Kaizen Project by Sanjay Humania

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KAIZEN PROJECT

DEPARTMENT : Training (Automation)

PROJECT NUMBER : 2

PROJECT TITLE :

Cleaning dust particles from optical beam

reflector of optical mouse & prevent it from

malfunctioning.

Sanjay Humania [www.sanjayhumania.com]

6/18/2016 2

PROJECT NO : 1

TITLE : Effective utilization of Hydraulic

training kit & Reduction of oil leakage/wastage.

BENEFITS :

•Avoid extra time for searching components.

•Avoid wastage of time for placement of components.

•Maximum utilization of class duration.

•Reduce hydraulic oil wastage

•Saving electricity

SUMMARY OF COMPLETED PROJECT


3

OUR FUNCTIONAL TEAM

Sanjay

Humania

Mr. V.M Bankar Sir

(Sr. Engineer)

Yes! WE WILL..

Training (LCA)

Mr. Sumeet

Singh Samanta

Mr. Ashutosh

KumarMr. Bijayanand

Satapathy

6/18/2016 Sanjay Humania [www.sanjayhumania.com]

6/18/2016 4

PROJECT PLAN

PROJECT START: 1st AUG 2014.

PROJECT COMPLETED : 31st OCT 2015.

(UNDER 3 MONTHS TIME VALIDATION CYCLE)


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WHY THIS PROJECT

1. To reduce malfunctioning of mouse

pointer.

2. To increase student & mouse

performance.

3. To enhance proper handling &

utilization of mouse.

4. To reduce time during using a

software & other applications.

5. To increase utilization of class hours.

6. Quality improvements in learning &

trainingSanjay Humania

[www.sanjayhumania.com]

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1.1 PROBLEM IDENTIFICATION

1. While practicing software,

malfunctioning of mouse occurs.

2. Problem in left and right click.

3. Mouse pointer deflected from its original

path.

4. Changing of mouse is not possible, on

the spot.

5. Student irritate and give unsatisfied

feedback at the end of courses.

6. Decreasing in quality in learning &

training.


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1.2 SELECTION OF PROBLEM

1)Quality reducing in learning

& training.

2)Student un-satisfaction.

3)Student performance.

4)Utilization of optical mouse.

5)Time wastage.

6)Kit/system failures.


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1.3 DEFINING THE PROBLEM

1. Due to heavy and continuous use of mouse-

Malfunctioning of left & right of a mouse

started.

2. Due to dust particles-

Optical reflector start malfunctioning.

3. Proper software utilization time reduces-

Poor mouse pointer control.

4. Trainee & students irritated-

Mouse is not working properly.

5. Un-satisfaction of trainees & students.

Less practice time and malfunctioning of mouse.

6. Quality in learning & training reduces.

Less practice time and malfunctioning of mouse.Sanjay Humania


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Why Why AnalysisBrain Storming Sessions

1.4 ANALYSIS OF PROBLEM

TOOLS USED FOR ANALYSIS


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Brainstorming is a group or individual creativity

technique by which efforts are made to find a conclusion

for a specific problem by gathering a list of ideas

spontaneously contributed by its member(s)

Brain Storming Sessions

So we all trainee engineer discussed on the

above mentioned 1.2 SELECTION OF

PROBLEM & 1.3 DEFINING THE PROBLEM

And come to few conclusion and results. We

have also prepared a Project Plan /CHART

discussed in next slide.


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Project Plan /CHART

Collecting

Information of

present situation

Planning

Identify

Problems

Reality

CheckMake Changes Verify Changes

Measure

Results

Make this

the Standard

Celebrate

Do It

Again

Results:

A new way of work

Start


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1.4.1 ANALYSIS OF PROBLEM

1) Quality reducing in learning & training.

Root cause is PCs and infrastructure not fully

utilized.

2) Student un-satisfaction.

Root cause is optical mouse fault.

3) Student performance.

Root cause is shortage of time due to

malfunctioning of optical mouse.

4) Utilization of optical mouse.

Root cause is not proper cleaning and

handling.

