My supervisxn txld me that team wxrk

depends xn the perfxrmance xf every

single persxn xf the team. I ignxred the
idea until my supervisxr shxwed me hxw
the xffice typewriter perfxrms when just
xne single key is xut xf xrder. All the xther
keys xn xur typewriter wxrks just fine
except xne, but that xne destrxys the
effectiveness xf the typewriter. Nxw I
knxw that even thxugh I am xnly xne
persxn, I am needed if the team is tx wxrk
as a successful team shxuld.
mao&o saup&vaa[ja& nao mauJao
batayaa ik TImavak- (ekjauT haok&
kama k&naa) h& ek vyai@t ko kama
p& inaBa-& hO.maOM [sa ivacaa& kI
Avaholanaa k&ta &ha jaba tk mao&o
saup&vaa[ja& nao mauJao yah nahIM
idKayaa ik Aa^ifsa Ta[-p&a[T& ]sa
samaya iksa t&h kama k&ta hO jaba
[sakI ek kuMjaI K&aba hao.isaf- ek
kao CaoD,k& hmaa&o Ta[-p&a[T& kI
baakI saba kuinjayaa^M zIk t&h kama
 Abnormality

Excessive wear

Breakdown Accidents

Rejections
Philosophy of Quality Maintenance

Machines can produce

defects and each
defect can be
prevented
Classification of Rejections

Three Categories…

A type

B type

C type
A

Operator takes
action in ‘A’
type rejection
B

Exact reason is
not known and
process becomes
OK by itself
C
Initial output is
NG and operator
action is required
Rejection tag
 Sona QUALITY MAINTENANCE PROCESS : FACING & CENTRING DEFECT TYPE A B C

KAIZEN TO ELIMINATE REJECTION DUE TO FACE

KAIZEN IDEA : PROVIDE ORIENTATION MECHANISM
THEME : DAMAGE DURING MILLING

PHYSICAL PHENOMENON BEFORE KAIZEN

PISTON ROD

CLAMP NOT TOUCHING

THE COMPONENT.
RADIAL DISPLACEMENT CLAMP NO ORIENTATION
OF CLAMP IN MECHANISM FOR
CLOCKWISE DIRECTION. CLAMP

COMP

ANALYSIS AFTER KAIZEN RESULTS

ACTION TAKEN BY OPERATOR : MOVED THE CLAMP IN
ANTICLOCKWISE DIRECTION ORIENTAION REJ DUE TO FACE DAMAGE
DURING MILLING
WHY-WHY ANALYSIS PIN
5

MOVED THE CLAMP IN ANTICLOCKWISE DIRECTION

Kaizen done on
4
12-03-03
CLAMP IS EASY TO MOVE
3
NO ORIENTATION MECHANISM FOR CLAMP

PROVIDED ORIENTATION PIN

FINAL ACTION : PROVIDED ORIENTATION MECHANISM. 0
NOV DEC JAN FEB MAR APR
 Sona QUALITY MAINTENANCE PROCESS : GEAR SHAPING DEFECT TYPE A B C

KAIZEN TO ELIMINATE REJECTION DUE TO POOR KAIZEN IDEA : STANDARDIZE RECONDITIONING FREQUENCY OF
THEME : FINISH CUTTER HEAD

PHYSICAL PHENOMENON BEFORE KAIZEN

CUTTER HEAD
RELATIVE RADIAL MOTION
BETWEEN COMPONENT &
CUTER HEAD DURING M/CING COPPER PLATE

HINGE BLOCK

CUTTER
COMPONENT

ANALYSIS AFTER KAIZEN RESULTS

REJ DUE TO POOR FINISH

4 Kaizen done on
27-01-03

STANDARDIZED RECONDITIONING 0
FINAL ACTION : RECONDITIONED CUTTER HEAD.
FREQUENCY. NOV DEC JAN FEB MAR APR
STANDARDIZED RECONDITIONING FREQUENCY.
 Sona QUALITY MAINTENANCE PROCESS : RACEWAY GRINDING DEFECT TYPE A B C

KAIZEN TO ELIMINATE REJECTION DUE TO

KAIZEN IDEA : FIXTURE DESIGN CHANGED
THEME : POSITION SHIFT

PHYSICAL PHENOMENON BEFORE KAIZEN

RACK TEETH BROACHING SHIFT

OFFSET BETWEEN CENTER LINE OF BALL NUT" XX" AND BROACH "YY"

