ALAMADHI SEMEN STATION

Chennai
(A unit of NDDB Dairy Services) 1

Theme : Involving People through Quality

Concepts to Make India Global Leader

Team : NANDI
30th Chennai Chapter Convention on Quality Concepts (CCCQC – 2021)
 ALAMADHI SEMEN STATION
Chennai
(A unit of NDDB Dairy Services) 2

Title : Resource Optimization in Semen Lab

 Team
3

Dr. S.Harisankar
General Manager
Alamadhi SS

Dr. E. Sairavindranath Mr. Althaf Mr. Ramakrishnan K Mr. Manoj Arora

Manager - Ops Officer – Semen Lab Supervisor – Semen Lab Coordinator
Alamadhi SS Alamadhi SS Alamadhi SS
 ALAMADHI SEMEN STATION
Chennai
(A unit of NDDB Dairy Services) 4

NDDB Dairy Services

A wholly owned subsidiary of NDDB

registered as not for profit company

Delivery arm of the NDDB for field operations relating

to promoting Productivity Services and Producer
Companies

Owns and manages 5 mega Semen Station

in the country
 ALAMADHI SEMEN STATION
Chennai
(A unit of NDDB Dairy Services) 5
Alamadhi Semen Station
A Mega SS is touted to be one of the best SS in the country
Spread
over 358.58
acres
To ensure the easy availability of High Quality Bovine Semen in
the southern states of India

Maintains
Installed capacity of 12 million doses per annum 300
breeding
bulls
 ALAMADHI SEMEN STATION
Chennai
(A unit of NDDB Dairy Services) 6
Finished Products from Bulls (Frozen Semen Doses)
 Key Milestones
7

ISO 9001:2008
standard upgraded
2018 July 2018 with latest ISO
Government of India 9001:2015
adjudged Top 2nd SS standard

2018

ISO 9001:2008 2016 July

Certification (BVQI, 2016 Government of India
London) adjudged Top 2nd SS

2015

2015
Alamadhi Semen
Station Established
 Reward and Recognition
8

Agra Convention – 2019 Chennai Convention – 2020 Varanasi Convention –

Kaizen – Gold Award Kaizen – Gold Award 2019
Kaizen – Excellent Award

NCCQC Convention – 2020

Kaizen – Par Excellence
Award
Selection of the problem
9
 Selection of the problem
10
Title: Resource Optimization in Semen Lab

 In the era of cut throat competitive market, We at Alamadhi Semen

Station are following Kaizen concept to continuously reduce the
cost and improve product quality. The main objective is to provide
our employees, a road map for investigating the opportunities to
reduce cost and improve productivity and quality in the existing
production system through the application of Kaizen concept.

 The selected Kaizen (A&B) are among the top two Kaizen of the
Total 19 Kaizen of Alamadhi Semen Station for the current year.
11
 CHC(Cold Handling Cabinet)
12

• Cold Handling Cabinet(CHC) is used to lower the temperature to

4 degrees Centigrade.
• CHC is used to balance the sperm. It brings the sperm in straws
from room temperature to a temperature of 4 degrees, the
starting temperature for freezing semen.
 Selection of the problem
13
Title: Resource Optimization in Semen Lab

Frequent
Breakdown
Quality of FSD
deteriorates Safety Hazard

Loss
Wastage of Time in Of
Selection
Repairing Of the Money due to
Problem frequent breakage
 14
Problem
In Semen Lab the CHC (Cold Handling Cabinet) the glass
breakage was observed during its handling.
 15
Before
 Analysis (Why-Why)
17
Why – Why
Frequent Breakage of glass of Cold Handling Cabinet
Why

Repeatedly handling by persons during routine process

Why

High Usage and poor handling of CHC

Solution : In-house repair of Cold

Handling Cabinet Glass .
Counter Measure
18
 19
Counter Measure
In- house repair of glass cabinet
Improvement
20
 21
After
 22
After
 Improvement
23
Results and Tangible Benefits

 Reduce Cost of repeatedly outsourced glass

repair of CHC. Savings of Rs 24000 made through
implementation of this Kaizen

Annual cost
savings of
Rs. 24000/-
 Improvement
24
Results and Tangible Benefits

CHC
Company Charges Local Inhouse charges
Require 4 lids, 1 lid Annual cost
savings of
cost around 8000 rs, Rs. 24000/-
In house we made
4*8000.Around
total repair in 8000rs.
32000 price will be
for repair the CHC.
 25
Intangible Benefits

 Change in attitude of team members resulting in more flexibility.

Involvement of grass root workers in problem solving and

learnt a systematic method of problem solving.

Improved Teamwork & Motivation level.

Team got confidence in applying Kaizen concept.

