2. Presented by Dhananjay Metal Craft Pvt Ltd-1 Shendra Aurangabad

3. PRODUCT RANGE CORE PACKTOP ARMFINE BLANKING

4. CUSTOMERS OEM’s Auto-ancillary

5. Achievements Long Term Association 2011 - award by Varroc Excellent Effort 2008 - TPM award by Endurance Group Award By DIC Maha Govt 2004 TPM Implementation 2012 – award by Endurance Group Bronze Quality – award by Endurance Group TPM Award by Mr. Anurang Jain (M.D. Endurance Group) Award for Excellence by Sulzer

6. TEAM - SAIRAT Leader Mr. Jayant Tambe Member Mr. Pawn Jadhav Member Mr. Shubham Jadhav

7. THEAME SELECTION What Kaizen I can do ForProductivity increase………..??? ?? Production target not achieved as per daily demand Extra drilling operation for removing burr which is generated at chamfer Two times manual cleaning is to be done Double debarring operation for burr removal Debarring output not as per required

8. EXISTING PROCESS FLOW CHART

9. KAIZEN THEME TO REDUCE MATERIAL ISSUE TIME ON LINE. INCREASE PRODUCTIVITY BY THE USE OF LEAN

10. PRESENT STATUS Define the Problem PRESENT STATUS : Define the problem Daily customer demand not achieved due to excess process has to be done on part

11. HOW TO IMPROVE EXISTING CONDITION Improve the Existing Condition Improve the Existing Condition One debarring must be eliminated Extra drilling should be eliminated Debarring output must be increased Part should clean properly

12. WHY WHY ANALYSIS Less productivity due to excess process Why? Two time debarring operation Blanking and piercing is separate Providing grove up to 1 mm at piercing Why? Root Cause : Kaizen Idea :

13. WHY WHY ANALYSIS Less productivity due to excess process Why? Debarring output is less Total conveyer belt is not in use Due to slotted roller and taper on roller Flat roller used which clear all conveyer belt Why? Root Cause : Kaizen Idea :

14. WHY WHY ANALYSIS Less productivity due to excess process Why? More time required for cleaning Due to that excess manpower is deputed Washing machine used for part cleaning Why? Root Cause : Kaizen Idea :

15. WHY WHY ANALYSIS Less productivity due to excess process Why? Extra drilling operation Gauge not pass after chamfering Excess burr of chamfer generate at bottom side Step drill used for chamfering operation Why? Root Cause : Kaizen Idea :

16. COUNTERMEASURE Improve the Existing Condition  Up to 1 mm Grove provided at piercing which save one debarring and one cleaning operation.  Flat roller used for debarring which use all conveyer belt and output is increased.  Washing machine used for part cleaning.  Step drill used for chamfering operation.

18. PROCESS FLOW AFTER LEAN BEFOREAFTER

19. RESULTS Customer demand fulfilled. 3 operation save. Productivity increases. Quality improves. Moral Increased.

20. Productivity Increases IN %

21. Operation saving

22. Manpower saving

23. BENEFITS Moral Increased

24. COST SAVING One debarring operation saved. Per piece debarring cost=0.30p Total part debar /day =20000 Total cost saving per Month =1.5 Lack Washing machine used for cleaning Total 6 manpower Saving Per month Per manpower rate = 8000 Rs

25. COST SAVING Total Manpower cost saving per month = 48 Thousand One drilling operation save Total drilling parts /Day=5000 Total Man-day Saving in cost per months= 8000 Total Cost Saving Per month =2.06 Lack Horizontal deployment to other 6 parts. Total cost saving after horizontal depl.per Year= 24.36 Lack

26. SUSTENANCE

27. SUSTANNANCE For groves point add in PM check sheet for monitoring For debarring roller and washing machine decide frequency of roller rubarising and added in Check sheet. After every 10000 nos step drill changed for sharpening.

28. Lever change avengerAll grip flow parts

29. HORIZONTAL DEPLOYMENT To all grip flow parts.

30. Your Questions & Suggestions are most welcome

31. The Journey Continues The Journey Continues