X X
Y
Y

OFFSET
CHIIP

ANALYSIS AFTER KAIZEN RESULTS

ACTION TAKEN BY OPERATOR : REJECTION TREND

18
16 KAIZEN
16
IMPLIMENTED
27-2-03
14

12

10 9

QTY
8

RELIEVING 2
0 0
PROVIDED 0
FINAL ACTION : FIXTURE DESIGN CHANGED TO REDUCE JAN FEB MAR APR
THE POSSIBILITY OF CHIPS ACCUMULATION MONTHS
 Poka-yoke Sheet
Sona Koyo Steering Systems Ltd. Sona
PROBLEM : REJECTION DUE TO WRONG LOADING
BETWEEN CENTRES
SOLUTION : POKAYOKE PROVIDED TO PRE LOCATE THE CUSTOMER
SHUT DOWN
COMPONENT AT BOTTOM CENTRE PREVENT ERROR COMPLAINT

KEY IMPROVEMENT : IN-HOUSE REJECTION CONTROL ASSY REJECTION

DETECT ERROR ALARM PROCESS SCRAP

BEFORE AFTER
WRONG LOADING OF COMPONENT BETWEEN LOCTOR PROVIDED TO GUIDE THE COMPONENT O.D. TO
CENTRES (AS SHOWN IN SKETCH) AVOID WRONG LOADING.
UPPER CENTRE

COMPONENT

CUTTER

MECHANICAL
POKAYOKE
PROVIDED

LOWER CENTRE
 Sona QUALITY MAINTENANCE PROCESS : FACING & CENTRING DEFECT TYPE A B C

KAIZEN TO ELIMINATE REJECTION DUE TO FACE

KAIZEN IDEA : INCREASE CLAMP HEIGHT
THEME : DAMAGE DURING MILLING

PHYSICAL PHENOMENON BEFORE KAIZEN

PISTON ROD

CLAMP NOT
TOUCHING THE
COMPONENT. RADIAL CLAMP
DISPLACEMENT OF
CLAMP.

COMP

ANALYSIS AFTER KAIZEN RESULTS

ACTION TAKEN BY OPERATOR : MOVED CLAMP RADIALLY
REJ DUE TO FACE DAMAGE
DURING MILLING
WHY-WHY ANALYSIS
5
MOVED CLAMP RADIALLY PHOTO
Kaizen done on
4 12-09-03
CLAMP GOT DISTURBED

3
EASY TO MOVE

CLAMP DESIGN CHANGED

FINAL ACTION : INCREASED CLAMP HEIGHT HEIGHT OF CLAMP INCREASED TO GUIDE 0
MAY JUN JUL AUG SEP OCT
BY THE CYLINDER BRACKET
 Sona QUALITY MAINTENANCE PROCESS : GEARSHAPING DEFECT TYPE A B C

KAIZEN TO ELIMINATE REJECTION DUE TO WALL KAIZEN IDEA : TO PROVIDE DEDICATED DOG RAILS FOR DIFFERENT
THEME : THICKNESS LESS MODELS

PHYSICAL PHENOMENON BEFORE KAIZEN

E=F E=F D1 D2

COMMON DOG RAIL FOR

OMNI & GYPSY MODELS

LS1 LS2

OK NG

ANALYSIS RESULTS
ACTION TAKEN BY OPERATOR : MOVED DOG (D2) FORWARD
REJ DUE TO FACE DAMAGE
OMNI
DURING MILLING
5
WHY-WHY ANALYSIS
MOVED DOG FORWARD Kaizen done on
4 18-08-03
GYPSY
L/S NOT RELEASED AT FORWARD POSITION
3
DOG SETTING NG
2
MISJUDGEMENT IN DOG SETTING PROVIDED DIFFERENT DOG
RAILS FOR OMNI & GYPSY 1
MODELS

FINAL ACTION : PROVIDED DEDICATED DOG RAILS FOR 0

APR MAY JUN JUL AUG SEP OCT
DIFFERENT MODELS
 Poka-yoke Sheet
Sona Koyo Steering Systems Ltd. Sona
PROBLEM : REJECTION DUE TO WRONG LOADING
BETWEEN CENTRES
SOLUTION : POKAYOKE PROVIDED TO PRE LOCATE THE CUSTOMER
SHUT DOWN
COMPONENT AT BOTTOM CENTRE PREVENT ERROR COMPLAINT

