Dept.

wise First level Karakui kaizens for president's Trophy competition
Sr. no 1 2

KARAKURI KAIZENS COMPETITION
Cyl. Head & cover material transfer for rocker shaft assembly. Energy saving on cam milling machine chip conveyor driven with machine slide Periscopic Karakuri for easy checking of Flushing activity & fallen components Compressed air generation by using dynomometer. Common automatic lubrication system for FRD head line by Karakuri

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16200 / Year. Spare conveyor is used in other dept.Electric motor driven link conveyor used for transfer of components from main conveyor to subassembly stage.Rs.Weight balance gravity conveyor is developed for component transfer. Schematic view of karakuri: AFTER:. Before After Cost calculation of karakuri: Manufacturing cost. Karakuri user’s feedback: New arm designed is useful for electricity saving . VILAS WADEKAR ANAND VARMA Description of mechanism of karakuri : BEFORE:. Rs. 1200 Benefits: 1) 2) Electricity used for motor driven conveyor is saved .KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Engine Assly Karakuri theme: Discover head & cover transfer from main conveyor to sub-assembly stage Karakuri functioning start date:17/06/08 Team members: 1) 2) 3) S S PACHPOR.

Before After .

KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Steel shop Karakuri theme: Energy saving on cam milling machine Chip conveyor driven with machine slide Karakuri functioning start date:18/05/08 Team members: 1) 2) 3) DILIP BORSE VILAS WADEKAR. S S PACHPOR Description of mechanism of karakuri : BEFORE:. Cost calculation of karakuri: Material Cost : RS 3100 .200 / year 2) Motor is spare for other function. AFTER:.A sprocket & chain arrangement provided between magnetic chip conveyor and Z axis.16. Karakuri user’s feedback: Good karakuri for electricity saving . Total Cost = Rs 4700 Benefits: 1) Energy cost is Saved by Rs..Separate motor to operate magnetic Schematic view of karakuri: Chip conveyor rotation through ‘Z’ axis slide movement chip conveyor. Labour Cost : RS 1600 .With the forward movement of Z axis magnetic conveyor operates to carry & push the chips in chip trolley.

Karakuri user’s feedback: 1) Inspection and monitoring made easy . when operator comes in front of periscope to observe. then light is operated by sensor i. 8640/ year. Sensor is fixed at front side of periscope. Total time saved 9600 min/year. Unsafe act eliminated.KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Paint shop ABS cell Karakuri functioning start date:12/05/08 Team members: 1) 2) 3) S.KULKARNI UMESH KUMBHAR S S PACHPOR Karakuri theme: Easy checking of Flushing activity in ABS cell by use of periscope Description of mechanism of karakuri : BEFORE:.Periscope is fixed at booth for easy visualization of flushing activity.Climb on a ladder up to first floor for checking of flushing activity in ABS cell AFTER:.e light operates when needed only. 3) 4) Labour cost saving of Rs. Schematic view of karakuri: Sensor fitted In front of periscope Periscope Cost calculation of karakuri: 1) 2) 3) Cost of pipe & mirror = Rs 1200 Labour cost = Rs 300 Total cost = Rs 1500 Benefits: 1) 2) Checking time reduced by 4 min/ occ. Also we can monitor fallen components in tunnel.H.

Schematic view of karakuri: AFTER:.External compressed air is supplied for operation of nut runners. TULSHIRAM KUMBHAR GANESH BADHE Description of mechanism of karakuri : BEFORE:.Rs 1200. Benefits: 1) 2) 3) With existing setup 0.Rs 1200 3) Total cost .PACHPOR VILAS WADEKAR.Compressed air is generated from dynomometer testing stage. 33.S.Compressor operates with belt drive connected to vehicle testing dynomometer shaft.KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Vehicle Assly Karakuri theme: Compressed air generation by using Dynomometer at Vehicle testing stage Karakuri functioning start date:16/06/08 Team members: 1) 2) 3) 4) S. Assembly work Cost calculation of karakuri: 1) Compressor reservoir unit – spare unit used 2) Labor cost .000/year Karakuri user’s feedback: Good kaizen for compressed air generation .525 Paise/ vehicle saved With enhance capacity of compressor and use on three lines projected saving = 3 paise / vehicle Total saving will be Rs.

