Date : 20/12/2010

Dept. : WELDING
KAIZEN SHEET Machine : TACK WELDING

Kaizen Theme : To increase productivity by reduce Wastage in Target Completion

(WHAT& WHICH) Welding process Date : 28/12/2010 Date : 27/12/2010

Counter measure : Benefits/Results after

Problem Status:
SMAW Process eliminated And Implementation :
Less Productivity in weld tacking
operation. GMAW(Co2 Gas) process introduced
for Tacking operation of all welding parts 1. Chipping operation eliminated.
wastage of Arc electrodes. 2. Manpower reduced.
More time consumption in changing Before Counter Measure :
3. Productivity increased to
electrodes. Extra Man power required 350 Nos / 8 Hrs
for chipping operation. 4.No fatigue on operator & Helper
Analysis : [Mention Statistical tools
Used / Why Why Analysis]
In SMAW welding it is not possible
to consumption of full electrode.
More time required for changing After counter measure :
electrode. (10 sec / 1 Electrode) Scope & plan for horizontal
Extra man & time require for deployment :
Sr Item Tgt.Dt Impl.Dt:
chipping process. In other Sister
Less production (200 Nos / 8 Hrs) concern 11/02/11
1 company
Root Cause : 2
SMAW process not suitable 3
4
for Mass production & to increase Standardization : 5
productivity. While designing welding process GMAW 6
Idea : 7
process to be used for mass production to
To increase productivity we have increase productivity.
to reduce waste by implementing
Implemented by : Krishna, Parmeshwar , Sharma. Kaizen no. : PM/KZ/001
atomization
 Date : 28/12/2010
Dept. : WELDING
KAIZEN SHEET Machine : WELDING M/Cs

Kaizen Theme : To increase productivity by reduce Wastage in Target Completion

(WHAT& WHICH) Welding process Date : 30/12/2010 Date : 30/12/2010

Counter measure : Benefits/Results after

Problem Status:
Co2 Gas banking system introduced for Implementation :
Less Productivity in full welding
Welding operation Co2 gas cylinder changing time
operation. More time consumption
in changing Co2 gas Cylinders. Before Counter Measure : reduced (2min/Cylinder)
More Co2 Gas consumption. Co2 gas consumption reduced
Unsafe Handling of Co2 cylinders (2 Cylinder/1Day).
1 manpower reduced.
Productivity increased to
Analysis : [Mention Statistical tools
200 Nos/8 Hrs
Used / Why Why Analysis]
No fatigue on operator and Helper
More time consumption for
changing co2 gas cylinders. After counter measure : Scope & plan for horizontal
(15 Min/ 1 Cylinder) deployment :
More gas consumption per machine
Sr Item Tgt.Dt Impl.Dt:
(1cylinder/1Day/ M/C) In other Sister
Less Productivity (100 Nos / 8 Hrs) concern 15/2/2011
1 company
Root Cause : 2
3
Co2 Gas cylinders using 4
for Individual welding M/C 5
Standardization : 6
Idea : To reduce time required for
While welding Co2 Gas bank system to be 7
changing Co2 cylinders by used for mass production to increase
Introducing Co2 gas Banking System productivity.
for productivity improvement &
Implemented by : Krishna, Shaikh , Chauhan. Kaizen no. : PM/KZ/00
avoid unsafe handling
 Date : 30/12/2010
Dept. : WELDING
KAIZEN SHEET Machine : WELDING M/Cs

Kaizen Theme : To increase productivity by eliminating Target Completion

(WHAT& WHICH) unnecessary movements of welders . Date : 04/01/2011 Date : 03/01/2011

Counter measure : Benefits/Results after

Problem Status:
Welding trolley modified to make space for Implementation :
Keeping loose parts & avoid waste movement
Less Productivity in Tack welding
Before Counter Measure : Cycle Time reduced: 100 Sec/1No
Operation due to unnecessary
movement during taking of child
Parts and welding torch movement Productivity increased to
270 Nos/8 Hrs
Analysis : [Mention Statistical tools
No fatigue on operator.
Used / Why Why Analysis]
Unnecessary waste movements for
taking child parts for tacking.
After counter measure : Scope & plan for horizontal
More Cycle Time for Tacking i.e, deployment :
111.7Sec/1 No Job
Less Productivity (242 Nos /8 Hrs) Sr Item Tgt.Dt Impl.Dt:
1 0118 CM 15/2/2011
Root Cause : 2 0107 CM 18/02/2011
3
No arrangement provided to keep 4
nut plate & welding torch in 5
welding trolley. 6
Standardization : 7

Idea : While welding all welding trolleys to be

Increase productivity by making provide necessary arrangements for user
arrangements to welding trolley for friendly requirements.
keeping parts & welding torch Implemented by : Rajesh, Parmeshwar. Kaizen no. : PM/KZ/00