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KAIZEN - SHEET

SKF India Ltd
Bangalore

Category:

A

B

C

Providing

Changing

Kaizen Theme & Target:
Elimination of HIT caging defect
Problem / Present Status:

Before Improvement:

Improper rivetting Bearings found at
MGO.

Analysis:

After improvement:

Whenever hydropneumatic cylinder oil
lvevel goes low 2nd pressure (high)
pressing not taking place, leading to
generation of defective bearing. There was
no oil level indicator, a sensor is provided
on the piston end, if the oil level
decreases, the sensor gets ON and Red
lamp glows, whenever red lamp glows
operator will get the oil filled and
prevented defect generation.
Root Cause:
Idea:
Counter measure:

There is no oil level incicator in the cylinder by design,
To detect the oil by capturing the position of piston displacement
Sensor fitted with Red lamp inciction to alert the operator to fill the oil

Banuprakash Result / Benefit: Defect due to low oil level or pressure not found from Dec 26th 2009 Kaizen type: If reversible update in: Reversible Ir-reversible Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing New machines coming to channel must have this feature built in. K N Jayakumar. SL No 1 Scope & plan for horizontal deployment M/C NO Target date Responsibilty status HIT1B Jan 2nd 2010 Arun Completed Poka Yoke Type & Function Prevention Detection Shutdown Control Warning . H Nagaraj.Unit Sub comm ETW QM Year 2010 SL.NO 001/QM/DGBB/2010 Machine No: HIT 1A and HIT 1B Team members: Arunkumar.

SHEET SKF India Ltd Bangalore Category: A B C Providing Changing Kaizen Theme & Target: To eliminate customer complaint Introduction of accumulator for uniform spray of preservative oil Problem / Present Status: Before Improvement: Excess preservative spray on bearing.KAIZEN . non uniformity of spray (1 Customer concern from BOSCH) DIAPRAGM PUMP NOZZLE OIL TANK REGULATOR Analysis: Why 1 : Why customer concern ? Excess preservative spray on bearing Why 2 : Why excess spray? Oil spray through regulator non uniform Why 3 : Why spray is non uniform? Pressure drop at regulator Root Cause: Idea: Counter measure: After improvement: DIAPRAGM PUMP OIL TANK Pressure drop at regulator Introduction of accumulator for uniform spray of preervative oil Provide accumulator to eliminate the pressure drop at regulator REGULATOR .

46 Kaizen type: Reversible If reversible update in: NOZZLE Std.NO Year 2010 Machine No: TOS . Dev = 0. Dev = 0.16 Ir-reversible Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing Scope & plan for horizontal deployment SL No M/C NO Target date Responsibilty status REGULATOR Poka Yoke Type & Function Prevention Detection Shutdown Control Warning . MM Jaikumar Result / Benefit: Uniform spray of preservative through regulator NOZZLE Before After Std.Unit Sub comm ETW QM SL.Ch 01 Team members: C Ravi .

1) Rings not being pushed after running type in hardening zone during changeover. Root Cause: Idea: Action:Pusher modification. No space for movement. 3)Pusher getting heated up.Difficult to hold pusher 4)Manual intervention at the hardening entrance leads to improper holding of pusher & pushing of rings. 1)More surface area created for pushing rings2)Pushing can now be done easily 3)Pusher getting heated up.KAIZEN . 3)Pusher becomes hot when it is in use.SHEET SKF India Ltd Bangalore Category: A B C Providing Changing Kaizen Theme & Target:Zero Defect/ Zero Breakdowns/ Zero Accidents Avoid Defect Generation at heat treatment / Operator Safety / Efficiency Improvement in Channels Problem / Present Status: Before Improvement: 1)Loss in Channel Effeciency 2)Finger probe damage 3)Downtime at Channel 4)Break downs at Channel 5)Operator morale too low at HT 6)Unsafe condition for pushing of rings 7)Stagnation of rings at HT AFTER IMPROVEMENT 1)Space constrains for pushing rings2)High Temperature at the entrance of furnace operator inconvenience.But handling is easy 4)Orientation of pusher is now fixed. 5)No other method of pushing available.Pusher becomes very hot when it enters the furnace.Rings stagnating on hardening chute 2)Pusher which is being used is not user friendly. 5)Clearing of rings at the hardening chute varies from Before Analysis: After improvement: Problem:Ring mixup in Hoppers leading to production loss & downtime at Channels.Rings not getting cleared at Hardening Chute exit.while removing pusher from furnace. 5)Stagnation of rings elliminated. Why Why analysis attatched Avoid breakdowns/ Increase in Effeciency/ Avoid defect generation . 4)Manual pushing leads to improper orientation of pusher which results in ring stagnation at hardening chute.Area for pushing is too hot for operator to perform the process.Does not vary from one operator to the other.while removing pusher from furnace.

.Counter measure: Sustaining the pusher mechanism for unifrom pushing of ring.

NO 05 & 06 Machine No: Furnace 01 . Saliyan & HT Team Result / Benefit: 1)Reduce mixup at channel from 25 nos to 2 nos per batch 2)Reduction in finger probe damage and replacement 3)Increase in Channel Effeciency 4)Increase in operator morale 5)Operator safety while operator high temperature furnace 6)No stagnation of rings at Hardening Chute AFTER IMPROVEMENT nation at hardening ing chute varies from AFTER IMPROVEMENT If reversible update in: Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing Scope & plan for horizontal deployment SL No M/C NO Target date Responsibilty Status 1 Fc 01 Poka Yoke Type & Function Prevention Q1 Swarup / Arun / HT Team / Implement Surendraed R&D Contract Shutdown Control .Unit Sub comm ETW QM Year 2010 SL.02 & 04 Team members:V.

Detection Warning .

Root Cause: Idea: Introduce Poke Yoke to check presence of 'N' groove on outer ring OD inplace of manual inspection. Customer: Bajaj Auto Ltd. There is no other Poke Yoke .KAIZEN . Counter measure: .SHEET SKF India Ltd Bangalore Category: A B C Providing Changing Kaizen Theme & Target: Elimination of N Groove & Normal Bearings Mix-up in Ch-1 & Ch-6 Problem / Present Status: N groove and Normal Bearings mix-up observed at Customer end. Analysis: Before Improvement: NO Poke-Yoke After improvement: Sensor to detect presence of ‘N’ groove on bearing OD Manula Inspection of Bearings .

NO Year 2010 3 Poke-Yoke after HHC/HHE Team members: SH/MMJ/CR/GK/NR Result / Benefit: Poke -Yoke detects the mix-up of Normal & N-Groove Bearings. Kaizen type: Reversible Ir-reversible If reversible update in: Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing Scope & plan for horizontal deployment SL No M/C NO Target date Responsibilty status Ch-6 after 1 HHC/HHE Poka Yoke Type & Function Prevention Detection MMJ/CR Shutdown Control Warning .Unit Sub comm ETW QM Machine No: SL.

As this snap ring fitment operation is manual in nature.KAIZEN . the operator might have missed the pressing operation and arranged the un-pressed bearing along with the finished bearings in the bin. The semi finished bearings with ‘N’ – groove is collected in bins and is moved to off line press for snap ring fitment. This activity is out sourced and the trained contract worker fits the snap ring on to the bearing groove by using a pneumatic press and later the bearings are packed and delivered. Subsequently the bearings were despatched to customer.SHEET SKF India Ltd Bangalore Category: A B C Providing Changing Kaizen Theme & Target: Elimination of Snap ring missing & Type mix-up 1 nos to Zero Problem / Present Status: Snap Ring Missing was noticed at Hero Motors 6304 NR/C3 (1 no.) This was registered as Customer Complaint Before Improvement: NO Automatic Poke-Yoke Only Manual Inspection Analysis: After improvement: Snap ring fitment process is a manual operation. Root Cause: Idea: Counter measure: Manual Inspection Automatic Poke-Yoke to detect Snap Ring Missing & Bore mix-up .

