Kaizen Sheet

Productivity Quality Delivery Safety Material Energy Morale Kaizen Title: To Reduce the setup time for 25mm width part numbers Problem/Present Status:
a.25mm width part number taking 270min setup time ,when compared to all other part number it taking 15-20 min.

Company TIMKEN

MM/YY NOV 11

S.No

T1- 1

Before Improvement:
W H E E L
W H E E

Implemented Area: Face Grinder -1 Implemented by:

Praveen Kumar Pathak Wasim Akram Jagadeeswaran.D

L
85 mm GUIDE ROD ASSEMBLY

85 mm GUIDE PLATE ADJUSTMENT ASSEMBLY

Result/Benefit: (a) Qualitative

1. Reduced the fatigue to the person

GUIDE PLATE

1INCH PART

Real Root Cause Identification:

270min setup time for 25mm width part number

After improvement:
W H E E L
W H E E L

(b) Quantitative
2 setup per month for 25mm width parts 30sec cycle time for 1 piece 1080 piece produced with this available time

Guide plates Qualification required to do for 25mm part number which takes 4hrs
Guide plate adjustment assembly has to be shifted from its position to new drilled position Guide plate adjustment stroke is less

Standardization:
100 mm 1INCH PART
GUIDE ROD ASSEMBLY

100 mm
GUIDE ROD ASSEMBLY GUIDE PLATE

1.Setup manual updated 2.Machine manual updated

Root cause Idea to eliminate root cause Counter-measure

Guide plate adjustment stroke is less for 25mm width part number Guide Plate adjustment stroke length increased to avoid the shifting of guide plate assembly Lead screw rod increased by 15mm each side

How many places this Kaizen can be deployed horizontally

Nil Confederation of Indian Industry

Kaizen Sheet
Productivity Quality Delivery Safety Material Energy Morale Kaizen Title: To decrease the setup time for Diamond Change in Cone Rib Grinders

Company TIMKEN

MM/YY

S.No

JAN2012

T1-2

Implemented Area: X3-RIB grinder Implemented by: Praveen Kumar Pathak Wasim Akram Jagadeeswaran.D Result/Benefit: (a) Qualitative 1. Easy to remove the diamond

Problem/Present Status:
1. 15min. For removing the diamond 2. 180min. Break down due to wrong mounting/Removing of diamond collet nut

Before Improvement:

Real Root Cause Identification: After Improvement: To remove the diamond , difficult to hold the stem and remove the nut.

Space constrains to remove the diamond

Collet and nut is difficult to handle in this machine

(b) Quantitative 1. Diamond Change/ month = 150 Time saved/ diamond Change = 12 min. Time Saved/month = 150*12 =1800min 2.Break down time reduced from 3 hrs to Zero Hrs due to improper diamond Entry/Removal 3.Spare parts of nut and collet (a). Ordering time (b). Ordering cost (c). inventory are eliminated

Standardization: 1.Machine manual Updated 3.Monthly PM check list updated for checking the screw thread Root cause Idea to eliminate root cause Counter-measure Stem of diamond turner changed Collet and nut is difficult to handle in this machine Changed the collet stem design to screw locking method 5 RIB Grinder How many places this Kaizen can be deployed horizontally

Confederation of Indian Industry

Kaizen Sheet
Productivity Quality Delivery Safety Material Energy Morale

Company TIMKEN

MM/YY

S.No

JAN2012

T1-3

Kaizen Title: To Reduce the Breakdown time due to improper indexing of the table

Implemented Area: JX1-Close In Press Implemented by: Praveen Kumar Pathak Wasim Akram Jagadeeswaran.D Result/Benefit: (a) Qualitative 1.Shaft damage avoided 2.Operator fatigue reduced 3. Manual Mode of operating the press not required

Problem/Present Status:
1.Table indexer not working due to shaft getting damage frequently

Before Improvement:
INDEXER TABLE

Free space

M O T O R

Real Root Cause Identification: Shaft damage

After Improvement:
INDEXER TABLE

Shaft key getting misaligned from the slot during the rotation

screw
(b) Quantitative 1.Machine down time reduced from 2 hrs to zero

Slot in the female shaft which allows the key to come out from the motor shaft
M O T O R

Standardization: Machine manual updated

How many places this Kaizen can be deployed horizontally

Root cause Idea to eliminate root cause Counter-measure

Slot in the female shaft which allows the key to come out from the motor shaft Spacer filled in the female shaft and grub screw locking provided Gap filled with grub locking

Nil

Confederation of Indian Industry