Kaizen No.

- 0054 Result : Productivity improvement, Manpower

Deptt.: -Assembly (Assy) saving, Space saving, Energy saving, Two MAR'11
fixtures eliminated
Theme : Manpower Saving & Productivity improvement Process : Body insert assy + Terminal insertion + Greasing
1. Manpower, Man-hour
Before Improvement After Improvement Saving
√
( Photo or Explanation Drawing ) ( Photo or Explanation Drawing ) 2. Physical Distribution
(Transporting distance)
√
WORK FLOW BODY TERMINAL GREASING 3. Space saving √
Body insert
INSERT ASSY. (3)
Assy Punch 4. Commanisation,
ASSY (2) √
(1) unification
Terminal Assy
Punch 5. Weight reduction

6. Energy Saving √
7. Yield

8. Quality improvement √
9. 5S √
GREASING
Auto 10. Cost Reduction √
Greasing
11. Safety √
12. Horizontal Application √
13. Others

Three processes is done at separate stations by three Three processes merge into single process with auto
operators 1) ejection and transported to next process by single Cost Saving /year- Rs. 215820/-
Body Insert Assy. operator & station
2) Terminal Assy. Date of
26-03-2011
3) Greasing Implementation
WHY-WHY ANALYSIS HORIZONTAL DEPLOYMENT
1) S01062-000 DLS(Batch Marking & Body Insert assy.) Production
Delivery Failure Line Capacity Constraint Suggested by
Deptt
(Customer Demand Increased) More Man Power used 2) Plan made for S02001 BLS(Stamping & Caulcking)

Quality
BENEFITS:- PRODUCTIVITY IMPROVED & TWO MAN POWER SAVED Approved By
(Manager)