Break Through Kaizen (Drilling & Tapping)

By: Mr Suchit SinghIndustrial Engineer (IIT

Roorkee)

BEFORE AFTER

Modification / Improvement : Two different Tools got replaced by Single Drill cum Tap Tool

Modification Benefits : M/C time reduced by 11.67 min./Shift & Tool Cost reduced by 20.15 %

Drill Dia. 5 &Tap M6*1.0 Used Separately

Drill & Tap together in Process

KAIZEN: DRILL CUM TAP

GAP OBSERVED

NVA VA(6 Sec) (3.5 Sec)

Tool Change, Rapid Motion & Go to Home Position Drilling & Tapping

BASIC TOOL STRUCTURE

Cutting Edge

Shank

Body

To Remove the Material

To Transmit Force, Torque & Motion

To hold the Tool

Feature FunctionTool

TOOL COMBINATION STRUCTURE

DRILLTAP

Process Parameters

Drill cum Tap M6*1.0

Drilling

S = 1500 RPMF = 350 mm/min.

Tapping

S = 1000 RPMF = 1.0 mm/rev.

Cutting Length7.6 mm/Job

RESULTS : GAIN TO COMPANY

BEFORE AFTER172173174175176177178179180181182

181

175

BEFORE AFTER138

139

140

141

142

143

144

145

140

144

M/C Cycle Time M/C Capacity

Cycl

e Ti

me

(in S

ec)

No.

of J

obs/

Shift

GOLDEN POINTS

One time one Process(OTOP Approach)

Wide Range for Horizontal Deployment

Thank you!