CASE BOTTOM MACHINING SHOP

ATLAS AUTOS (PVT) LIMITED

Traceability ImprovedKAIZEN

Muhammad Ahsan

2

WHY was it required?

Objectives:

To make the traceability process 100%

To make worker more accountable of its work.

To track the history and causes of a problem.

To differentiate In-house Part from Vendor’s Part.

Muhammad Ahsan

3

WHAT used to happen?

Manual Punching with Hammer

Punch letter Z Placing of Punch at desired location.

Hammering on the punch to have its impression on

Case Bottom.

Disadvantages in this Process1.

Very Dim Impression of the punch.

2. Operator’s tasks were increased.

3. Probability of missing a piece 4. Possibility of damages due to hammer.

Muhammad Ahsan

4

WHAT did we Innovate?

Automatic Punching with Modified Die

Punch placed in the modified part clamping jig.

Cylinder of Part holder moves forward, both clamping and

punching the part at the same time.

Part placed for clamping in the part holder.

Muhammad Ahsan

5

HOW did we do?

Manufacturing Process

Cylinder of Part holding Jig The new cylinder with punch assembled it.

New Cylinder formed, with a hole to place the punch

Advantages after Innovation1. Dark Impression of the punch. 2. No Fatigue for Operator3. No chance of Missing a Piece 4. No Possibility of damage on

parts.

Muhammad Ahsan

6

Achievements and Results

Sr. No. Objective Status

1. To make Traceability process 100%.(100% Traceability achieved as every part that is machined will be punched)

2. To make operator more accountable for his work.(A punch for each operator; One can now trace the operator of problematic part.)

3. To track the history and causes of a problem.(As per planned laser printing after painting, a problem may be monitored)

4. To differentiate In-house Part from Vendor’s Part.(The part with punch mark is AAL In house; while without punch is Al-Badar)