 Kaizen Format
26
1.Result Areas Productivity Quality Cost Delivery Safety Morale
Kaizen No: ASS/079 Machine / Area : Semen Processing Lab
Kaizen Idea : To Identify an localised solution/In house for
Kaizen Theme: In house Repair of Cold Handling
Cost repair /Replacements for Proprietary Machine in Animal
Cabinet
Reproduction .

BEFORE AFTER
2. Problem (Previous Status) :
Frequent requirement for Cold Handling
cabinet repair and replacements which is
high costly affair

3. Root Cause Analysis (Why-Why)

Routine Handling / Usage of CHC in daily
operation of Processing of FSD Doses for
Equilibration.

4. Countermeasure: Identify Local in house

Repair for Cold Handling Cabinet . Team Members
Dr Sai Ravindranath Ramakrishnan R
Althaf Sheikh Basha Manoj Arora

6.Shop floor feedback / Benefits:

5. Result: Reduction in Replacement Cost and Ease of
Found an cost effective way to repair Replacement locally /In House
cold handling cabinet repair
Kaizen Start Date: 1-09-2021 Bench mark CHC Repair Locally 7- Scope & Horizontal Deployment : Informed other
Kaizen Finish Date:15-09-
Target CHC in Full Functional status Semen Station and being implemented
2021
27
Selection of the problem
28
 Freezing Racks
29

• Freezing racks are used for Arranging of FSD (Frozen Semen

Doses) straws for placement into cold handling cabinet
• The FSD straws are kept in racks inside CHC for equilibrium and
then it is taken to Bio Freezer for Deep Freezing to -196 degree C
• It facilitates easy and precise counting of the straws.
 Selection of the problem
30
Title: Resource Optimization in Semen Lab

Frequent
Breakdown
Quality of FSD
deteriorates Safety Hazard

Loss
Wastage of Time in Of
Selection
Repairing Of the Money due to
Problem frequent breakage
 31
Problem

In Semen Lab the Freezing Rack handle got damaged

as well as broken during its handling during semen
straw processing .
 32
Before

Broken Handle
 Analysis (Why-Why)
33
Why - Why
Breaking/Wearing out of handle of Freezing Racks
Why

Regular use leading to tear and worn out handle

Why

Routine high usage

Solution : In house repair of Freezing

Racks
 33
Counter Measures (Improvement)

• In house repair of Freezing Racks at Semen Station.

 34
Before
 35
After
In house Repair of Freezing Racks
 Improvement
37
Results and Tangible Benefits

Reduce Cost of Purchase of New Freezing Racks by in house repairing in

Semen Station .

 Annual Savings of Approx. Rs 146800

Annual cost
savings of
Rs. 146800/-.
(Approx.)
 Improvement
38
Results and Tangible Benefits

Freezing Racks
Annual cost
savings of
Company Charges In house Repair charges
Rs. 146800/-.
(Approx.)

16 racks was damaged. One new We repaired 16 racks in house with the
Freezing rack purchasing cost around cost of 1 rack being Rs 200, Total Rs
Rs 10000 = 16*10000. 3200 we have spent and repaired 16
Total Rs. 1,60,000 racks.
 39
Intangible Benefits

 Change in attitude of team members resulting in more flexibility.

Involvement of grass root workers in problem solving and

learnt a systematic method of problem solving.

Improved Teamwork & Motivation level.

Team got confidence in applying Kaizen.

 Kaizen Format
39
ALAMADHI SEMEN STATION
(A Unit of NDDB Dairy Services)
1.Result Areas Productivity Quality Cost Delivery Safety Morale
Kaizen No: ASS/080 Machine / Area : Semen Processing Lab
Kaizen Idea : To Identify an localised/In House solution for Cost
Kaizen Theme: Freezing Racks Replacement and
repair /Replacements for Proprietary Machine in Animal
Repair
Reproduction .
BEFORE AFTER
2. Problem (Previous Status) :Freezing Racks
getting damaged due to Routine Heavy
Usage .

3. Root Cause Analysis (Why-Why)

Excess usage and Handling

4. Countermeasure:
Find Localised/In house Fabrication for
Repair of Racks damage Team Members
Dr Sai Ravindranath Ramakrishnan R
Althaf Sheikh Basha Manoj Arora

5. Result: 6.Shop floor feedback / Benefits:

The Damaged Racks are put to use Immediate replacement of damaged Racks without
immediately. need to replacement from Proprietary services in Animal
Reproduction
Kaizen Start Date: 5-09-2021 Bench Repairs of Racks for Freezing
Kaizen Finish Date:20-09- Placement of Racks Adequately for Daily 7- Scope & Horizontal Deployment
2021 usage Informed other semen stations and being implemented .
40
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