01/15

2nd CII National Kaizen Circle

Compétition 2019

A Kaizen Presentation By

(SANDEN VIKAS INDIA PVT. L.TD. )

On: 11 & 12th June -19

Venue : India Habitat Centre , New Delhi

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Company Profile 02/15

SVL- PV
2 L
SV SVL-
P 4

SVL-
3

50:50 Joint Venture Since

1982 between
Vikas Group India and
Sanden Japan

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 03/15
Company Product & Customers
Collaboration Products Customers
SOB % 1) Compressor
 SDV(6V)
STR
 SDV(7V)
SD7
SVL 2) HVAC
Sanden Vikas 50 50
India
3) Hose & Pipe

1) Condenser
PVL 2) Evaporator
Pranav Vikas 76 24
India 3) Heater Core

SVP
Sanden Vikas
2 CII NATIONAL
nd 1) Aluminium
49 51KAIZEN CIRCLE COMPETITION 2019
HPDC
 Kaizen Theme 04/15

Kaizen Theme:- TO REDUCE THE CHANGE OVER TIME OF REAR HEAD

BOLT TIGHTENING MACHINE.

Implemented Area:- COMPRESSOR ASSY. LINE

Implementation Team:- TEAM CREATIVITY CREW

Rajesh Aggarwal Mayank Kaveya Rashid Tarun

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Problem / Present Status 05/15

Min.

Time Contribution of Activity

Min.

During Changeover

THE LOWEST AVERAGE CHANGE OVER TIME OF LINE IS 10 MIN. SO TO BALANCE

THE LINE, WE TAKE OUR TARGET TO REDUCE FROM 17 MIN. TO 10 MIN.

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 06/15
Root Cause Analysis
FISHBONE ANALYSIS
Machine Man

Low Skill
Model Change-over
Time is More M/C Need Some Less Practical
2 time 1
Training
Complex Programming for
change over
Change Over
Time (17 Min.)
Jig Change-over
Time is More Tool design Is
Complex

3
Material Method

Accredit all Probable Causes and Found 3 Main Causes

Out of 3 Main Causes

High change over time

on R.H. Bolt tightening Valid Jig change over time is high.
(We validate it through gemba audit.)
station

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Root Cause and Idea Generation 07/15

ROOT CAUSE IDEA GENERATION

STR-06
JIG CHANGE OVER TIME IS MORE. WHY-1

TWO DIFFERENT JIGS USED FOR TWO

MODELS. WHY-2

STR-08

LOCATION OF DISCHARGE PORTS

ARE DIFF. IN BOTH MODELS. WHY-3

COMMON JIG DESIGN

CONSIDERATION WAS NOT TAKEN FINAL ROOT
WHY-4
CAUSE IN BOTH MODELS , THE LOCATION OF
DURING NEW MODEL DISCHARGE PORTS ARE DIFFERENT. SO WE
IMPLEMENTATION NEED TO COMMONIZE THE JIGS.

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Countermeasure 08/15

FOR STR-06 FOR STR-08

3 1

6
5

2
4

Cutting the Cross-section Area Into One Jig & Make Use In Both
Models Easily.

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Before Situation 09/15

In Past , We Are Using Two

Different Jigs For Our 2
Models & It Takes 12.3 Min.
To Change The Jigs &
Programme In PLC.
Befor
FOR STR-06
e FOR STR-08
Min.

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 After Situation 10/15

Cutting the Cross-section

3 1
Area Into One Jig & Make
6 5 Use In Both Model Easily.

2
4
Min.

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Benefits Achieved 11/15

Qualitative:- HOW TO WORK IN A TEAM , STRONG DETERMINATION ,

DEVELEOP AS A FAMILY (EACH MEMBER,DEPT. &
ORGANIZATION)

Quantitative:- WE INCREASE THE PRODUCTIVITY BY 1.80 TO 1.83

Productivity :
SAVED MIN. (17 TO 10 MIN.) 7 MIN.
CYCLE TIME IS 1 MIN.

TOTAL COMP. WILL INCREASE 7 NOS.

AVRG. CHANGEOVER IN MONTH 20 TIMES

20X7 = 140
IT MEANS WE INCREASE COMPRESSORS
PER MONTH

COST OF 140 COMPRESSORS 140X4805 = 1176700 INR.

TOTAL INVESTMENT IN KAIZENS 97217 INR.

SO , WE SAVED TOTAL INR . 1079483 INR.

WE SAVE 1.07 MILLION

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
 Standardization 12/15

1. TOOLS , JIGS & FIXTURES SHEET UPDATED

1 Template 06 P-1100-1 1 Set - - 60 2

2 Template 08 P-1100-2 1 Set 2

Head Bolt
P-1100 Tightening Communized tool for STR-08 &
Station 3 P-1100-3 1 Set - - 60 12
STR-06

4 Bolt Ht. Checking Tool Shaft P-1100-4 1 Nos. 1350 - 20 6

2. PM CHECK SHEET UPDATED 3. NEW MODIFIED JIG

3 1
6 5
2 4

IN NEW JIG DESIGN WE HAVE A WIRE DRESSING

GROOVE TO PROTECT THE WIRES SENSORS

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Horizontal Deployment 13/15

SAME ACTION TO BE
IMPLEMENTED IN
OTHER RELEVANT
ASSEMBLY LINES
AFTER CHECKING
FEASIBILITY

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019

 Kaizen Sheet Category: Compa MM/Y Sr.
ny Y No.
Reactive Proactive Innovative SVL 02/19 1
Kaizen Title: TO REDUCE THE CHANGE OVER TIME OF STR Implemented Area:-
LINE. STR LINE
Problem/Present Status: Before Improvement: Implemented by:-
PROD./P.E.
Result/Benefit:
(a)Qualitative
1.WROK I N TEAM
Root Cause After Improvement:FOR STR-08
FOR STR-06 2.DEVELOP AS A
Identification: FAMILY

JIGS CHANGE OVER TIME IS MORE. WHY-1

(b) Quantitative
1.INCREASE
TWO DIFFERENT JIGS USED FOR TWO MODELS. WHY-2 PRODUCTIVITY
3 1
2.BY 1.80 TO 1.83
LOCATION OF DISCHARGE PORTS ARE DIFF. IN
WHY-3
BOTH MODELS.
6 5 Standardization:
FINAL ROOT
2 4 1.Tools , Jigs &
COMMON JIGS DESIGN CONSIDERATION WAS NOT
TAKEN DURING NEW MODEL IMPLEMENTATION CAUSE
fixtures list
2.PM check sheet
Root cause:- COMMON JIGS How many places
DESIGN CONSIDERATION WAS NOT this Kaizen can be
TAKEN DURING NEW MODEL
IMPLEMENTATION. deployed
horizontally:-
Idea to eliminate root 1. SDV 2. SD7
cause :- COMMUNIZED 14/15
THE BOTH TOOLS
 15/15

2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019