KEY IMPROVEMENT : IN-HOUSE REJECTION CONTROL ASSY REJECTION

DETECT ERROR ALARM PROCESS SCRAP

BEFORE AFTER
WRONG LOADING OF COMPONENT BETWEEN LOCTOR PROVIDED TO GUIDE THE COMPONENT O.D. TO
CENTRES (AS SHOWN IN SKETCH) AVOID WRONG LOADING.
COMP
UPPER CENTRE

SUPPORT
V -BLOCK

COMPONENT

ROUGH
LOCATOR
PROVIDED
BOTTOM CENTRE
 Poka-yoke Sheet
Sona Koyo Steering Systems Ltd. Sona
PROBLEM : REJECTION DUE TO LOCK STRIP NOT PUT

SOLUTION : BRACKET DESIGN MODIFIED TO PROVIDED CUSTOMER

SHUT DOWN
MECHANICAL POKAYOKE PREVENT ERROR COMPLAINT

KEY IMPROVEMENT : IN-HOUSE REJECTION CONTROL ASSY REJECTION

DETECT ERROR ALARM PROCESS SCRAP

BEFORE AFTER
COMPONENT NOT CLAMPED BECAUSE OPERATOR DESIGN OF BRACKET MODIFIED TO LOCK UPWARD
FORGOT TO PUT BACK LOCK STRIP MOVEMENT OF PISTON ROD.
LOCK STRIP

PISTON ROD BRACKET

 Sona QUALITY MAINTENANCE PROCESS : Serration rolling DEFECT TYPE A B C

KAIZEN THEME : Eliminate rejection due to serration

KAIZEN IDEA : Provide setting master to set roll slide.
oversize in rolling.

Physical Phenomenon : Distance " x " between two rolls Before Kaizen
Photo / Sketch increases Photo / Sketch
Misjudgement in setting the distance 'X' between two rolls.

Analysis After Kaizen Result

Photo / Sketch
ACTION TAKEN BY OPERATOR : Moved the roll slide backwards REJ. DUE TO SERRATION U/S
WHY-WHY ANALYSIS
Rolls are brought forward and distance is set by Kaizen
2.5 implemented
SERRATION OVERSIZE touching rolls on setting master dt:5-10-02
2 2 2

2
DISTANCE 'X' IS MORE SETTING MASTER

1.5
MISJUDGEMENT IN ROLL SETTING
NO GO
1 1

0.5

0 0

May
Apr

Jun

Oct
Jul

Aug

Sep
FINAL ACTION : PROVIDE SETTING MASTER FOR SETTING ROLL
SLIDE GO
 Sona QUALITY MAINTENANCE PROCESS : Centring and Facing DEFECT TYPE A B C

KAIZEN THEME : Eliminate rejection due to run out more

KAIZEN IDEA : Rest pad design changed
than spec.

Physical Phenomenon : Distance "X" between two centre Before Kaizen

Photo / Sketch holes more Photo / Sketch

CHIPS ACCOMODATION
ON COUNTER HOLE

Analysis After Kaizen Result

Photo / Sketch REJ. DUE TO R/O MORE
ACTION TAKEN BY OPERATOR : Clean the chips THAN SEC.
WHY-WHY ANALYSIS
3.5
RUN OUT MORE THAN SPEC, ON OUTER DIAMETER
3 3
3 Kaizen
COMPONENT LIFTED FROM REST PAD DURING MACHINING implemented
2.5 Dated 10-9-02

2
ACCUMULATION OF CHIPS ON REST PAD
1.5
1 1 1
COUNTER HOLES ON THE TOP FACE OF REST PAD 1

0.5
0 0
FINAL ACTION : COUNTER HOLES PROVIDED AT THE BOTTOM OF 0
TAPPING HOLE PROVIDED IN

May
Apr

Jun

Jul

Aug

Sep

Oct
REST PAD.
REST PAD BOTTOM
 Sona QUALITY MAINTENANCE PROCESS : Serration hobbing. DEFECT TYPE A B C

KAIZEN THEME : Eliminate rejection due to center shift KAIZEN IDEA : Change the position of spring loaded portion (away from
more than spec. chips area).

Physical Phenomenon : Distance 'X' between component & Before Kaizen

Photo / Sketch locator should be zero. Photo / Sketch

Cutting being done

here

X Chips coming
here in fixture
Locator

Spring loaded portion here

Fixture assy movement direction

Analysis After Kaizen Result
Photo / Sketch
REJ. DUE TO CENTRE
ACTION TAKEN BY OPERATOR : Cleaned the chips from fixture
SHIFT MORE THAN SEC.