Lubrication oil is supplied from common tank to 5 machine by pipe.S .PACHPOR TULSHIRAM KUMBHAR Schematic view of karakuri: Benefits: 1) 2) 3) 4) Manual oil filling activity eliminated.14168/ year Karakuri user’s feedback: Manual activity eliminated .Lubricating Oil filling manual activity which takes 3 mins/machine. 57mins/month time saved.(Rs 51/ month saved) Total labour cost saving Rs. Description of mechanism of karakuri : BEFORE:.KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Aluminum shop Karakuri theme: Automatic lubrication oil filling system for FRD head line by Karakuri.(1 nos) 2) Labour cost = Rs 500/Total = Rs 1500/Karakuri functioning start date:13/06/08 Team members: 1) 2) 3) 4) 5) SANDEEP CHATI GANESH KADAM KIRAN KALELE.Common oil tank is placed on height above the m/c top level. Floating knob is fixed on each machine for controlling oil level. S. AFTER:.616/year For all 115 machines labour cost saving = Rs. Cost calculation of karakuri: 1) Cost of material = Rs 1000/.

4500 3) Inverter cost . AFTER :. Karakuri user’s feedback: This is good karakui for electricity generation. 27800 Benefits: Total power cost saved = Rs 115. (On vehicle testing dynomometer.Rs 9000 .Rs.2 /day.Tube lights in inspection conveyor using state electricity. .KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Vehicle Assly Karakuri theme: Electricity generation by using Dynomometer Karakuri functioning start date: 10/06/08 Team members: 1) 2) 3) S S PACHPOR VILAS WADEKAR TULSHIRAM KUMBHAR CFL Lamps Description of mechanism of karakuri : BEFORE :. 2) Battery cost .Tube lights replaced by CFL & electricity generation by dyno rotation. alternator is fixed on dynomometer shaft.Rs.2 = Rs 34560/year. which is supplied to CFL Lamp on inspection conveyor.) Schematic view of karakuri: Previous lamp Dynomometer & battery Main switch Cost calculation of karakuri: 1) Dynomo /Alternator cost . = 300*115. 4500 4) CFL Lamps – Rs 8800 4) Labor cost .Rs.1000 TOTAL COST :. which generates electricity and stored into battery.Rs.

1) Inspection of belt. So electricity saving is Rs 115.Monthly PM Points :. Benefits :.ELECTRICITY GENERATION BY DYNOMOMETER Engineering Principal :. battery & invertor.Once in 6 months.0.Lamps replaced by CFL working with electricity supply by dynomometer through alternator .2 = Rs 34560/year.5 Volts .2 Per year = Rs 34560 After :.= 25600 Units Cost /Unit is = Rs 4. = 300*115.40 tube lights * 40W *16 Hrs.2 / day & Per year Rs 34560 Pay back period :.VEHICLE ASSEMBLY :.Electricity generation using dynomometer (Used for vehicle testing) Before :.9 Months (Karakuri cost Rs 27800) Sustenance :JH Points :.noise & vibrations – Monthly 2) Alternator voltage 12 +/.2 /day.Total cost saving on 3 conveyors will be Rs 34560*3 = Rs 103680 / Year .Total power cost saved = Rs 115.5 Total cost of power / Day = Rs 115.1) Battery charging current & Invertors voltage . With horizontal deployment on reaming 2 conveyors.

Time saved 4 sec. TULSHIRAM KUMBHAR Description of mechanism of karakuri : Before:-Operator has to rotate fixture of c'shaft trolley it takes 4 sec / occ.5500 Rs. VILAS WADEKAR.1200 Rs./ occ Total time saved 640 sec/ day Total cost saving on one conveyor = Rs.KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Engine Assly Karakuri theme: Use of gravity conveyor for auto rotation of crank shaft trolley. 17. to take c'shaft for assembly. Karakuri functioning start date: 15/6/08 Team members: 1) 2) 3) S S PACHPOR.600 /year Fatigue reduced & time saved Karakuri user’s feedback: . Schematic view of karakuri: Lower sloping point Cost calculation of karakuri: 1) Material cost . Benefits: 1) 2) 3) 4) Fatigue reduced. After:-New trolley designed in which fixture rotate automatically due to weight of c'shaft (due to Fulcrum & weight balance on c'shaft). 2) Labor cost .

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