
with setting oil pattern and appling oil to
part or die
36
Inspect it visually.
0.3
---0.3
Total adjust activity time
11.7
1.1
Total activity time
45.15
9.05
Inside to outside activities ,
Series to parallel activities,
Speed up activities

ACTIVITY
Kaizens for set up & adjustment time reduction

Process : Pressing
Kaizen - Inside to Outside
BEFORE

M/C No.- BA 4294 ( 650T ISJEC)

AFTER

No Die Centering Arrangement Die Centering with Pin.

Die Centering done by Trial
and Error.
Time Required - 1.8 Mins
Time Required - One touch (0 mins)

ACTIVITY

Kaizen - Speed Up
BEFORE

Manual Clamping 8 bolts of punch

and blank holder with punch
and blank holder slide.
Time Required- 13.85 mins

AFTER

Auto clamping 8 bolts of punch

and blank holder with punch
and blank holder slide.
Time Required - One touch (0 mins.)

ACTIVITY

Kaizen : Speed up
BEFORE

AFTER

Oil Pattern and quantity setting

Auto oil pattern and quantity setting

manually by trial and error.

with PLC logic.

Time required - 11 mins

Time required - 0.4 mins

RESULTS
BEFORE

Minutes
50

45.15

80 %

40

Remove

30

BEFORE
AFTER
48 %

20
10

AFTER

9.8

9.8
5.05

Fix
23.65
23.65
2.9

5.05

Adjust Time/Occ
11.7

45.15

1.1
88 %

9.05

2.9

07 Kaizen
Ideas
Implemented

11.7

91 %

9.05

1.1

Better

0
Remove

Fix

Adjust

Time/Occ

Dec-05
08

Cell No 1

Cell No 2

Cell No3

Cell No 4

RESULTS
Summary of the Results Plant Set time reduction
2000

BM-Feb01
BM Dec 05
Actual Jun 07
Mar.05

1800

Total time
BM-Feb01 1800
1500 Mar.05
620

68 %
6.3 %

1000

237

620
223

500
0
Total time

Production / hour

Set up change Time

250
200
150
100
50
0

Nos.

Pressing
19

Machining

Fabrication

Painting

113

11

191

13

Total 42 Kaizens

11
Cell No-1

Cell No-2

Cell No-2

9
Cell No-4

Results

Results

PROD/ HR. TREND ( Plant Level )

Results

Output / Man Trend (Plant level )

( Plant Level Summary)

Target : Cost Reduction

COST LOSS REDUCTION METHODOLOGY

Cost Reduction

Cost Data Collection Element wise

Define Element wise Cost Loss

Identify Cost Loss
Define Methodology For Cost Loss
Elimination
Counter Measures / Kaizens
Horizontal Deployment

Cost Loss Reduction Methodology

Labour

Tool Cost

Reduce line organization

loss

Modification of
Tool

Deletion / Combination of
operations

Method change

Reduce movement
Automation
Reduce material handling
Cycle time improvement
Motion loss reduction

Elimination
Standardization

Consumables

Elimination

Energy

Modify Equipment

Method Change
Alternate
Material

Auto Timer
Optimum utilization

Labour cost ReductionKaizen Theme To Reduce Line Organization loss

Tool Cost ReductionKaizen theme : To reduce tool cost by increasing life.

Before
CBN Insert CCGW 09T304 BN250 is
used for boring dia.20 Gear Comp
Prim Drivn DK101129, 73117320.

After
High wear resistance PCD insert of
Grade DA2200 from Sumitomo tried and
regularised.

Before condition

After condition

Tool life 3000 components

Tool life 5000 components.

Result Tool cost reduced by 0.43 Rs./ component.

Consumable Cost ReductionKaizen theme : To reduce consumption of cutting oil

Before

Before condition
Oil carry over with components
Oil waste 0.22 Rs/Veh

After

After condition
Provision of Spinner to avoid oil carry over
with component.
Oil waste 0.05 Rs/Veh

Energy Cost ReductionKaizen theme : To reduce electrical power consumption

Before

After

Coolant chilling unit is

continuously ON.

Logic modified, chilling

unit supply will be turned OFF
after pressing emergency push
button

Before condition
No provision to turn OFF chilling unit
Power consumption is 174 Kwh/month

After condition
Provision to turn OFF chilling unit
Power consumption is 91 Kwh/month

Idea : Provision to turn OFF

Result - Power cost saved, 352 Rs./ month

Total kaizen Ideas Plant for Cost loss Reduction

3
2

Labour

Tools

Consumables

Energy

Variable Conversion Cost Reduction Results

BM

ACTUAL
BM

Rs/ Veh.

TARGET

BM

ACTUAL
TARGET

ACTUAL
TARGET

THANK YOU