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Kaizen Sheet Company MM/YY S.No

Productivity Quality Delivery Safety Material Energy Morale TIMKEN NOV 11 T1- 1

Kaizen Title: To Reduce the setup time for 25mm width part numbers Implemented Area:

Face Grinder -1Problem/Present Status:a.25mm width part number taking 270min

setup time ,when compared to all otherpart number it taking 15-20 min.

Before Improvement:Implemented by:

Praveen Kumar PathakWasim Akram

Jagadeeswaran.D

Result/Benefit:

(a) Qualitative1. Reduced the fatigue to the

person

Real Root Cause Identification:270min setup time for 25mm width part

number

Guide plates Qualification required to do

for 25mm part number which takes 4hrs

Guide plate adjustment assembly has to be

shifted from its position to new drilledposition

Guide plate adjustment stroke is less

After improvement:(b) Quantitative2 setup per month for 25mm width

parts

30sec cycle time for 1 piece

1080 piece produced with this

available time

Standardization:

1.Setup manual updated2.Machine manual updated

Root cause Guide plate adjustment stroke is less for 25mmwidth part number

Guide Plate adjustment stroke length increased to

avoid the shifting of guide plate assembly

Lead screw rod increased by 15mm each side

How many places this Kaizen

can be deployed horizontally

Nil

Idea to eliminate root cause

Counter-measureConfederation of Indian Industr

WH

E

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L

WH

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1INCH

PART

85 mm 85 mm

GUIDE PLATE

ADJUSTMENT

ASSEMBLY

GUIDE

ROD

ASSEMBLY

GUIDE

PLATE

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H

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W

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1INCH

PART

100 mm 100 mm

GUIDE ROD

ASSEMBLY

GUIDE

ROD

ASSEMBLY

GUIDE

PLATE

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Kaizen Sheet Company MM/YY S.No

Productivity Quality Delivery Safety Material Energy Morale TIMKEN JAN2012 T1-2

Kaizen Title: To decrease the setup time for Diamond Change in Cone Rib Grinders Implemented Area: X3-RIB grinder

Problem/Present Status:1. 15min. For removing the diamond

2. 180min. Break down due to wrong

mounting/Removing of diamond collet nut

Before Improvement: Implemented by:

Praveen Kumar Pathak

Wasim Akram

Jagadeeswaran.D

Result/Benefit:

(a) Qualitative

1. Easy to remove the diamond

Real Root Cause Identification:

To remove the diamond , difficult to hold thestem and remove the nut.

Space constrains to remove the diamond

Collet and nut is difficult to handle in this

machine

After Improvement:

(b) Quantitative

1. Diamond Change/ month = 150

Time saved/ diamond Change = 12 min.Time Saved/month = 150*12 =1800min

2.Break down time reduced from 3 hrs

to Zero Hrs due to improper

diamond Entry/Removal

3.Spare parts of nut and collet (a).

Ordering time (b). Ordering cost

(c). inventory are eliminated

Standardization:

1.Machine manual Updated

3.Monthly PM check list updated for

checking the screw thread

Root cause Collet and nut is difficult to handle in this machine

Changed the collet stem design to screw locking method

Stem of diamond turner changed

How many places this Kaizen can be

deployed horizontally

5 RIB Grinder

Idea to eliminate root cause

Counter-measure

Confederation of Indian Industry

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Kaizen Sheet Company MM/YY S.No

Productivity Quality Delivery Safety Material Energy Morale TIMKEN JAN2012 T1-3

Kaizen Title: To Reduce the Breakdown time due to improper indexing of the table Implemented Area: JX1-Close In Press

Problem/Present Status:

1.Table indexer not working due to shaft getting

damage frequently

Before Improvement:Implemented by:

Praveen Kumar Pathak

Wasim Akram

Jagadeeswaran.D

Result/Benefit:

(a) Qualitative

1.Shaft damage avoided

2.Operator fatigue reduced

3. Manual Mode of operating the press

not required

Real Root Cause Identification:

Shaft damage

Shaft key getting misaligned from the slot

during the rotation

Slot in the female shaft which allows the key to

come out from the motor shaft

After Improvement:

(b) Quantitative

1.Machine down time reduced from 2

hrs to zero

Standardization:

Machine manual updated

Root cause Slot in the female shaft which allows the key to come out fromthe motor shaft

Spacer filled in the female shaft and grub screw locking

provided

Gap filled with grub locking

How many places this Kaizen can be

deployed horizontally

Nil

Idea to eliminate root cause

Counter-measure

Confederation of Indian Industr

M

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INDEXER TABLE

Free space

screw

INDEXER TABLE

M

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R