TPM Circle No .
: Activity KK QM PM JH SHE OT DM E&T
TPM Circle Name.: Loss no./ Step √
KAIZEN IDEA SHEET
Dept:-PLANT MAINT Result Area P Q Def. A / B / C C D S M Kaizen No:SAEPL/2502/JUNE/KZN/201
Line: SPM Cell Name: SPM-19 Machine / Stage: Notching Operation: Main stand pipe notching.
Kaizen Theme : To eliminate rejection due to improper Idea: To provide locating cylinder for proper loading of component.
notching.
Problem / Present Status : Notching not proper. Countermeasure : Provided locating cylinder behind job loading
Bench Mark
area so that components is placed properly.
Target
KAIZEN Start 6/6/2023
KAIZEN Finish 6/11/2023
Team Members :- Deepak Roundal, Basant Samadhiya
Benefits:
P:
Q : Improvement in quality as component is as per requirement.
C : Elimination of cost due to rejection.
D:
S:
M:
Before :- Job locating not proper and rejection due to After :- Job locating cylinder installed so that job is pushed at
improper notching. its location and notching is as per requirement.
Why-Why Analysis:- Result:- KAIZEN SUSTAINANCE
1) Elimination of rejection due to improper notching.
2) Improvement in quality as component is as per requirement.
Why 1 : Carbide inserts getting damaged. 3) Cost saving due to rejection elimination. What to do:- To check working of cylinder.
Why 2 : Due to sudden power outage during operation. How to do:- Visually during operation.
Why 3 : Continuous power supply not available so that machine keeps Payback period: Immediate.
running for some time.
Why 4 : Cost incurred for marking Kaizen
Why 5 : Material Cost Rs. Labour Cost Rs Total Cost Rs
Root Cause: Uninterrupted power supply not available. 3000 3000
Scope & Plan For Horizontal Deployment
Registration No. & Date :- 5/6/2023
Sr. Cell Target Responsibility Status
Registered By:- Basant Samadhiya
Manager's Sign:- Deepak S. Roundal
TPM Circle No .: Activity KK QM PM JH SHE OT DM E&T
TPM Circle Name.: Loss no./ Step √
KAIZEN IDEA SHEET
Dept:-PLANT MAINT Result Area P Q Def. A / B / C C D S M Kaizen No:SAEPL/2502/JUNE/KZN/203
Line: SPM Cell Name: SPM-13 Machine / Stage: Head pipe boring Operation: Rough boring
Kaizen Theme : To prevent moving of NG head pipes to frame Idea: To install sensor in gauge along with rejection box and annunciation unit so that NG head pipes do not move in frame line.
line.
Problem / Present Status : NG head pipes getting mixed with Countermeasure : Installed sensor in gauge along with rejection
OK head pipes. Bench Mark
box and annunciation unit so that short length head pipes are
sensed in gauge and machine stops. Unless NG head pipe is not
put in rejection box, machine will not work for another cycle. Target
KAIZEN Start 6/13/2023
KAIZEN Finish 6/18/2023
Team Members :- Satyendra Yadav, Deepak Roundal
Benefits:
P:
Q : Improvement in quality as NG head pipes have to be kept in
box and machine will not operate unless it is done.
C : Elimination of cost if NG head pipes move to frame line and
get welded.
D:
S:
M:
Before :- NG head pipes lying on table and sometimes After :- NG head pipes have to be put in box and annunciation
getting mixed with OK pipes. occurs if any NG pipe is sensed in gauge.
Why-Why Analysis:- Result:- KAIZEN SUSTAINANCE
1) NG head pipes are kept in rejection box which is locked.
Why 1 : NG pipes getting mixed with OK head pipes. What to do:- To check working of sensor and annunciation unit.
Why 2 : No separate box for NG pipes which do not qualify in gauge. How to do:- Visually.
Why 3 : Operator negligence. Payback period: Immediate.
Why 4 : Poka yoke not available. Cost incurred for marking Kaizen
Why 5 : Material Cost Rs. Labour Cost Rs Total Cost Rs
Root Cause: Poka yoke not available. 5000 5000
Scope & Plan For Horizontal Deployment
Registration No. & Date :- 12/6/2023
To be done for another head pipe boring machine.
Sr. Cell Target Responsibility Status
Registered By:- Satyendra Yadav
1 7/25/2023 Deepak Roundal In progress
Manager's Sign:- Deepak S. Roundal