WHY-WHY ANALYSIS
3.5
RADIAL SHIFT MORE THAN SPEC.
3 3
3
CENTRAL TOOTH NOT LOCATED IN LOCATOR Kaizen implemented
2.5
Only locator is Dated 03-11-02
2
moved 2
LOCATOR STUCK (NOT MOVING UNDER SPRING ACTION)
1.5
1 1
CHIPS COME IN FIXTURE SPRING LOADED PORTION (SPRING LOADED 1
PORTION POSITIONED IN THE AREA OF CHIPS)
0.5
Spring loaded 0 0
FINAL ACTION : CHANGED POSITION OF SPRING LOADED PORTION ( 0
portion here

May

Oct
Jul

Aug

Sep
Apr

Jun
AWAY FROM CHIPS AREA ). Fixture is now fixed
 Sona QUALITY MAINTENANCE PROCESS : Thread rolling DEFECT TYPE A B C

KAIZEN THEME : Elimianate rejection due to thread

KAIZEN IDEA : Provide setting master to set the thread length
length less during changeover

Physical Phenomenon Before Kaizen

Photo / Sketch Photo / Sketch
End stopper set by judjment by operator Team members
End stopper
End stopper

QM TEAM RBS

This distance varies

3. Analysis After Kaizen Result

Photo / Sketch
ACTION TAKEN BY OPERATOR : Move the end stopper
Setting master provided to set thread length in rolling

THREAD LENGTH NG SETTING MASTER

REJ. DUE TO THREAD LENGTH NG
8
END STOPPER POSITION NG 7
7

NO. OF PIECES
END STOPPER SET BY JUDGMENT 5
4 4
4
3
3
NO PROVISION FOR SETTING END STOPPER
2

1
0
0
DEC. JAN. FEB. MAR. UPTO 14
MONTH-02 APR.

FINAL ACTION : PROVIDE SETTING MASTER FOR END STOPPER

 Sona QUALITY MAINTENANCE PROCESS : Milling machine DEFECT TYPE A C
KAIZEN THEME : To eliminate rejection due KAIZEN IDEA : Setting Master Start Date : 17/08/2004
to serration milling position wrong Finish Date : 24/09/2004
Physical Phenomenon
Difference 'D"
BEFORE KAIZEN AFTER KAIZEN
What to do ?
Comp. centre line 'A' Cutter See the setting master is tightened
Serration centre line 'B'

Comp.

How to do ?
Difference between Comp. Centre Manual
line 'A' and Serration centre line 'B

Fixture
No setting master

Analysis AFTER KAIZEN Result

A or C type : Final Action taken by Operator to correct Rejection due to Serration
milling position wrong
MOVED FIXTURE SLIDE INSIDE (AWAY FROM OP) 5

DIFFERENCE BETWEEN COMP CENTRE & TOOL CENTRE LINE 4

Kaizen done
SETTING DONE BY JUDGEMENT (VISUAL) on 24/09/04
3

Setting 1
I Did not do : 1
master
I DID NOT PROVIDE SETTING MASTER Provided setting master
0 0 0 0 0
0
APR MAY JUN JUL AUG SEP
Sona QUALITY MAINTENANCE Process : V-punching DEFECT TYPE B
KAIZEN THEME : To eliminate rejection due to V KAIZEN IDEA : Chips flushing Start Date : 05/09/2004
punch axis twist more than spec. Finish Date : 06/09/2004
Physical Phenomenon BEFORE KAIZEN AFTER KAIZEN
What to do ?
I will see there are no chips on locator

How to do ?
Visual
Daily
Angular difference between component centre line & V-punch axis
more than spec. Earlier, there were chances of chips accumulation
on tooth locator.
Analysis : B TYPE: AFTER KAIZEN Result
WHY O.K WHY NOT O.K
Rejection due to V-punch
axis twist more than spec
Clamping pr. As per spec Clamping pr. Low 5
Fixture tightened Fixture loose
Kaizen done
No chips at locator Chips at locator
4 on 26/09/04
V-punch holding rigid V-punch holding loose
No dents at fixture base Dents at fixture base
3

1
Now, we have provided auto flusing of chips by air
pressure. The chips do not accumulate. 0 0 0 0 0 0
0
APR MAY JUN JUL AUG SEP