KAIZEN
Koyama Precision Works India Pvt Ltd
Line : FML Inspection
Department: Quality
No: 001
Theme : Providing locating jig for spline
gauge inspection.
Area :
Analysis:
Action :
Start : 28.01.2016
Date
FML inspection
Name : Monica
Result :
Locating Jig fabricated to do
the spline gauge inspection
easily.
There is no proper tools available to
do the spline gauge inspection. Tape
bundles used by the operator for spline
gauge inspection.
End : 28.01.2016
Date
Easy and proper way of spline
gauge inspection.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 002
Start :
04.02.2016
Date
Theme : Re - use of inspection tag.
Area :
Analysis:
Waiting for inspection tags used onetime
and throw away daily.
Action :
Already available tags were
laminated and we can reuse
once used, by erasing the data.
Final inspection
area
End : 04.02.2016
Date
Name : Monica
Result :
1.Cost saving .
2.Effective utilization of inspection
tags
Cost :
Before
After
RS.1000 / year
Horizontal deployment &
Standardization :
We can implement the same in all
other tags used areas.
With lamination
Without lamination
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 003
Start :
16.02.2016
Date
Theme : Arresting variation in part
weight .
Area :
Analysis:
Variation seen in part weight value
because of load cell sensing the air
circulation due to fan fixed on top of the
weighing machine.
Action :
Fan arrangement made adjacent
to weight and inspection table.
Weight and Visual
Inspection
End : 16.02.2016
Date
Name : Gopal
Result :
1. Part weight variation arrested.
Cost :
Before
After
Nil.
Horizontal deployment &
Standardization :
Nil.
Fan attached with
inspection table
Category
Fan removed from
inspection table
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 004
Start :
24.02.2016
Date
Theme : Runout & Face out checking
fixture.
Area :
Analysis:
Orientation block getting tilted when
inspecting the part for face out and
runout, which causes inspection error .
Action :
Separate fixture to be made
with ;
1. Orientation and resting
block fixed.
2. Easy inspection of both
face out and runout in same
fixture.
Saw &
Chamfering
inspection area
Before
After
End : 24.02.2016
Date
Name : B.Monica
Result :
1. Reduces the inspection error.
2. Improves the quality.
3. Reduces the time of
inspection.
Cost :
Nil
Horizontal deployment &
Standardization :
Nil
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 005
Start :
27.02.2016
Date
Theme : Preventing part falling down.
Area :
Analysis:
There is no proper arrangement to
locate the part in load plate . Due to
this inadequate arrangement part
getting falling down while inspecting
Action :
Locating block to be made .
Weight and Visual
Inspection
End : 27.02.2016
Date
Name : Gopal
Result :
1. Easy for inspector to check.
2. Avoids part damage.
3. Avoids weighing machine
damage.
Cost :
Before
After
Nil.
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 006
Start :
18.02.2016
Date
Theme : Comparator stand for
parallelism inspection .
Area :
Analysis:
Difficult for the operator to check
parallelism with Vernier height gauge.
Action :
Comparator stand
arrangement to be made.
Sawing
End : 08.03.2016
Date
Name : C. Kumaravel
Result :
1. Easy for inspector to check.
2. Reduces the time of
inspection.
Cost :
Before
After
Nil.
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Line : Final Inspection
Department: Quality
No: 007
Start :
22.03.2016
Date
Theme : Reducing the part weight
variation & Inspection time .
Area :
Analysis:
Variation seen in part weight value
because of burrs on load plate .
Inspector always cleaning with hands
Action :
For cleaning the burrs brush to
be fixed in the station.
Weight & Visual
Inspection
End : 22.03.2016
Date
Name : M.Raja
Result :
1. Reduces inspection error.
2. Reduces the time of
inspection.
3. Improves 5S.
Cost :
Before
After
Nil.
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
Koyama Precision Works India Pvt Ltd
KAIZEN
Department: Quality
No: 008
Start : 25.04.2016
Date
Theme : To prevent part falling down on floor
Area : Weight
and Visual
Inspection
Name : Kishore
Analysis:
Action :
Result :
Because of no guard available on bottom
chute parts falling down to floor at the
time of inspection.
Guard to be provide on bottom chute to
prevent part falling down on floor.
1. Improves the parts quality.
End : 25.04.2016
Date
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 009
Start :
18.05.2016
Date
Theme :To Mark the NG status of
parts
Area
:Inspection
table
Name :Nathiya
Analysis:
NG parts are identified with red
marker by inspector . Since the
markers are placed on their
pockets or inside the QA
room,Everytime searching and
picking takes so much time.
Action :
Marker holder to be made
for placing the marker on
inspection table.
Result :
End :18.05.2016
Date
1. Easy to identify the NG Parts.
2. Easy accessible to inspectors.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Implemented for all
inspection tables.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 010
Start :
18.05.2016
Date
Theme : Proper segregation of RM NG
parts
Area :Weight
and Visual
Inspection
Name :Nathiya
Analysis:
In weight & visual inspection
area all raw material rejection
kept in single box . No
differentiation of NG parts found
with respect to dimension and
appearance NG
Action :
Partition made on raw
material NG bins for easy
identification of
dimensional and
appearance NG parts.
