kaizen presentation in 5th national kaizen competition at CICU ludhiana-Punjab- (INDIA)

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A small award winning Presentation....from M/S Perfect Industries, C65,Focal Point .Ludhiana..India--Mob no: -+91 75083-37007.Best Kaizen in New Product Design-------Thanks to the honorable JUdgES......

Indústria automotiva

An ISO-TS 2001:16949 Company

Date:-24/12/13

We are manufacturing automobile fasteners & special
items as per customer requirement.

Presentation by:- Baldeep Singh
Prepared by:- Amandeep Singh

Title:- Improved Tooling Design
PART NAME :- Hex Screw M5×25

KAIZE
N

Company name :-Perfect Industries (India)
Tooling Design by: :- Mr. Maninder Singh

Before

After

Comments:1)

Comments :-

1. Burr observed after trimming process
2. Burr found more sharp after heat treatment.
3.Customer failed the screws due to burr
4. Screws are used in aluminum compressors after
tightening the screw , burr damaged the surface it
increase the risk of leakage of compressor.

1. Quality Improved no burr observed with new
designed tooling .
2. No need to trim hex at another machine.
3.Production increased.
4.Party approved the samples.

Benefits

:

cost

pro

quality

IDEA EXECUTE BY :- Design & Dev. Dept.

time

money

TITLE:- Improved tooling design
PART NAME :- Hex screws M5×25

Description

Before

KAIZE
SAVING
N
After

Daily
Production

100 ×8=16800

23120 ×8= 24960

Machines &
tooling used for

Bolt header +
trimming
machine

Multi Station Bolt
Forging machine

Electricity
Consumed

.746×3=2.23
units per hour

Machine Process
removed.
0 cost

Manpower Used

2.23units×8
hours=17.90
units
17.90×6=rs107/
2 nos.

Man hours Used

16 hours per day

8 hours per day

Rejection

5%

0.02%

(per day)

1 nos

Material Saved- .003gram(material saved from one
piece) .003×rs70=5250/
Trimming tooling saved=1400/
Electricity SavedDaily 17.90 units saved (17 .90×rs 6.00=107/)
Manpower Saved Rs.194x 7 =Rs.1358/
Rejection decreased from 5% to .
02%=9840/
TOTAL SAVINGS FROM A LOT OF 1 LAC
PIECES=
5250+1400+107+1358+9840=17955
KAIZEN INVESTEMENT
Skilled Operator salary =2800/7 days
Tooling =Rs.18000/
PAY BACK TIME – 1 .5 days
BENEFITS
1. Customer Satisfaction & zero complaint
2. QUALITY IMPROVED
3. PRODUCTIVITY INCREASE
4. LESS MANPOWER
5. MACHINE PROCESS SAVED

HORIZONTAL DEPLOYMENT- YES

3

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kaizen presentation in 5th national kaizen competition at CICU ludhiana-Punjab- (INDIA)

1. An ISO-TS 2001:16949 Company Date:-24/12/13 We are manufacturing automobile fasteners & special items as per customer requirement. Presentation by:- Baldeep Singh Prepared by:- Amandeep Singh

2. Title:- Improved Tooling Design PART NAME :- Hex Screw M5×25 KAIZE N Company name :-Perfect Industries (India) Tooling Design by: :- Mr. Maninder Singh Before After Comments:1) Comments :- 1. Burr observed after trimming process 2. Burr found more sharp after heat treatment. 3.Customer failed the screws due to burr 4. Screws are used in aluminum compressors after tightening the screw , burr damaged the surface it increase the risk of leakage of compressor. 1. Quality Improved no burr observed with new designed tooling . 2. No need to trim hex at another machine. 3.Production increased. 4.Party approved the samples. Benefits : cost pro quality IDEA EXECUTE BY :- Design & Dev. Dept. time money

3. TITLE:- Improved tooling design PART NAME :- Hex screws M5×25 Description Before KAIZE SAVING N After Daily Production 100 ×8=16800 23120 ×8= 24960 Machines & tooling used for Bolt header + trimming machine Multi Station Bolt Forging machine Electricity Consumed .746×3=2.23 units per hour Machine Process removed. 0 cost Manpower Used 2.23units×8 hours=17.90 units 17.90×6=rs107/ 2 nos. Man hours Used 16 hours per day 8 hours per day Rejection 5% 0.02% (per day) 1 nos Material Saved- .003gram(material saved from one piece) .003×rs70=5250/ Trimming tooling saved=1400/ Electricity SavedDaily 17.90 units saved (17 .90×rs 6.00=107/) Manpower Saved Rs.194x 7 =Rs.1358/ Rejection decreased from 5% to . 02%=9840/ TOTAL SAVINGS FROM A LOT OF 1 LAC PIECES= 5250+1400+107+1358+9840=17955 KAIZEN INVESTEMENT Skilled Operator salary =2800/7 days Tooling =Rs.18000/ PAY BACK TIME – 1 .5 days BENEFITS 1. Customer Satisfaction & zero complaint 2. QUALITY IMPROVED 3. PRODUCTIVITY INCREASE 4. LESS MANPOWER 5. MACHINE PROCESS SAVED HORIZONTAL DEPLOYMENT- YES 3

kaizen presentation in 5th national kaizen competition at CICU ludhiana-Punjab- (INDIA)

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