Kaizen basics training on Muri and Mura.ppt

Kaizen

1. Methodology followed -PDCA
Day 1 action plan
•Planned 6 Completed 5
•
1.Cause and effect/Verification and Why Why anlaysis of
Centre Hub Bearing
2. Change jack seal of Trolley no 2 and fix axel of the same
3 SS randon trailor painting/attachment with body
4. High consumption value GGNi/MRRNI items data anlaysis
5.Amend checklist for all forklift with check for
waterpump/Alternator bearing
6. RFN Tractor/Trolley workload analysis

2. Methodology followed -PDCASep-14 Oct-14 Nov-14 Dec-14 Jan-15
-
200.00
400.00
600.00
800.00
1,000.00
1,200.00
279.97
362.39
432.78
630.28
957.33
314.96
422.78
370.96 378.17
319.11
GGNI SS TROLLEY MTBF
sub-title
with out bearing
With Bearing
Y Axis Title Oct-14 Nov-14 Dec-14 Jan-15
-
500.00
1,000.00
1,500.00
2,000.00
2,500.00
739.50
1,399.00 1,354.00
1,078.00
739.50
1,399.00
2,031.00
1,617.00
MRRNI SS TROLLEY MTBF
sub-title
with out bearing
With Bearing
Day 1 action plan

3. Methodology followed -PDCA
Cause and effect of Cenre Hub bearing Breaking

4. Methodology followed -PDCA
Cause TR No 5 TR No 6 TR No 10Total
Man Rough Driving 1 0 0 1
Excess tighting of the bearing 0 0 0 0
Excess weight on the trolley 1 0 0 1
Poor workman ship 0 0 1 1
No greasing 1 0 1 2
Sharp coners 1 1 1 3
Material Poor quality of bearing/Cone 0 0 0 0
Method Wrong tools used 0 0 0 0
Wrong place of bearing 1 1 1 3
Rough road/Sharp bend 1 1 1 3
Trye Pressure 0 0 0 0
Machine Water/Salt contamination with bearing 0 1 1 2
Wrong design 1 1 1 3
Wrong size/Capacity of bearing 0 0 0 0
Verification of causes

5. Methodology followed -PDCA
WHY WHY ANALYSIS(Wrong Design/Sharp corners)

6. Methodology followed -PDCA
RFN Tractor /Trolley workload analysis

7. Methodology followed -PDCA
Updated checklist of forklift

8. Methodology followed -PDCA
Code Description QTY Value %
P02808 Engine Oil RimulaR3 15W / 40 3553 924786.23 10.0%
P04639 Tyre 20.5 R25 4610344.83 6.6%
P02830 Gear Oil Spirax S2 G 80W90 2299 585141.48 6.3%
P11908 Tyres 385/65 R22.5 Cargo GY 9 421292.7 4.6%
P05016 Tellus Oil AWS 32 1463 340113.83 3.7%
P02595 S/S Pipe 2” SCH 40 8 285600 3.1%
P10420 Fort Lift Fork 4 206559 2.2%
P10812 Bearing 33019/Q 21 200275.74 2.2%
P12922 Gear Pump P/NO 60004298 Sany Crane 2143103.44 1.5%
P07677 Self Starter 24V 6000733 2 130000 1.4%
P12733RHydraulic Cylinder P/NO 9957904 Libheer R944C 1 120800 1.3%
P05260 Ener Grease Gadus v220 2 252105142.942 1.1%
GGNI HIGH CONSUMPTION VALUE

9. Methodology followed -PDCA
P02808Engine Oil Rimula R3 15W / 40 41801087983.815.6%
P07818EnerGrease (Alvania) Retinax EP2 540225305.82 3.2%
P05016Tellus Oil AWS 32 836194350.76 2.8%
P10812Bearing 33019/Q 17162127.98 2.3%
P12845Cutting Edge P/NO 1CA1073746 CAT
938G
4161083.04 2.3%
P02830Gear Oil Spirax S2 G 80W90 627159584.04 2.3%
P04639Tyre 20.5 R25 1152586.20
8
2.2%
MRRNI EXCLUDING D9 and Washery Items HIGH
CONSUMPTION VALUE

10. •Before After Photos
•Before Photo details:Hydraulic
oil leakage at jack
•After Photo details:replaced with
new seal and painted
•Gemba:Garage GGN
•Do

11. Methodology followed -PDCA
Day 2 action plan
•Planned 5 Completed 3
•
1.Cause and effect of hyster forklift chain link cracking
2. Change jack seal 2 nos Trolley
3. Implentation of tools and equipments based on tranning
provided on tubeless tyre
4.
.

12. Methodology followed -PDCA
Thank you
12