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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Target

Sr. No. Who

1 NA

Kaizen Unique No: - MBU/01/10 11/1 (HORIN

DEPLOYMENT)

Kaizen Theme:- To give proper identification

to master batches.

Kaizen Idea:- Toimprove the space and proper marking of master

batches.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:- Buckets are provided for

keeping the master batches and proper

identification done on each bucket.Problem Status:- Earlier master batches are

kept in Bags without identification.

Team:- MUSAFIR BROTHERS UDYOG

Completio

Productivity 15 Min 0Min

Start Date:- 7-10-2010

Cost

Quality

After:- Env

Horizontal Deploymen

Where

Before:-

OHS

Delivery

Morale

NA

Root Cause : No proper marking and proper place

for master batches.Results:-

Problem Analysis:-

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Targ

Sr. No. Who

1

Kaizen Unique No: - MBU/01/10 11/2 (HOR

DEPLOYMENT)

Kaizen Theme:- To improve productivity at

suppliers end.

Kaizen Idea:-To improve the process with reduction in set-up

time & using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-

Mould lifting which was earlier done by Metal

Chain which require high man time due to

Nut/Bolt Assy. & being heavy in wt. Same

replaced to Synthetic Sling which is easy to fit

& operate.

Problem Status:- Less Productivity due to high

set-up time observed in Plastic Component.

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 26-9-2010 Comple

Productivity 24 Min 15 M

Cost

Quality

After:- Env

Horizontal Deploym

Where

Before:-

OHS

Delivery

Morale

NA

NA

Root Cause : Improper operations & lack of

knowledge about SMED resulted in high mould set

up time

Results:-Tool Changeover time on 180 T M/c reduced by 8 Min

with this change

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time in lifting the tool found to be 2nd

bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 24 min were for tool

lifting

Lack of proper knowledge , unutilization of

productivity improvement tools.

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Ta

Sr. No. W

1

Kaizen Unique No: - MBU/01/10 11/3 (H

DEPLOYMENT)

Kaizen Theme:- To improve productivity at

suppliers end.

Kaizen Idea:- Toimprove the process with reduction in set-up time &

using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-Conventional cooling nipples on which cooling pipe

was fitted after heating & sealed with metallic wire

replaced by push fit PU Nipples which proved to be

more productive .

Problem Status:- Less Productivity due to high

set-up time observed in Plastic Component.

Team:- MUSAFIR BROTHERS UDYO

Com

Productivity 22 Min 10

Start Date:- 05-10-2010

Cost

Quality

After:- Env

Horizontal Depl

Where

Before:-

OHS

Delivery

Morale

NA

Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set

up time.

Results:-Tool Changeover time on 180 T M/c reduced by 10

Min with this change

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time in fixing tool cooling nipples found

to be 3rd

bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 22 Min were for fixing

cooling nipples/pipes on tool

Lack of proper knowledge , unutilization of

productivity improvement tools.

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MUSAFIR BROTHERS UDYOG

Kaizen Theme:- To improve productivity atsuppliers end.

Problem Status:- Less Productivity due to high

set-up time observed in Plastic Component.

Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set

up time.

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time found to be bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 21 Min were for making

cooling battery operational.

Lack of proper knowledge , unutilization of

productivity improvement tools.

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4

"KAIZEN IDEA SHEET"

Result Area h i Before

Sr. No.

1

Kaizen Unique No: - MBU/01/10 1

DEPLOYMENT)

Kaizen Idea:- Toimprove the process with reduction in set-up time

& using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-Ordinary cooling battery (for Hydraulic Oil Cooling)

which had ordinary cooling pipes (heated & sealed)

replaced by quick fit cooling battery with push fit

PU nipples.

Team:- MUSAFIR BROTHERS

Start Date:- 05-10-2010

Productivity 21

Cost

Quality

After:- Env

Horizontal

Where

Before:-

OHS

Delivery

Morale

NA

Results:-Tool Changeover time on 180 T M/c reduced by 9

Min with this change

Page 5

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4

Target After Verified By

Who When Status

/4 (HORINZONTAL

DYOG

Completion Date:- 15-10-2010

10 12Akash; during

supplier visit

Deployment

NA NA NA

Page 6

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Targe

Sr. No. Who

1

Kaizen Unique No: - MBU/01/10 11/5(HOR

DEPLOYMENT)

Kaizen Theme:- To improve productivity at

suppliers end.

Kaizen Idea:- Toimprove the process with reduction in set-up time &

using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-

Locating Rings made w.r.t all mould/machine

dimensions & used for easy changeover. Usage

of locating rings reduced adjustment time

between M/c Nozzle & mould Sprue Bush

Problem Status:- Less Productivity due to high

set-up time observed in Plastic Component.

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 17-9-2010 Comple

Productivity 10 Min 2 Min

Cost

Quality

After:- Env

Horizontal Deploym

Where

Before:-

OHS

Delivery

Morale

Root Cause : Improper operations & lack of

knowledge about SMED resulted in high mould setup time.

