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
1 Over Transport reduced
2 Over Motion reduced
3 Over Processing reduced
4 Inventory reduced
5 Defect reduced
6 3D Elimination
7 Waiting
8 Stop 6+2 Elimination
No. Of Waste Closed Benefits.
2 175 Km/year
3 395 mins./year
3 13 mins./component
0 0 Nos.
2 Zero defect
9 5 S score improvement
1 16 mins./component
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