KAIZEN

TRAY PROVIDED AT BOTTOM OF THE M/C 01

Date : 30/09/2016

BEFORE
Previously, there was no tray at the bottom
of the machine, which caused to oil &
coolant spillage issue at the machine
surrounding.
AFTER
Presently, separate tray provided at
the bottom of the machine to avoid
the spillage issue at work station.

Benefits : 1) House keeping Improved at work station 2) Spillage issue reduced

Person Done : PRESS SHOP TEAM Dept : PRODN.

SLP/CIF/F/02
 KAIZEN
MATERIAL HOLDING TRAY PROVIDED ON M/C 02
Date : 01/10/2016

BEFORE
Previously, flat paper was provided for
keeping the input material on spot welding
machine, which caused to material falling
issue and more time consumed during
lifting material due mix-up issue
AFTER
Presently, separate material holding
tray provided on each spot welding
machine ( 3) to avoid material falling
issue as well mix-up issue eliminated

Benefits : 1) Mix-up issue (head & tell) eliminated 2) Material Falling issue on shop floor 3) Work efficiency
improver (Earlier Production Qty / shift : 3300 Nos. Presently : Production Qty / Shift : 3500 Nos.

Person Done : PRESS SHOP TEAM Dept : PRODN.

 KAIZEN
CAP PROVIDED TO THE WORKMEN 03
Date : 01/10/2016

BEFORE AFTER
Earlier, there was no hair guard cap Presently, hair guard cap provided
provided to the workmen, which caused to
hair contamination issue found in material.
to the workmen.

Benefits : 1) Mix-up issue (head & tell) eliminated 2) Material Falling issue on shop floor 3) Work efficiency
improver (Earlier Production Qty / shift : 3300 Nos. Presently : Production Qty / Shift : 3500 Nos.

Person Done : MOULDING TEAM Dept : PRODN.

 KAIZEN

BURR REMOVING EQUIPMENT INSTALLED 04

ON COIL STRAITNER M/C Date : 08/10/2016

BEFORE AFTER
Previously, burr removing process was done Presently, burr removing process is
additionally in separate machine, which done simultaneously in single
caused to increased the processing cost.
machine by using the coil straiter
equipment.

Benefits : 1) Processing cost reduced ( one man power eliminated/shift) (4 x 300 )= 1200 1200x24= Rs. 28800 saved month
2) Work efficiency improved 3) Work process improved

Person Done : PRESS SHOP TEAM Dept : PRODN.

 KAIZEN
05
VISUAL MANAGEMENT DONE IN QC OFFICE
Date : 08/10/2016

BEFORE AFTER
Previously, the floor layouts and Presently , the identification on
identification on electrical switches were switches as well as office layout has
not done in QA office area, which caused
been done.
to poor visual management as well as less
space issue observed.

Benefits : 1) Visual Management improved. 1) House keeping improved 3) Work area improved

Person Done : QA TEAM Dept : QA

 KAIZEN
DAILY DEPARTMENTAL MORNING MEETING 06
INTIATED IN QC OFFICE Date : 08/10/2016

BEFORE AFTER
Previously, no departmental meeting was Presently , daily departmental morning meeting is
started with all QA team members. Its help to
conducted in plant. communicate and evaluate the major rejection of
individual areas in plant

The corrective action and target date is planned /

recorded in daily morning meeting register for
tracking & closing of each issues.

Benefits : 1) Work Culture improved 2) information flow faster 3) Team sprit improved
Person Done : QA TEAM Dept : QA
 KAIZEN

SOFTWARE UPGRADED FOR LASER MARKING 07

Date : 25/11/2016

BEFORE
Serial numbers for security seal (example :
SL06107696) and Barcode numbers (||||||||)
were feeded separately (two times) in SG
software during the re-laser marking of defective
security seals.
AFTER
Presently, Serial numbers for
security seal and Barcode numbers
are feeding simultaneously in SG
software during the re-laser marking
of defective security seals.

Serial Number

Barcode Number

Serial Number & Barcode numbers are

feeding simultaneously.