Results:-Tool Changeover time on 180 T M/c reduced by 8

Min with this change

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time found to be bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 7-8 Min were for tool

adjustment in absence of locating ring.

Lack of proper knowledge , unutilization of

productivity improvement tools.

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Targ

Sr. No. Wh

1 NA

Kaizen Unique No: - MBU/01/10 11/6 (HOR

DEPLOYMENT)

Kaizen Theme:- To improve productivity at

suppliers end.

Kaizen Idea:- Toimprove the process with reduction in set-up time &

using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-

Mould moved on a make shift arrangement

requiring 2 people to do the job instead a pallet

lifter deployed which does the job more

effeciently requiring only a single person.

Problem Status:- Less Productivity due to high

set-up time observed in Plastic Component.

Team:- MUSAFIR BROTHERS UDYOG

Comple

Productivity 10 Min 7 Mi

Start Date:- 29-09-2010

Cost

Quality

After:- Env

Horizontal Deploy

Where

Before:-

OHS

Delivery

Morale

NA

Root Cause : Improper operations & lack of

knowledge about SMED resulted in high mould set

up time

Results:-Tool movement time to M/c reduced by 3 Min with

this change

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time found to be bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 10 Min were for Mould

Movement to M/c.

Lack of proper knowledge , unutilization of

productivity improvement tools.

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Result Area h i Before Ta

Sr. No. W

1 N

Kaizen Unique No: - MBU/01/10 11/7 (H

DEPLOYMENT)

Kaizen Theme:- To improve productivity at

suppliers end.

Kaizen Idea:- Toimprove the process with reduction in set-up time &

using minimum workforce.

Zone/Dept Coordinator:- 1

Team Leader:- Akash

Counter Measure:-Allen Key replaced by ratchet spanner Allen key

which proved to be more handy & productiveProblem Status:- Less Productivity due to high

set-up time/labour shortage observed in Plastic

Component.

Team:- MUSAFIR BROTHERS UDYO

Com

Productivity 7 Min 5

Start Date:- 23-10-2010

Cost

Quality

After:- Env

Horizontal Deplo

Where

Before:-

OHS

Delivery

Morale

NA

Root Cause : Improper operations & lack ofknowledge about SMED resulted in high mould set

up time

Results:-Tool Changeover time on 180 T M/c reduced by 2

Min with this change

Problem Analysis:-Study made on Process Flow of IM Comp. Manff. &

high set-up time found to be bottleneck operation.

Average tool changeover time was in the range of

90 to 170 Min. Out of which 7 Min were for

operations involving searching & usage of allen key

Lack of proper knowledge , unutilization of

productivity improvement tools.

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MUSAFIR BROTHERS UDYOG "KAIZEN IDEA SHEET"

Root Cause : No arrangement of tools Results:-5-10 min saved in searching of tool.

Problem Analysis:- there is no

proper place for tools, which give rise

to wastage of time in searching of

tools.After:-

Before:-

Kaizen Theme:- To save time insearching of tools.

Kaizen Idea:-To develop a tool box for tools.

Counter Measure:- Spanner & other

tools are arranged on shadow board

and near to machines.

Problem Status:- As the tools are not

arranged and at proper place,

workers has to waste there time in

searching tools.

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Result Areah i

Before Target After Verified By

Sr. No. Who When Status

1 NA NA NA

Horizontal Deployment

Where

NA

Morale

OHS

Delivery

Env

Cost

Quality

Productivity 10 Min 0 min 0 Min Akash; during supplier visit

Kaizen Unique No: - MBU/03/10 11/8 (HORINZONTAL

DEPLOYMENT)

Zone/Dept Coordinator:- 3

Team Leader:- Akash

Team:- MUSAFIR BROTHERS UDYOG

Start Date:- 10-10-2010 Completion Date:- 17-10-2010

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MUSAFIR BROTHERS UDYOG

Kaizen Theme:- To Save time For searching

Dies.

Problem Status:- Worker has to search for dies

since not arranged and marked.

Root Cause : No arrangement & numbering of dies

accordingly.

Problem Analysis:-Since Dies are not arranged or marked, lots of time

is waste in searching of dies,which reduces the

production and manpower.

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"KAIZEN IDEA SHEET"

Result Area h i Before

Sr. No.

1

Kaizen Unique No: - MBU/03/10 1

DEPLOYMENT)

Kaizen Idea:-

To develop die stand & give numbers to each

die.

Zone/Dept Coordinator:- 3

Team Leader:- Akash

Counter Measure:-

Now die stand is made for arrangement of dies

and they are arranged on stand according to

there number.

Team:- MUSAFIR BROTHERS

Productivity 22 Min

Start Date:- 17-9-2010

Cost

Quality

After:- Env

Horizontal

Where

Before:-

OHS

Delivery

Morale

NA

Results:-Tool Changeover time on 180 T M/c reduced by 10

Min with this change

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Target After Verified By

Who When Status

NA NA NA

/9 (HORINZONTAL

DYOG

Completion Date:- 20-10-2010

10 Min 12 MinAkash; during

supplier visit

Deployment

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