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4th KAIZEN CONFERENCE

KAIZEN IDEA - SHEET

Activity
Loss No./ Step

KK

JH

QM

PM

SHE

OTPM

DM

ET

2 Step 3
P Q C D S M

Result Area

4
Plant : Mahindra & Mahindra Ltd. Kandivli Kaizen theme :To reduce set up loss Problem/present status :
Set up time on lapping Machine is high (35 minutes). 2 parts viz. Output shaft & Rev. sub shaft having different lengths and different diameters, are lapped on the same machine in shaft cell of Transmission PU Rev. Sub shaft

Machine : Lapping Machine 1930 (Shaft Cell, Transmission PU) Idea : Common lapping roll and Easy to adjust Countermeasure :
a) Made new common lapping roll with a groove in the center to accommodate the flange in the output shaft. b) Provided a recess in the Rev. subshaft equal to width of the groove in the lapping roll without affecting it's function c) Provided a quick insertable mandrel for Rev. Sub shaft to make the length equal to the Output shaft length to avoid tailstock adjustment d) Provided a gauge to make lapping cross slide adjustment instantaneous.
insertable mandrel

Bench mark Target Kaizen start Kaizen Finish Team members

35 minutes 1 minute Dec. 03 Dec. 03

L1

Lapping Output shaft


Common lapping roll with a groove

M N Choudhary M.Sinha R. P. Oza G K Nair

Key word - Different Rolls and difficult to adjust

L1 = L2 b, c
Gauge between lapping cross slide

a L2 d Analysis :
Set up time on lapping machine is more Tailstock and slide require Minutes / Occurence Both parts have different lengths (L1, L2) and diameters 40 30 20 10 0 Before

Results :

Benefits:

Lapping rolls require to Different rolls for different parts

Set Up Time

Production Per day


700 500

35
Nos.

627

381
300
100 Before After

Before Activity
Change lapping Roll Adjust TailstockLoosen mounting bolts and move TS towards headstock for clamping of smaller length output shaft Adjust Cross slide by sensing the contact between lapping paper and part manually Total

Before minutes
20

After Activity
-

After minutes
0

C'Measure ref. No.


a, b

1
After

Cycle Time
7 No adjustment of Tailstock 0 c

200 Seconds 150 100 50 0

180
120

Adjust cross slide by inserting gauge of required dimension in the cross slide

Before
1

After

35