Benefits : 1) Manual error during the re-typing is eliminated 2) Time saved 3) Work Process Improved

Dept : PRODN – LASER MARKING

 KAIZEN

METAL GUARD PROVIDED AT THE CURING 08

OVEN BOTH SIDE GATE Date : 20/12/2015

BEFORE AFTER
Previously, no guard provided at the curing Presently, separate guards are
oven both side gate, which caused to heat provided at the curing oven both side
loss issue as well as more humidity
gates.
occurred during the powder coating
process.

Benefits : 1) Heat Loss reduced 2) Humidity reduced 3) Electricity saved 4) Safety improved

Person Done : POWDER COATING TEAM Dept : PRODN - COATING

 09
KAIZEN

CABLE HOLDING CHANNEL PROVIDED ON GUN STAND

Date : 21/12/2016

BEFORE AFTER
Previously, no cable holding channel was Presently, cable holding channel is
provided on gun stand machine, which provided on gun stand machine.
caused to powder pipe breakage issue as
uneven coating thickness occurred during
running the machine.

Benefits : 1) Powder Pipe breakage issue eliminated 2) Uneven coating thickness reduced
3) Work process improved

Person Done : POWDER COATING TEAM Dept : PRODN - COATING

 KAIZEN

STOPPER PROVIDED AT THE BOTTOM OF 10

GUN STAND M/c Date : 21/12/2016

BEFORE AFTER
Previously, no stopper was provided at the Presently, separate stopper is
bottom of gun stand, caused to product provided at the bottom of gun stand.
quality issue such as uneven coating
thickness and safety concern due to
vibration problem.

Benefits : 1) Safety Improved 2) Product quality Improved.

Person Done : POWDER COATING TEAM Dept : PRODN - COATING

 KAIZEN

SLOT PROVIDED ON HANGING TABLE 11

Date : 25/12/2016

BEFORE AFTER
Previously, no slot was provided on Presently, slot was provided on
hanging table, which caused to wire hanging table.
tightening issue during the metal tie
hanging in powder coating frame.

Benefits : 1) Work method Improved 2) Productivity improved

Person Done : POWDER COATING TEAM Dept : PRODN - COATING

 KAIZEN
STAND FOR 12
HAZARDOUS AND NON-HAZARDOUS COLLECTION INSIDE THE PLANT
Date : 05/01/2017

BEFORE AFTER
Earlier, Hazardous & Non Hazardous
Presently, Hazardous & Non Hazardous
materials were collected in small sizes of
waste materials collection method is
used scarp drums . which caused to stores
standardized.
problem and waste materials collection
method was not standardized

Benefits : 1) Hazardous & Non Hazardous waste materials collections method

standardized 2) Awareness level improved 4) Employee moral will be improved.

Dept : PRODN. & HR.

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13
LIFT SAFETY IMPROVED
Date : 10/01/2017

BEFORE AFTER
Earlier, Limit switch was not working Limit switch repaired
properly, which caused to major safety
concern.

Benefits : 1) Human Safety Improved

Dept : Maintenance
 KAIZEN
HANGING TUB LIGHT REQUIRED ON INSPECTION TABLE 14
FOR VISUAL INSPECTION
Date : 20/01/2017

BEFORE AFTER
Presently, tub lights are fitted on roof of the
Packing & Assembly area and lux level is very less
as required for visual inspection of FG material, Need to be installed
which may caused to escape OF material with
Flash and black spot to customer end. Hanging Chain Details :

Chain required Height Each = 180 cm

first WE NEED TO IMPLEMENT on 4 inspection table
Total Chain length required for each set = 180x4 cm
=720 cm

Total 4 sets required = 720x4 cm = 2880 cm

Benefits : 1) Defective material can visible easily 2) Work efficiency will be improved 3)
Employee moral will be improved.
Dept : PRODN. (PACKING & ASSEMBLY SECTION)
 KAIZEN
PLASTIC CARATES WITH TOP COVER REQUIRED 15
Date : 20/01/2017

