West Bokaro Division 1

West Bokaro Division 2

Introduction

SGA Circle : Tulika

West Bokaro Division 3

Kaizens Implemented : FY’15

Kaizen ID Kaizen Title Tangible Saving

(Rs lakhs)

QUIKS/KZN/135808 LENS SETTING INNOVATIVELY MODIFIED IN TOTAL STATION FOR OPTIMAL VISION /CLARITY DURING SURVEYING

0.5

QUIKS/KZN/139016 TOTAL STATION SCREEN PROVIDED WITH ADDITIONAL MAGNIFICATION LAYER FOR BETTER READING

0.1

QUIKS/KZN/143500 DOUBLE SIDED PRINTING ON OLD PLANS TO SAVE PAPER COST 0.1

QUIKS/KZN/147831 TOTAL STATION PROVIDED WITH A INNOVATIVE TRIPOD STAND FOR BETTER STABILITY IN ALL KIND OF ROUGH SURFACES

1

QUIKS/KZN/152046 LINE OF SIGHT OF OLD TOTAL STATION INNOVATIVELY FINE TUNED FOR FOSTERING ACCURACY 0.1

QUIKS/KZN/156362 GLOBAL COORDINATES UPDATED AND RECONCILED WITH LOCAL COORDINATES THROUGH INNOVATIVE METHOD

1

QUIKS/KZN/161268 NEW DGPS SURVEY HANDS-ON INFORMATIVE MODULE DEVELOPED TO CREATE KNOWLEDGE BASE FOR FUTURE

1

QUIKS/KZN/165478 DATABASE MIGRATED TO NEW SURVEY SOFTWARE AUTOPLOTTER FOR BETTER SURVEYING ACCURACY

0

QUIKS/KZN/171180 TOTAL STATION MOUNTING BOLT MODIFIED FOR HIGH PRECISION AND FOOL PROOF JOINTING 0

QUIKS/KZN/174608 HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH DURABLE PLASTIC MADE CUSTOMISED TYPE FOR LONGEVITY AND SAFETY

1

QUIKS/KZN/179905 INNOVATIVE VOLUME CALCULATOR MACRO PREPARED IN SURPAC TO AUTO CALUCLATE TEDIOUS TASKS

0

QUIKS/KZN/184279 EXCEL MACRO DEVELOPED TO COMPARE AND POINT OUT ERRORS IN RL READINS TAKEN BY HANDHELD GPS AND TOTAL STATION

0.05

West Bokaro Division 4

Kaizen Title Mithilesh Kr Singh Lakshman Singh Ramnandan Singh Mahendra Yadav Wtd. Average

1 LENS SETTING INNOVATIVELY MODIFIED IN TOTAL STATION FOR OPTIMAL VISION /CLARITY DURING SURVEYING

4 5 3 4 4

2 TOTAL STATION SCREEN PROVIDED WITH ADDITIONAL MAGNIFICATION LAYER FOR BETTER READING

5 5 2 5 4.25

3 DOUBLE SIDED PRINTING ON OLD PLANS TO SAVE PAPER COST 8 8 7 8 7.75

4 TOTAL STATION PROVIDED WITH A INNOVATIVE TRIPOD STAND FOR BETTER STABILITY IN ALL KIND OF ROUGH SURFACES

7 6 7 7 6.75

5 LINE OF SIGHT OF OLD TOTAL STATION INNOVATIVELY FINE TUNED FOR FOSTERING ACCURACY

6 6 6 5 5.75

6 GLOBAL COORDINATES UPDATED AND RECONCILED WITH LOCAL COORDINATES THROUGH INNOVATIVE METHOD

6 4 3 5 4.5

7 NEW DGPS SURVEY HANDS-ON INFORMATIVE MODULE DEVELOPED TO CREATE KNOWLEDGE BASE FOR FUTURE

7 5 7 5 6

8 DATABASE MIGRATED TO NEW SURVEY SOFTWARE AUTOPLOTTER FOR BETTER SURVEYING ACCURACY

6 6 6 2 5

9 TOTAL STATION MOUNTING BOLT MODIFIED FOR HIGH PRECISION AND FOOL PROOF JOINTING

5 5 4 5 4.75

10 HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH DURABLE PLASTIC MADE CUSTOMISED TYPE FOR LONGEVITY AND SAFETY

9 8 9 9 8.75

11 INNOVATIVE VOLUME CALCULATOR MACRO PREPARED IN SURPAC TO AUTO CALUCLATE TEDIOUS TASKS

6 5 6 6 5.75

12 EXCEL MACRO DEVELOPED TO COMPARE AND POINT OUT ERRORS IN RL READINS TAKEN BY HANDHELD GPS AND TOTAL STATION

4 4 5 6 4.75

Weighted Average Matrix for arriving at the best Kaizens

West Bokaro Division 5

Star Kaizen-1

HANDLE OF TOTAL STATION CARRYING CASE REPLACED WITH

DURABLE METAL ALLOY & PLASTIC MADE CUSTOMISED TYPE FOR

LONGEVITY AND SAFETY

West Bokaro Division 6

Problem Statement : Total Station used for Survey Measurements is a delicate and expensive instrument. It has to be protected from exposure to inclement weather and manhandling to safeguard the integrity of its lens and other critical components. Any deficiency can severely compromise the quality of readings recorded. Total Station is safely encased in a carrying case for comprehensive protection. The handle of the carrying case gave away unexpectedly and the safety of the Total station was at stake. Further, Total station is a cumbersome equipment that needed a case for moving around. Manufacturer company does not provide support for substitution of case’s handle. This implied that we had to invest in a new case, that would approx. cost around 1.5 Lakhs. The safety of Total Station was potential threatened as it became vulnerable to damages.

Before

West Bokaro Division 7

West Bokaro Division 8

West Bokaro Division 9

West Bokaro Division 10

West Bokaro Division 11

Man

Manhandling induced damage

Unwittingly left at site due to overlook

Machine

Environment Method

Delay in Survey as no one would be willing to assume responsibility of the Total Station

Defect may set in Lens

Critical components may get damaged

Component replacement may not be supported by manufacturer

Survey would be interrupted till replacement

Inclement weather / elements can corrupt sensitive components

Lens can become obscured/ scratchy/ spotty

Subjection to harsh conditions can result in glitches which becomes visible over time

Fishbone analysis

Readings recorded may be corrupted

Erroneous data may lead to fatal mistakes getting reflected in entire mine planning process

West Bokaro Division 12

The problem was deliberated over by team members. We could not afford much time as delay in measurement would occur. After brainstorming and consultation with the experts at Workshop, an alternate solution was arrived at. A new handle was designed in-house. The handle is constructed out of a durable metal alloy which is resistant to corrosion, had a coating of hardened rubber to absorb and endure stress and finally is encased within a wooden frame for comfortable carrying.

Countermeasure

West Bokaro Division 13

After

West Bokaro Division 14

Tangible benefits

Amounts (₹ Lakhs)

Cost to be incurred for procuring new box ₹ 1.25

Material cost borne to develop customized solution indigenously

₹ 0.15

Craftsmanship Charges ₹ 0.10

Final Savings ₹ 1.00 Lakhs

Intangible benefits

• No compromise on data’s accuracy and reliability

• Integrity of crucial mine planning data maintained

• Sustained morale of employees

West Bokaro Division 15

Strategically altering the design of the Tripod Stand to eliminate inadvertent errors induced due to alignment problems on field

Next Project envisaged

West Bokaro Division 16