What is waste ?
Waste is anything that increases the cost of production. Any activities
that does not increase value to the product and customer is waste, and
any methods that does not fit with our goals and objectives is waste.
Activities that
increase added value Anything that is
unnecessary motion,
(Mounting, cutting, Net work
welding, etc) obvious waste
achieved ( Waiting, correction, etc)
Work MUDA
O
Motion Activities that do not produce
added value, but are necessary
Incidental work R under the present conditions
(Part of “Muda”) K (Conveyance, returning of
empty boxes, inspection, etc)
Types of Waste
Identify and eliminate
3M
Muda Mura Muri
Any form of waste Un-level Unreasonable
in the process… workloads on burden on people
people or or machines…
machines
MUDA
1) Over Processing 5) Inventory
2) Over Transport
6) Over Motions
3) Defect/Rework
4) Waiting Time
7) Over Production
Stop 6 + 2 , 3D
STOP 6 + 2 3D
Actuator - A Big - B Car - C D- Dirty
D - Difficult
Drop- D Electrical - E Fire - F
D - Danger
G – Gillette( Cut related) H – Health
related(Workability)
Our Approach towards Waste
elimination
Brain Storming
Observations
Workplace Take Video Film Waste Write down the
selection waste waste
identification
START
Sustenance Prioritize
on Quality ,
Fatigue &
Time Saving
Action
Take again Implementation
Start closing
Video Film Check Benefits Short Term
Waste & Long Term
Basis
Activity Chart
May '14
Sr. no. Activity
2 3 5 6 7 8 9 10 12 13 14 15 16 17 19 20 21 22 23 24 26 27 28 29 30 31
P p
1 Work Place Selection
A a
P p p
2 Video film Shooting
A A A
P P P
3 Waste Observation
A a a
Brainstorming & Waste P p p p
4
Identification A a a a
P p
5 Priotization of Waste
A a
P p p p p p p p p p p p p p p p p p
6 Action Implementation
A a a a a a a a a a a a a a
P p p p p p p p p p p p p p p
7 Check Benefits
A a a a
Again Take Video film P p p p
8
Shooting A
P p p p
9 Monitering & Sustenance
A
Apr 6, 2022 6
Waste
Elimination
Apr 6, 2022 7
Selection of Workplace
Scope: SL90/DV Crankshaft Line
• New line establishment (Transferred from Pune)
• Conventional machining set up.
• Variety of models.
• Manual intervention is more.
• New Manpower
Apr 6, 2022 8
Video Observations
Apr 6, 2022 9
Identification Of Wastes & Categorization
Observations
No. of
Waste
Identification
Prioritization
Actions on the Basis of
Safety & Fatigue
Quality Priotization Of
Waste
Time Saving
Apr 6, 2022 11
P
Apr 6, 2022
12
Implementing Actions
on Waste Elimination
04/06/22
Over Motion
Before After
Operating control panel modified and
Bending action of Operator while
provided at operating height which
operating the control panel switch
reduced the operator over motion
Benefits – Operator over motion reduced by 4800 times per year.
14
04/06/22
Over Transportation
Before After
Operator walks 2 meters every time to
Operator walking distance reduced to
collect each balance wt. from storage
0.5 meter by providing conveyor.
to balance wt. assembly.
Benefits – Operator walking distance reduced by 60 km per year.
15
04/06/22
Defect
Before After
Operator interference required for model Operator interference reduced by
wise component torque selection, providing model wise selector switch
( Possibility of wrong program selection.) for respective program.
Benefits – Customer complaints eliminated.
(Before 6 nos. of customer complaints. After - Zero customer complaints) .
04/06/22 16
Over Processing
Before After
Balance weight assembly is difficult Extra material removed in m/c process
due to extra material on web. More resulting in easy assembly of balance
time required to grind extra material . weight.
Benefits – Time saved 9 min./ Component
04/06/22 17
Over Processing
Before After
Reaming operation added for oil holes
For surface finish improvement to
component at supplier end
Crankshaft oil hole polishing operation Process improvement done at supplier
was performed manually with special end.(Implemented reaming operation
tool (flexon). for oil hole)
Benefits – 240 sec time saved per component
04/06/22 18
Over Motion
Before After
Bending action of operator due to low
Work station height increased to
working height of station (Torqueing
eliminate bending action
Station)
Benefits -Operator over motion reduced by 4800 times per year
04/06/22 19
Over Transportation
Before After
For balancing of crankshaft ,operator walks 3 Operator walk completely eliminated
meters every time to start & stop spindle. (Needs
to ON & OFF 8 times for balancing one as ON /OFF push button provided near
component) by the operator
Benefits – Operator walking distance reduced by 115 km per year.
04/06/22 20
STOP 6+2 - Drop
Before After
Component loading in between centers
V-block provided on machine bed to
with crane .Possibility of component
avoid component drop.
drop on machine bed.
Benefits – Unsafe condition eliminated.
04/06/22 21
Over Motion
Before After
Operating control panel modified and
Bending action of Operator while
provided at operating height which
operating the control panel switch
reduced the operator over motion
Benefits – Operator over motion reduced by 900 times per year.
22
04/06/22
Observations
Actions on Wastes
No. of
Waste
Identification
Benefits
Sr. No. Activity No. Of Waste Closed Benefits.
1 Over Transport reduced 2 175 Km/year
2 Over Motion reduced 3 395 mins./year
3 Over Processing reduced 3 13 mins./component
4 Inventory reduced 0 0 Nos.
5 Defect reduced 2 Zero defect
6 3D Elimination 9 5 S score improvement
7 Waiting 1 16 mins./component
8 Stop 6+2 Elimination 3 Unsafe condition closed
Future Activities Planned
for Pending Activities
Apr 6, 2022 25
Action Plan for Pending Points
Waste Elimination
Pending Activity Plan
Apr 6, 2022 26
Future Activities Planned
for Pending Activities
Apr 6, 2022 27
Stop 6 + 2 , Cut Related
Present Process Proposed Process
Number marking is done manually.
SN Disadvantage Advantages
1 Chances of fingure injury during punching on Safe working /Zero injuries.
web.
2 More time consuming activity Less time consuming activity.
3 Manual mistakes can happen. Poka yoke for wrong punching
4 Traceability & identification is poor. Traceability & identification is improved, as
activity is done on machine.
Apr 6, 2022 28
Defect
Present Process Proposed Process
Size is checked by micrometer manually Size will be checked by auto sizing
gauge .
SN Disadvantage Advantages
1 Unsafe act during checking, as the Grinding Elimination of unsafe act & condition as auto
wheel is rotating. gauging is in contact while grinding operation.
2 Inconsistency in quality. Consistency in quality.
3 Rejection /scrap is more. Rejection/scrap will be eliminated.
4 Skilled operator required. Semi skilled operator can work.
Apr 6, 2022 29
3D - Difficult
Before After
Chip removing is done manually . Chip conveyor is required to collect chip
at one particular position.
SN Disadvantage Advantages
1 Unsafe condition. Safe working environment.
2 Poor 5S. Good 5S.
3 Time consuming activity. No wastage of time.
Apr 6, 2022 30
6 + 2 - Actuator
Present Process Proposed Process
Gear heating is done in Oven. Induction heating machine is required
for gear heating & small oven for
Deflector plate.
SN Disadvantage Advantages
1 Unsafe conditions during Gear loading & Safe working environment.
unloading.
2 More energy is consumed in present oven. Due to induction heating, less power is
consumed.
Apr 6, 2022 31
Thank You