BEFORE AFTER
Presently, there is no top cover on caret , which
caused to black spot & dust issue observed
during production in nature nylon cable ties.
Need to be implemented

Benefits : 1) DUST & BLACK SPOT WILL BE REDUCED

Dept : PRODN. (INJECTION MOULDING)

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16
TEMPERATURE AND HUMIDITY PROVIDED IN R.M. STORE
Date : 20/01/2017

BEFORE AFTER
In Raw material storage area temperature Temperature and humidity monitoring
and humidity monitoring is not sheet displayed at RM store & same is
checked/followed. Ref: Raw material store monitored on daily basis

Benefits : 1)

Dept : Store
 KAIZEN
17
RACK WISE IDENTIFICATION DONE AT SFG STORE
Date : 23/01/2017

BEFORE AFTER
Earlier, there is no rack wise Rack wise identification done at SFG
identification done in SFG store store

Benefits : 1) 5S improved

Dept : Store
 KAIZEN
MATERIAL SHORTING & IDENTIFICATION DONE 18
IN SFG STORE Date : 24/01/2017

BEFORE AFTER
Grinding & other materials were lying at 5S improved
SFG stores in mix-up condition, which
caused to poor 5s

Benefits : 1) 5s improved 2) FIFO IMPROVED

Dept.: Stores
 KAIZEN
19
5S IMPLEMENTED IN MAINTENANCE STORES
Date : 25/01/2017

BEFORE
In maintenance storage area 3C-5S found worst condition
E.g : Thunder hose, gasket roll, wires ,tube light panel are
kept in the shop floor without any proper arrangement/
storage location
AFTER
5S implemented in stores.
Small spares will be kept on rack and large sizes of spares
like gasket sheet, house will be kept separately in other
location, because of space concern issue

Benefits : 1)

Dept : Maintenance
 KAIZEN
20
SEPARATE CHECK SHEET IS MAINTAINED FOR CLEANING THE CCS BLOWER
SYSTEM ON WEEKLY BASIS
Date : 25/01/2017

BEFORE AFTER
In central conveying system ,filters are cleaned on Separate check sheet is maintained for cleaning
weekly basis for the effective maintenance but the CCS blower system on weekly basis.
there is no monitoring check sheet for the CCS
cleaning activity. Suggest to review this Ref: suction
filter , Dust collecting bag etc.

Benefits : 1)

Dept : Production (Moulding)

 KAIZEN
21
PLASTIC COVER MADE FOR MOULDS COVERING TO AVOID DUST
Date : 25/01/2017

BEFORE AFTER
Molds are found dust and are not covered by Plastic cover made for Moulds covering to avoid
the mold cover, possibility of dust dust
accumulation Ref: Mold storage area

Benefits : 1) Dust accumulation prevent may improve the life of mould. 2) 5S improved

Dept : Production (Moulding)

 KAIZEN
22
CABLE ROUTING WAS OK , ONLY THE MCB COVER WAS OPENED PARTIALLY AND
ITS RECTIFIED IMMEDIATELY
Date : 25/01/2017

BEFORE
Cable routing and main switch panel for
elevator found improper and open
condition. Possibility of safety issue Ref:
Elevator main switch
AFTER
Cable routing was OK , only the MCB cover was
opened partially and its rectified immediately

Benefits : 1) Safety Improved 2) 5S Improved

Dept : Production (Moulding)

 KAIZEN
23
HDPE FLAP PROVIDED INSIDE THE HOPPER TO AVOID SUCH ISSUE IN FUTURE
Date : 25/01/2017

BEFORE AFTER
n regrinding machine some of the grinded material HDPE flap provided inside the hopper to avoid
chips are coming out of the machine with high such issue in future
force , chance of hitting the grinding operator eyes,
suggest to review this Ref: IM09 FM-350(2)

Benefits : 1) Human Safety Improved 2) 5s Improved

Dept : Production (Moulding)

