Kaizen at CoretecYuken)_0_0.pdf · 2013-04-18 · • The team consisted of one person from...
Transcript of Kaizen at CoretecYuken)_0_0.pdf · 2013-04-18 · • The team consisted of one person from...
Kaizen at CoretecKaizen at Coretec
Presented byNarayan RaoVP OperationsYuken India Limited
How Coretec became a totally transformed Company through major Kaizen efforts
AgendaAgenda
• Introduction to Coretec• Transformation at Coretec:
– The Methodology– Re-layout– Seiton and other Improvements– Introduction of Kanban– Use of barcode technology
• Summing-Up
Introduction to CoretecIntroduction to Coretec
About CoretecAbout Coretec
• An ancillary of Yuken India Limited
• Compact, independent unit
About CoretecAbout Coretec
• Set up and managed by a senior executive with over 35 years experience (25 years at Yuken)
About CoretecAbout Coretec
• Manufactures iron cores
• Used in solenoid-operated Direction Control Valves manufactured by Yuken India
01 AC
01 DC
03 AC 03 DC
Direction Control Valve
Iron cores
Iron core comes in here
The methodologyThe methodology
How it was all done!
Guidance, WorkshopGuidance, Workshop
• Mr. V.K. Grover, Kaizen Consultant, started guiding Yuken and its sister companies from April 2000
• Initially, training was given in 5-S and in Kaizen concepts including kanban
• A four-day Gemba Kaizen workshop was conducted at these companies from 12th to 15th July 2000
Guidance, WorkshopGuidance, Workshop
• The team consisted of one person from Coretec, and others from Yuken India Limited and Sai India Limited
• The team re-laid out the Factory and initiated most of the changes explained here
• Every Friday afternoon was reserved for continuation of Kaizen activities
Re-layout at CoretecRe-layout at Coretec
Wasteful movements drastically reduced!
Original layoutOriginal layout
Incoming items
Finished items
Assembly , final welding to despatch
Raw material to tube-to-tube weldingStopper welding
MD’s office
Welding
Storage racks
Stor
age
rack
s
Stor
age
rack
s
Storage racks
Enclosure for grinding, buffing
Ultrasonic cleaning
Inspection / AssemblyTesting For backbite
removal
To next shed for air leak test
Return after air leak test
Return after backbite removal
Revised layoutRevised layout
Finished items
Incoming items
Assembly , final welding to despatch
Raw material to tube-to-tube weldingStopper welding
For backbite removal
Return after backbite removal
Welding
Inspection, Assembly, Ultrasonic cleaning
Grinding, buffing
Ultrasonic cleaning, testing
BenefitsBenefits
• Material movement reduced by 10 kms by: – Re-layout– Some operations were brought in– Some operations were closer
• Total floor space released : 40%• Part of the space released used for:
– Enlarging Managing Director’s office by 30%: very cramped earlier
– Providing space for visitors
Seiton and other Seiton and other improvementsimprovements
Making the worker’s life easier
Arrangement of toolsArrangement of tools
• Tools and equipment required stored neatly near the work place
• Space for keeping rejection and rework items:– Stored by type of
defect
Grinding and buffingGrinding and buffing
• Lot of time was wasted in changing wheels for tip grinding:– Additional bench
grinder procured and located properly
• Dust extractor installed
New fixtureNew fixture
• Copper rods inserted into stainless steel tubes at time of welding
• Removing these rods after welding was manual, time-consuming
• New pneumatic fixture:– Removes copper rod– Inserts into tubes to be
welded next
Right-sized machinesRight-sized machines
• One large ultrasonic cleaning machine used earlier: batches of 50 cleaned at a time
• Now, two small ultrasonic machines clean 6 at a time
New machine
Old ultrasonic cleaning machine including panel
New ultrasonic cleaning
machine (no extra panel)
Testing – before KaizenTesting – before Kaizen
• Testing of iron cores very laborious:– Fill up oil, assemble
to valve body– Manually operate
switch 100 times for each iron core
– Assemble 49 at a time to manifold
– Test one by one for air leak and for movement of the manual pin
Testing – after KaizenTesting – after Kaizen
• New test rig using a hydraulic power pack and a timer mechanism:– Both tests done
separately earlier now combined
– Saving of 3 minutes per iron core
– Higher reliability of testing
Manpower ReductionManpower Reduction
Before Kaizen
After Kaizen (present status)
Final target
5 3 2
Introduction of KanbanIntroduction of Kanban
No more planning!
Kanban from Customer
Kanban to Supplier
Kanban from CustomerKanban from Customer
• Daily supply to Yuken:– Empty trays
collected from Yuken
– Required iron cores produced the same day
– Filled trays delivered to Yuken the next day
Kanban to SupplierKanban to Supplier
• Subcontractors also operate on kanban in a similar way
• Subcontractor visits daily, picks up empty trays and returns filled trays next day
• No more shortages, no more follow-up and tension!
Kanban to SupplierKanban to Supplier
• Kanban through trays operates even with a supplier located at Harihar, 350 kms away from Bangalore
• Trays sent by bus overnight and returned in 2 – 3 days
Benefits from KanbanBenefits from Kanban
Item Before Kanban
After Kanban
Reduction %age
Iron Cores at Yuken & Coretec
Rs. 0.4 million
Rs. 0.02 million
95%
Raw materials and components
Rs. 0.82 million
Rs. 0.4 million
52%
Total inventory Rs. 1.22 million
Rs. 0.4 million
66%
Benefits from KanbanBenefits from Kanban
0.82
0.4
0.4
0.02
0
0.2
0.4
0.6
0.8
1
1.2
1.4
Before After
Finished Iron CoresComponents
All values in Rupees millions
Use of barcode Use of barcode technologytechnology
Material movement fully computerised:
No more manual material accounting and reconciliation!
Bar-code technologyBar-code technology
• All trays affixed with bar code stickers
• Trays scanned:– Incoming– Outgoing
• Automatic generation of DC’s and MRNs
• Analysis of tray (and therefore material) movement easily possible
Summing-UpSumming-Up
Total transformation of operations!
Future PlansFuture Plans
• Buy a small lathe so that components do not go out for removing weld “backbite”
• Use the same welding transformer to run three independent welding stations so that true one-piece flow can be implemented
The Last WordThe Last Word
• Mr. T.R. Prasanna, the Managing Director of Coretec feels that Kaizen has made his Company run by itself and left him free to plan for expansion and further growth
Thank You!Thank You!