Result :
End :18.05.2016
Date
1. Improves the quality.
2. Easy for identification &
seggregation
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 011
Start :
19.05.2016
Date
Theme : To improve awareness & follow
the safety PPEs at inspection area
Area :
Inspection area
Name : M.Raja
Analysis:
No awareness among the
inspectors to follow the safety
PPEs at inspection area.
Action :
PPEs displays to be made
at all inspection area to
create awareness among
the inspectors.
Result :
End :19.05.2016
Date
1. Improves the safety
awareness.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
All inspection area.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 012
Start :
18.05.2016
Date
Theme :To improve & follow the safety while
doing fibre flow test
Area :
Container
Name : M.Raja
Analysis:
No awareness among the inspectors to
follow the safety PPEs at inspection area.
Action :
PPEs displays to be made at all
inspection area to create
awareness among the inspectors.
Result :
End :18.05.2016
Date
1. Improves the safety
awareness
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
Koyama Precision Works India Pvt Ltd
KAIZEN
Department: Quality
No: 013
Start :20.05.2016
Date
Theme : To reduce the runout inspection part
setting time.
Area : Runout
Inspection Table
Name : B.Monica
Analysis:
Inspectors taking 25 seconds to set the
part runout inspection.
Action :
Mandrill fixing identification mark
placed on bench centre for easy
setting the parts for runout
inspection ,thereby reduces setting
time to 15 seconds.
Result :
End :20.05.2016
Date
1. New inspectors can easily set
the part.
2. Improves inspection
productivity.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
Koyama Precision Works India Pvt Ltd
KAIZEN
Department: Quality
No: 014
Start :24.05.2016
Date
Theme : Runout inspection location setting.
Area : Runout
Inspection
Name : S.Nathiya
Analysis:
To fix the runout inspection location
inspectors fixing the location by
measuring with scale.
Action :
Standard master to be made with
actual location.
Result :
End :24.05.2016
Date
1. New inspectors can easily set
the part.
2. Improves quality.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
Koyama Precision Works India Pvt Ltd
KAIZEN
Department: Quality
No: 015
Start :24.05.2016
Date
Theme : Runout & faceout master / Runout fixture
validation.
Area : Sawing
& Chamfering
Name : M.Raja & V.Gopal
Analysis:
For operator cross validation no master
sample available for runout and faceout
inspection after sawing & chamfering .
Action :
1. Master made for all running
parts.
2. Master sample value displayed at
cell for operator verification.
3. Master sample value checked by
operator for each setting and same
noted in QC check sheet.
Result :
Before
After
End :27.05.2016
Date
1. Improves the quality.
Cost :
Nil
Horizontal deployment &
Standardization :
Master to be made for all fore
coming parts.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 016
Start :
24.05.2016
Date
Theme : Limit Sample/Master
Sample/Defect sample Display rack
needed.
Area : QA lab
Name : C. Kumar
Analysis:
Limit , Defect and Master
samples stored in bins not easily
identified and retrieved .
Action :
Easily visible display rack
to be made for easy
identification and retrieval
of all samples.
Result :
End :27.05.2016
Date
1. For training and
understanding the process.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Implemented for all parts.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 017
Start :
30.05.2016
Date
Theme : 5s zone in charge.
Area : Zone 3
Name : B.Monica
Analysis:
QA is taking care of 3rd
Zone ,but zones individual
responsibility not fixed
Action :
Individual area
responsibility fixed for
improvement of 5S
Result :
End :30.05.2016
Date
5S will be improved
drastically.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Implemented for all areas of
Zone 3
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 018
Start :
15.06.2016
Date
Theme : Ppes arrangement in Fibre
flow test room.
Area :
Container
Name : A. Kishore Kumar
Analysis:
PPEs not followed by
unauthorized persons and
external persons( customer &
other employees of koyama )
when they are entering into fibre
flow test room. Since the PPEs
are not easily accessible to them.
Action :
Essential PPEs needed for
fibre flow test room will be
displayed at the entrance .
Result :
End :15.06.2016
Date
1. Reduces health and safety
risks at work place.
2. Easy accessible to external
persons.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
Nil
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
KAIZEN
Koyama Precision Works India Pvt Ltd
Department: Quality
No: 019
Start :
23.06.2016
Date
Theme : Inspection table rack
arrangement.
Area :
Inspection table
Name : V.Gopal
Analysis:
Inspection table space not
utilized properly - Consumables
like (stamping ink,glooves etc. )
not arranged in proper manner.
Action :
Racks to be made for
keeping the required
consumables neatly.
Result :
End :23.06.2016
Date
1. Proper utilization of work
place.
Cost :
Before
After
Nil
Horizontal deployment &
Standardization :
If necessary for all inspection
tables.
Category
M
Format No: KPI/G/F/001,Rev:0, Rev.date :
01/12/2014