 KAIZEN
24
FIRE EXTINGUISHER MONITORING WILL BE DONE ON MONTHLY BASIS
Date : 25/01/2017

BEFORE AFTER
Fire extinguisher installed in the shop floor area Fire Extinguisher monitoring will be done
are not monitored , possibility of safety issue. on monthly basis
suggest to monitor in monthly basis

Latest
Photo
to be
paste
d

Benefits : 1)

Dept : Over Plant

 KAIZEN
25
PROCESS WISE INTERNAL REJECTION MONITORING DONE
Date : 25/01/2017

BEFORE AFTER
During final inspection non conformance parts kept in Process wise internal rejection monitoring
rejection bin are not covered /updated in the final
inspection check sheet/report and their corresponding done
analysis for rejections were not evidenced , suggest to
review this

Benefits : 1) System Improved

Dept : Production (Moulding)

 KAIZEN
26
PROCESS WISE INTERNAL REJECTION MONITORING DONE
Date : 25/01/2017

BEFORE AFTER
In final inspection area drying, inspecting, packing and
weighing activities are carried out in different stations and
Improvement
found no process sequence flow and also many band cables in
shop floor, possibility of material mix up, suggest to provide
separate process flow for each type band cable

Benefits : 1) Layout 2) Material flow improved

Dept : Production (Moulding)

 KAIZEN
STAIR PROVIDED AT FRONT ENTERNACE OF FG MATERIAL
RECEIVING GATE & OTHER AREAS.
27
Date : 25/01/2017

BEFORE AFTER
Earlier, there was no staircase at FG Presently, stair case provided at each area
material receiving gate, near to the
canteen & moisturisation area, which
caused to delayed in material movement
from one location to another location.

Near to the
Entrance of FG moisturisation exit area.
store

FG material Receiving
FG Material despatch
area near lift
area near canteen.

Benefits : 1) Muda (Waste) reduced due to delayed in material movement 2) Safety

improved.

Dept.: Production
 KAIZEN
5S IMPROVED IN MAINTENANCE STORE INSIDE FG AREA 28
Date : 25/01/2017

BEFORE AFTER
Wires and other repairing parts /
accessories laying in maintenance store
near FG store poor arrangement. Need
improvement

Benefits : 1) 5S IMPROVED, 2) SEARCHING TIME REDUCED 3) WORK PLACE IMPROVED

Dept.: Maintenance
 KAIZEN
FIFO STAND TO BE USED IN RM STORE
29
Date : 25/01/2017

BEFORE
Presently, we are using vertical stand
as baricate for painting of shop floor.
AFTER
After completion of painting works, same
stand will be used for FIFO system as “USE
ME FIRST”, USE ME SECOND & USE ME
THIRD, just adding the horizontal plate at
top. Refer the below image

Benefits : 1) 5S IMPROVED, 2) WORK PLACE IMPROVED

Dept.: RM Store
 KAIZEN
CENTRALIZED CONVEING SYSTEM NOT SEPARATALY 30
IDENTIFY Date : 25/01/2017

BEFORE AFTER

E D
NT
E
LEM
MP
E I
B
TO
Benefits : 1)

Dept.: Production (Moulding)

 KAIZEN
CENTRALIZED CONVEING SYSTEM HOPPERS NOT 31
SEPARATALY IDENTIFY Date : 25/01/2017

BEFORE AFTER

E D
NT
E
LEM
MP
E I
B
TO
Benefits : 1)

Dept.: Production (Moulding)

 KAIZEN
COOLING WATER SYSTEM PIPES (IN & OUT) NOT 32
SEPARATALY IDENTIFY Date : 25/01/2017

BEFORE AFTER

E D
NT
E
LEM
MP
E I
B
TO
Benefits : 1)

Dept.: Production (Moulding)

 KAIZEN
GRINDED MATERIALS FALL DOWN (UNDER THE GRINDING 33
M/C WHILE GRINDING Date : 25/01/2017

BEFORE AFTER

E D
NT
E
LEM
MP
E I
B
TO
Benefits : 1)

Dept.: Production (Moulding)