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Kaizen Formatd

The document describes two kaizen improvements made at Rams Engineering Industries in Chennai. The first improvement was to eliminate customer complaints about wiping system angle and gauge not being okay by installing a new crimping machine and fixture to complete the 3 required crimps in a single stroke instead of 3 individual strokes. The second improvement was to reduce rework cost by maintaining spindle link squareness within specifications after caulking. This was done by adding a spring loaded arm under the top tool to apply load to the oscillating link during caulking and prevent deflection. Both improvements eliminated 100% of rejections.

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subbu0815
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229 views2 pages

Kaizen Formatd

The document describes two kaizen improvements made at Rams Engineering Industries in Chennai. The first improvement was to eliminate customer complaints about wiping system angle and gauge not being okay by installing a new crimping machine and fixture to complete the 3 required crimps in a single stroke instead of 3 individual strokes. The second improvement was to reduce rework cost by maintaining spindle link squareness within specifications after caulking. This was done by adding a spring loaded arm under the top tool to apply load to the oscillating link during caulking and prevent deflection. Both improvements eliminated 100% of rejections.

Uploaded by

subbu0815
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
You are on page 1/ 2

KAIZEN - SHEET Supplier Name & Address

Category: P Q C D S M Rams Engineering


Industries,
Kaizen Theme & Target : To eliminate customer compliant Chennai – 600 098
Corrective action Team: B.A.Kumar ,JaiShankar.K,Subramanian .V,T.Kasirajan ,D.Sekar Part Details : Wiping system assy 2671 9192

Problem : Wiping system CRS gauge & Before improvement: Result & Benefits
Wiping angle not ok at Customer End 1)Rejection eliminated 100%
2)Improved productivity. Zero
Rejection

Root Cause Identification: After improvement:


Implementation Date: 18.10.2010
1.Why?
Kaizen type
Tube deflected during crimping operation Reversible Ir-reversible
2. Why ? If reversible updated in
Wiping system length more than 300mm so 3 Operation Standard / QCPC
crimping done by 3 individual stroke Quality Standard
Eqpt / fixture Drawing
Tool history card
Poka Yoke type
Prevention
Detection(A,B)

Root Cause 3 crimping operation done by 3 individual stroke


Plan for Horizontal Deployment
Nil

Idea to eliminate Root cause : 3 crimping operation to be done at single stroke Lucas TVS (Office use only)

. Reviewed by: Approved by:


Action Taken: New crimping machine & fixture to be provided for single stroke
KAIZEN - SHEET Supplier Name & Address

Category: P Q C D S M Rams Engineering


Industries,
Kaizen Theme & Target : To eliminate rework cost Chennai – 600 098
Corrective action Team: B.A.Kumar ,JaiShankar.K,Subramanian .V,T.Kasirajan ,D.Sekar Part Details : Spindle Link & pin assy 2671 9202

Problem: Squareness not maintaining Before improvement: Result & Benefits


consistently after spindle caulking . Osc link 1)Rejection reduced 100%
Squareness measured 0.10 to 0.7mm wrt 2)Reduced rework cost Rs2500/month
spindle .
Zero
Rejection

Root Cause Identification: After improvement:


Implementation Date: 15.6.2010
1.Why?
Kaizen type
Squareness not maintained with in spec ARM Reversible Ir-reversible
2. why ? If reversible updated in
Osc link deflected during spindle caulking Operation Standard / QCPC
Quality Standard
3.Why? Eqpt / fixture Drawing
Tool history card
Osc link freely during caulking operation
Poka Yoke type
4.WHY
Prevention
load not applied on osc link during caulking
operation. Detection(A,B)

Root Cause : Load not applied on Osc. Link During caulking operation Plan for Horizontal Deployment
Nil

Idea to eliminate Root cause : load applied on the Osc. Link Lucas TVS (Office use only)
Provide
. Arm under the top tool with spring loaded . Reviewed by: Approved by:
Action Taken: This arm press the osc link during spindle Caulking operation

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