You are on page 1of 10

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

3 4 5

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, VILAS WADEKAR ANAND VARMA

Description of mechanism of karakuri :


BEFORE:- Electric motor driven link conveyor used for transfer of components from main conveyor to subassembly stage.

Schematic view of karakuri:

AFTER:- Weight balance gravity conveyor is developed for component transfer.


Before After

Cost calculation of karakuri: Manufacturing cost- Rs. 1200

Benefits:
1) 2) Electricity used for motor driven conveyor is saved . Rs. 16200 / Year. Spare conveyor is used in other dept.

Karakuri users feedback: New arm designed is useful for electricity saving

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:- Separate motor to operate magnetic

Schematic view of karakuri:


Chip conveyor rotation through Z axis slide movement

chip conveyor.

AFTER:- A sprocket & chain arrangement

provided between magnetic chip conveyor and Z axis.With the forward movement of Z axis magnetic conveyor operates to carry & push the chips in chip trolley.

Cost calculation of karakuri: Material Cost : RS 3100 . Labour Cost : RS 1600 . Total Cost = Rs 4700

Benefits: 1) Energy cost is Saved by Rs..16,200 / year 2) Motor is spare for other function.

Karakuri users feedback: Good karakuri for electricity saving

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.H.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:- Climb on a ladder up to first floor for checking of flushing activity in ABS cell
AFTER:- Periscope is fixed at booth for easy visualization of flushing activity. Also we can monitor fallen components in tunnel. Sensor is fixed at front side of periscope, when operator comes in front of periscope to observe, then light is operated by sensor i.e light operates when needed only.

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. Total time saved 9600 min/year.

3) 4)

Labour cost saving of Rs. 8640/ year. Unsafe act eliminated.

Karakuri users feedback: 1) Inspection and monitoring made easy

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.S.PACHPOR VILAS WADEKAR, TULSHIRAM KUMBHAR GANESH BADHE

Description of mechanism of karakuri :


BEFORE:- External compressed air is supplied for operation of nut runners.

Schematic view of karakuri:

AFTER:- Compressed air is generated from dynomometer testing stage.Compressor operates with belt drive connected to vehicle testing dynomometer shaft.

Assembly work

Cost calculation of karakuri:


1) Compressor reservoir unit spare unit used 2) Labor cost - Rs 1200 3) Total cost - Rs 1200.

Benefits:
1) 2)
3)

With existing setup 0.525 Paise/ vehicle saved With enhance capacity of compressor and use on three lines projected saving = 3 paise / vehicle Total saving will be Rs. 33,000/year

Karakuri users feedback:

Good kaizen for compressed air generation

KARAKURI KAIZEN SHEET Plant: BAL Chakan Shop + Cell: Aluminum shop Karakuri theme: Automatic lubrication oil filling system for FRD head line by Karakuri. Description of mechanism of karakuri : BEFORE:- Lubricating Oil filling manual activity which takes 3 mins/machine. AFTER:- Common oil tank is placed on height above the m/c top level. Lubrication oil is supplied from common tank to 5 machine by pipe. Floating knob is fixed on each machine for controlling oil level. Cost calculation of karakuri: 1) Cost of material = Rs 1000/- (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. S.S .PACHPOR TULSHIRAM KUMBHAR

Schematic view of karakuri:

Benefits:
1) 2) 3) 4) Manual oil filling activity eliminated. 57mins/month time saved.(Rs 51/ month saved) Total labour cost saving Rs.616/year For all 115 machines labour cost saving = Rs.14168/ year

Karakuri users feedback: Manual activity eliminated

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 :- Tube lights in inspection conveyor using state electricity. AFTER :- Tube lights replaced by CFL & electricity generation by dyno rotation. (On vehicle testing dynomometer, alternator is fixed on dynomometer shaft, which generates electricity and stored into battery, 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 - Rs 9000 . 2) Battery cost - Rs.4500 3) Inverter cost - Rs. 4500 4) CFL Lamps Rs 8800 4) Labor cost - Rs.1000 TOTAL COST :- Rs. 27800

Benefits:
Total power cost saved = Rs 115.2 /day. = 300*115.2 = Rs 34560/year.

Karakuri users feedback: This is good karakui for electricity generation.

VEHICLE ASSEMBLY :- ELECTRICITY GENERATION BY DYNOMOMETER Engineering Principal :- Electricity generation using dynomometer (Used for vehicle testing) Before :- 40 tube lights * 40W *16 Hrs.= 25600 Units
Cost /Unit is = Rs 4.5 Total cost of power / Day = Rs 115.2 Per year = Rs 34560

After :- Lamps replaced by CFL working with electricity supply by dynomometer through alternator ,
battery & invertor. So electricity saving is Rs 115.2 / day & Per year Rs 34560

Pay back period :- 9 Months (Karakuri cost Rs 27800) Sustenance :JH Points :- 1) Inspection of belt,noise & vibrations Monthly
2) Alternator voltage 12 +/- 0.5 Volts - Monthly

PM Points :- 1) Battery charging current & Invertors voltage .Once in 6 months.


Benefits :- Total power cost saved = Rs 115.2 /day. = 300*115.2 = Rs 34560/year.
With horizontal deployment on reaming 2 conveyors.Total cost saving on 3 conveyors will be Rs 34560*3 = Rs 103680 / Year

KARAKURI KAIZEN SHEET


Plant: BAL Chakan Shop + Cell: Engine Assly Karakuri theme:
Use of gravity conveyor for auto rotation of crank shaft trolley.

Karakuri functioning start date: 15/6/08 Team members:


1) 2) 3) S S PACHPOR, VILAS WADEKAR, TULSHIRAM KUMBHAR

Description of mechanism of karakuri :


Before:-Operator has to rotate fixture of c'shaft trolley it takes 4 sec / occ. to take c'shaft for assembly. After:-New trolley designed in which fixture rotate automatically due to weight of c'shaft (due to Fulcrum & weight balance on c'shaft).

Schematic view of karakuri:

Lower sloping point

Cost calculation of karakuri:


1) Material cost - 5500 Rs. 2) Labor cost - 1200 Rs.

Benefits:
1) 2) 3) 4) Fatigue reduced. Time saved 4 sec./ occ Total time saved 640 sec/ day Total cost saving on one conveyor = Rs. 17,600 /year

Fatigue reduced & time saved Karakuri users feedback: