KAIZEN - SHEET

SKF India Ltd

Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:

Elimination of HIT caging defect
Problem / Present Status:

Before Improvement:

Improper rivetting Bearings found at

MGO.

Analysis:

After improvement:

Whenever hydropneumatic cylinder oil

lvevel goes low 2nd pressure (high)
pressing not taking place, leading to
generation of defective bearing. There was
no oil level indicator, a sensor is provided
on the piston end, if the oil level
decreases, the sensor gets ON and Red
lamp glows, whenever red lamp glows
operator will get the oil filled and
prevented defect generation.
Root Cause:
Idea:
Counter measure:

There is no oil level incicator in the cylinder by design,

To detect the oil by capturing the position of piston displacement
Sensor fitted with Red lamp inciction to alert the operator to fill the oil

Unit

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ETW

QM

Year
2010

SL.NO
001/QM/DGBB/2010

Machine No: HIT 1A and HIT 1B

Team members:
Arunkumar, H Nagaraj, K N Jayakumar, Banuprakash
Result / Benefit:

Defect due to low oil level or pressure not

found from Dec 26th 2009
Kaizen type:
If reversible update in:

Reversible

Ir-reversible

Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing New machines coming to channel must have this
feature built in.

SL No
1

Scope & plan for horizontal deployment

M/C NO
Target date Responsibilty status
HIT1B Jan 2nd 2010
Arun
Completed

Poka Yoke Type & Function

Prevention
Detection

Shutdown
Control
Warning

KAIZEN - SHEET
SKF India Ltd
Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:

To eliminate customer complaint
Introduction of accumulator for uniform spray of preservative oil
Problem / Present Status:
Before Improvement:
Excess preservative spray on bearing, non uniformity of
spray (1 Customer concern from BOSCH)

DIAPRAGM PUMP

NOZZLE

OIL TANK

REGULATOR

Analysis:
Why 1 : Why customer concern ?
Excess preservative spray on bearing
Why 2 : Why excess spray?
Oil spray through regulator non uniform
Why 3 : Why spray is non uniform?
Pressure drop at regulator

Root Cause:
Idea:
Counter measure:

After improvement:

DIAPRAGM PUMP

OIL TANK

Pressure drop at regulator

Introduction of accumulator for uniform spray of preervative oil
Provide accumulator to eliminate the pressure drop at regulator

REGULATOR

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QM

SL.NO

Year
2010

Machine No: TOS - Ch 01

Team members: C Ravi , MM Jaikumar
Result / Benefit:
Uniform spray of preservative through regulator

NOZZLE

Before

After

Std. Dev = 0.46

Kaizen type:
Reversible
If reversible update in:
NOZZLE

Std. Dev = 0.16

Ir-reversible

Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing
Scope & plan for horizontal deployment
SL No
M/C NO
Target date Responsibilty
status

REGULATOR

Poka Yoke Type & Function

Prevention
Detection

Shutdown
Control
Warning

KAIZEN - SHEET
SKF India Ltd
Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:Zero Defect/ Zero Breakdowns/ Zero Accidents

Avoid Defect Generation at heat treatment / Operator Safety / Efficiency Improvement in Channels
Problem / Present Status:

Before Improvement:

1)Loss in Channel Effeciency

2)Finger probe damage
3)Downtime at Channel
4)Break downs at Channel
5)Operator morale too low at HT
6)Unsafe condition for pushing of rings
7)Stagnation of rings at HT
AFTER IMPROVEMENT

1)Space constrains for pushing rings2)High Temperature at the entrance of furnace operator inconvenience.
3)Pusher getting heated up,while removing pusher
from furnace.
4)Manual pushing leads to improper orientation of
pusher which results in ring stagnation at hardening
chute.
5)Clearing of rings at the hardening chute varies from

Before
Analysis:

After improvement:

Problem:Ring mixup in Hoppers leading to

production loss & downtime at Channels.
1) Rings not being pushed after running type in
hardening zone during changeover.Rings
stagnating on hardening chute
2)Pusher
which is being used is not user friendly. No
space for movement.Rings not getting cleared
at Hardening Chute exit.
3)Pusher
becomes hot when it is in use.Area for pushing
is too hot for operator to perform the
process.Difficult to hold pusher
4)Manual intervention at the hardening
entrance leads to improper holding of pusher &
pushing of rings.Pusher becomes very hot
when it enters the furnace.
5)No other method of pushing available.
Root Cause:
Idea:

Action:Pusher modification.
1)More surface
area created for pushing rings2)Pushing can now be done easily
3)Pusher getting heated up,while removing pusher
from furnace.But handling is easy
4)Orientation of pusher is now fixed.Does not vary
from one operator to the other.
5)Stagnation of rings elliminated.

Why Why analysis attatched

Avoid breakdowns/ Increase in Effeciency/ Avoid defect generation

Counter measure:

Sustaining the pusher mechanism for unifrom pushing of ring.

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QM

Year
2010

SL.NO
05 & 06

Machine No: Furnace 01 ,02 & 04

Team members:V. Saliyan & HT Team
Result / Benefit:
1)Reduce mixup at channel from 25 nos to 2 nos per batch
2)Reduction in finger probe damage and replacement
3)Increase in Channel Effeciency
4)Increase in operator morale
5)Operator safety while operator high temperature furnace
6)No stagnation of rings at Hardening Chute
AFTER IMPROVEMENT

nation at hardening

ing chute varies from

AFTER IMPROVEMENT
If reversible update in:
Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing
Scope & plan for horizontal deployment
SL No
M/C NO
Target date Responsibilty Status

Fc 01

Poka Yoke Type & Function

Prevention

Q1

Swarup / Arun
/ HT Team / Implement
Surendraed
R&D Contract

Shutdown
Control

Detection

Warning

KAIZEN - SHEET
SKF India Ltd
Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:

Elimination of N Groove & Normal Bearings Mix-up in Ch-1 & Ch-6
Problem / Present Status:

N groove and Normal Bearings mix-up observed at

Customer end.
Customer: Bajaj Auto Ltd.

Analysis:

Before Improvement:

NO Poke-Yoke

After improvement:

Sensor to detect presence

of N groove on bearing OD

Manula Inspection of Bearings . There is no other Poke

Yoke .
Root Cause:
Idea:
Introduce Poke Yoke to check presence of 'N' groove on outer ring OD inplace of manual inspection.
Counter measure:

Unit

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ETW

QM

Machine No:

SL.NO

Year
2010

Poke-Yoke after HHC/HHE

Team members: SH/MMJ/CR/GK/NR

Result / Benefit:

Poke -Yoke detects the mix-up of Normal & N-Groove Bearings.

Kaizen type:
Reversible
Ir-reversible
If reversible update in:
Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing
Scope & plan for horizontal deployment
SL No
M/C NO
Target date Responsibilty status

Ch-6 after
1
HHC/HHE
Poka Yoke Type & Function
Prevention
Detection

MMJ/CR
Shutdown
Control
Warning

KAIZEN - SHEET
SKF India Ltd
Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:

Elimination of Snap ring missing & Type mix-up 1 nos to Zero
Problem / Present Status:
Snap Ring Missing was noticed at Hero Motors 6304
NR/C3 (1 no.)
This
was registered as Customer Complaint

Before Improvement:

NO Automatic Poke-Yoke Only

Manual Inspection

Analysis:

After improvement:

Snap ring fitment process is a manual operation.

The semi finished bearings with N groove is collected
in bins and is moved to off line press for snap ring
fitment.
This activity is out sourced and the trained contract
worker fits the snap ring on to the bearing groove by
using a pneumatic press and later the bearings are
packed and delivered.
As this snap ring fitment operation is manual in nature,
the operator might have missed the pressing operation
and arranged the un-pressed bearing along with the
finished bearings in the bin. Subsequently the bearings
were despatched to customer.
Root Cause:
Idea:
Counter measure:

Manual Inspection
Automatic Poke-Yoke to detect Snap Ring Missing & Bore mix-up

Unit

Sub comm

Year

SL.NO

ETW

QM

2010

Machine No: Snap Ring Fitment Press

Team members: NR/MMJ/DKJ/KS/VR
Result / Benefit:

Detection of Snap Ring missing & type mix-up with snap ring .
Kaizen type:
Reversible
Ir-reversible
If reversible update in:
Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing

SL No

Scope & plan for horizontal deployment

M/C NO
Target date Responsibilty status

Poka Yoke Type & Function

Prevention
Detection

Shutdown
Control
Warning

KAIZEN - SHEET
SKF India Ltd
Bangalore

Category:

Providing

Changing

Kaizen Theme & Target:

Elimination of Grease leakage from Bearings ( 3 nos. to Zero)
Problem / Present Status:

Before Improvement:

Customer BOSCH Complaint:

Grease Leakage from seal lip & inner ring interface
noticed at rotor slip ring turning operation (Bosch
Process).
BB1-0372AE (Zeta Alternator Rotor Bearing).

Analysis:
After improvement:
The probable causes for grease leakage :
1. The seal lip & inner ring seal anchorage (seal
groove) clearance (-0.21 mm)/interference (+0.13mm):
Out of specification due to tolerance stack up.
2. The seal anchorage dimensional non-conformance
with respect to specification.
3. Oil separation of grease in supply condition GHP
from M/s. KYODO YUSHI, Japan.
4. Excessive residual white spirit on the seal groove of
inner & outer ring on random bearings. The
Argentina factory maintains the residual white spirit
(Exxsol D60) approx. 55 mg.
5. Excess grease fill quantity (approx. 0.9 gms).
6. Excess hydrol content in white spirit (>5%)
Root Cause:
Idea:
Counter measure:

Excessive white spirit residues in the bearing causing Grease Leakage

Air Blower in the Washing machine to remove the white spirit
Adiitional Air Blowers.

Unit

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ETW
Machine No:

SL.NO

Year

QM

2010

Washing Machine

Team members: GK/MMJ/RTR/CR/SD/VT/AND

Result / Benefit:

Introduction of Blower with Air knife nozzles, has eliminated

the grease leakage issue.
NO Customer Complaints for Grease Leakage

Kaizen type:
If reversible update in:

Reversible

Ir-reversible

Operation Standard
JH Check Sheet
PM Check Sheet
Eqpt/ fixture Drawing
Scope & plan for horizontal deployment
SL No
M/C NO
Target date Responsibilty status

Washing m/c

Poka Yoke Type & Function

Prevention
Detection

MMJ/CR

Shutdown
Control
Warning

KAIZEN IDEA - SHEET

Activity
Loss No./

Step
Supervisor / Manager
Level Kaizen
Result Area
HIT Machine
Plant : DGBB Bangalore
Machine :
Kaizen theme :
Idea :
To eliminate customer complaint
To match Die profile and Cage

Problem/present status :

Countermeasure :
Die Profile and Cage profile matched

Rivet improper pressing customer complaint. Before

No of customer complaints - 6 Nos / Year

After

No of products observed with Improper

Cage = 790 Nos

Customer Complaint
8
6

Better

4
2

Before

Root cause
Die profile relief not matching with cage
Graph Data:
Before After
790
0
Before After
6
0

After

Defect Generation
Numbers

Why 1: Rivet improper pressing in 6003

Due to Improper Cage alignment
Why 2: Improper cage alignment
Cage misalignment
Why 3: Due to Die Pocket profile
Profile relief allows the cage to misalign

Results :

Numbers

Analysis :

1000
800
600
400
200
0

KK

Result Area

JH

QM PM SHE OTPM

DM

ET

SKF India Limited, Bangalore

match Die profile and Cage

Bench mark
Target
Kaizen start
Kaizen Finish
Team members

ched

Defect generation - 790 Nos and Customer

complaint - 6 Nos
Zero
7/4/2008
7/5/2008
C. Ravi
M.M Jaikumar
Ananth Bhat
Ashwin Padmavar

Benefits:
Customer complaint due to improper riveting
eliminated in 6003 type

Defect Generation
790

Better

0
Before

After

Scope & plan for Horizontal Deployment

S no
M/c
Targert date
Responsibility
No.
1
All Ch Aug' 08 end
CR

Status
In progress