Kaizen type: Reversible Ir-reversible If reversible update in: Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing SL No Scope & plan for horizontal deployment M/C NO Target date Responsibilty status Poka Yoke Type & Function Prevention Detection Shutdown Control Warning .NO ETW QM 2010 4 Machine No: Snap Ring Fitment Press Team members: NR/MMJ/DKJ/KS/VR Result / Benefit: Detection of Snap Ring missing & type mix-up with snap ring .Unit Sub comm Year SL.

Analysis: After improvement: The probable causes for grease leakage : 1.KAIZEN . Excess hydrol content in white spirit (>5%) Root Cause: Idea: Counter measure: Excessive white spirit residues in the bearing causing Grease Leakage Air Blower in the Washing machine to remove the white spirit Adiitional Air Blowers. to Zero) Problem / Present Status: Before Improvement: Customer BOSCH Complaint: Grease Leakage from seal lip & inner ring interface noticed at rotor slip ring turning operation (Bosch Process). The seal anchorage dimensional non-conformance with respect to specification. The seal lip & inner ring seal anchorage (seal groove) clearance (-0. BB1-0372AE (Zeta Alternator – Rotor Bearing). Japan. Excessive residual white spirit on the seal groove of inner & outer ring – on random bearings.SHEET SKF India Ltd Bangalore Category: B A C Providing Changing Kaizen Theme & Target: Elimination of Grease leakage from Bearings ( 3 nos. 5. Oil separation of grease in supply condition – GHP from M/s. 0. KYODO YUSHI. Excess grease fill quantity (approx. 2. 4.13mm): Out of specification due to tolerance stack up. The Argentina factory maintains the residual white spirit (Exxsol D60) approx. . 6. 55 mg.21 mm)/interference (+0. 3.9 gms).

NO Customer Complaints for Grease Leakage Kaizen type: If reversible update in: Reversible Ir-reversible Operation Standard JH Check Sheet PM Check Sheet Eqpt/ fixture Drawing Scope & plan for horizontal deployment SL No M/C NO Target date Responsibilty status 1 Washing m/c Poka Yoke Type & Function Prevention Detection MMJ/CR Shutdown Control Warning . has eliminated the grease leakage issue.Unit Sub comm ETW Machine No: SL.NO Year QM 2010 2 Washing Machine Team members: GK/MMJ/RTR/CR/SD/VT/AND Result / Benefit: Introduction of Blower with Air knife nozzles.

l KAIZEN IDEA ./ Step Supervisor / Manager Level Kaizen Result Area HIT Machine Plant : DGBB Bangalore Machine : Kaizen theme : Idea : To eliminate customer complaint To match Die profile and Cage Problem/present status : Countermeasure : Die Profile and Cage profile matched Rivet improper pressing customer complaint. Before No of customer complaints .6 Nos / Year After No of products observed with Improper Cage = 790 Nos Customer Complaint 8 6 6 Better 4 2 0 0 Before Root cause Die profile relief not matching with cage Graph Data: Before After 790 0 Before After 6 0 After Defect Generation Numbers Why 1: Rivet improper pressing in 6003 Due to Improper Cage alignment Why 2: Improper cage alignment Cage misalignment Why 3: Due to Die Pocket profile Profile relief allows the cage to misalign Results : Numbers Analysis : 1000 800 600 400 200 0 .SHEET Activity Loss No.

M Jaikumar Ananth Bhat Ashwin Padmavar Benefits: Customer complaint due to improper riveting eliminated in 6003 type Defect Generation 790 Better 0 Before After Scope & plan for Horizontal Deployment S no M/c Targert date Responsibility No.6 Nos Zero 7/4/2008 7/5/2008 C.790 Nos and Customer complaint . 1 All Ch Aug' 08 end CR Status In progress . Ravi M. Bangalore match Die profile and Cage Bench mark Target Kaizen start Kaizen Finish Team members ched Defect generation .KK Result Area JH P QM PM SHE OTPM Q C D S DM ET M SKF India Limited.