5) Kit/system failures.

Root cause is faulty peripherals of PCs & kits.


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1.4.2(a) ANALYSIS OF PROBLEM

W

H

Y

W

H

Y

A

N

A

L

Y

S

I

S

Optical mouse malfunctioning !

Optical ray deflection !

Lack of transparency in optical ray

guide

Dust particles on optical ray guide

Proper cleaning

Quality improvements in

learning & training

why

why

KAIZEN

why

why

why

why

Dusty flooring in class rooms


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1.5 IDENTIFICATION OF CAUSES

SR.

NO. MAJOR ACTIVITY CAUSE

1) Time consumption Faulty Mouse

2) Student performanceMalfunction on mouse

control

5)Quality improvements in

learning & trainingLack of all the above topics


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1.6 FINDING OUT THE ROOT CAUSE

Need systematic & continuous

evaluating process for all problems

Lack of fault finding, cleaning

& handling of mouse.


• Approx. price of a optical mouse we used in our practical class room is Rs. 425/-

• Total class room is XXX

• Total PCs is XXX

• 40% mouse malfunction in periodically.

• 10% to 20% are replaced by hardware networking.

• After a month again malfunctioning started.

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1.7 DATA ANALYSIS

* Mouse price information is collected from http://www.naaptol.com/mouse/hcl-usb-optical-mouse/p/3682827.html


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1.7 DATA ANALYSIS

Cost per unit

Mouse we use in

our Lab.


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1.7 DATA ANALYSIS

Cost per unit

Mouse we use in

our Lab.


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1.8 DEVELOPING SOLUTIONS

1.Solution of “root cause” is to clean optical

ray crystal guide inside optical mouse

periodically. Minimum with in interval of 3

to 4 month.

2.If we are planning to change mouse, then we

should replace it with a new one. We should

not repair the faulty one. Because repairing

cost is more and no guarantee of working

properly.

3.Air cleaning can be done in minimum cost.


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1.8 DEVELOPING SOLUTIONS

Open a single screw on the backside of the mouse

Clean internal circuit with air flow


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KAIZEN PROCESS

.

ACTION BY WHOM BY WHEN STATUS

Oil wastage is stopped by

using oil try

By Sr. Engineer

(Mr. V. M.

Bankar)

12-NOV-14Oil wastage

reduces upto 85%

Hose oil wastage is

checked by using oil

bucket

By Me &

Mr.Vinod

Wairagade

(Trainee)

25-NOV-14Oil wastage

reduces upto 80%

Component arrangement

& allocating fixed place

By Me &

Mr.Gyan C.

Majhi (Trainee)

27-NOV-14

Searching time

reduces upto

100%

Labeling, arranging and

preparing proper data

sheets for components

By Me &

Mr.Vinod

Wairagade

(Trainee)

02-DEC-14Quality increases

upto 90%

Making arrangement of

theory & practical classes

in same classroom

By Me &

Mr.Animesh Kala

(Trainee)

10-JAN-15Class room

utilization 100%

Dividing total class

strength in to groups

By Me &

Mr.Avinash

Khandagale

28-JAN-15Training kit

utilization 100% Sanjay Humania


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1.9 FORESEEING PROBABLE RESISTANCE

1.Availability of casual

2.Time apart from daily class schedule

3.Internet (needed for proper

documentation)

4.Implementing the solution for the

problem & checking the results is time

consuming


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1.10 IMPLEMENTATION PROCESS

Open the back screw with a screw driver

Upper portion is detached


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Left click button

Right click button

LED

Optical sensor IC

Optical ray guide is under this PCB


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Backside of the PCB

Optical ray guide

Optical Lens

Optical sensor


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Cleaning optical sensor IC with air flow

Cleaning optical ray guide with air flow (up side)


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Cleaning LED with air flow

Cleaning optical ray guide with air flow (down side)


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Fixing up all components in mouse


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1.10 TRIAL IMPLEMENTATION AND

CHECKING THE PERFORMANCE

1. After implementing all our solutions all working

perfectly.

2. Same cleaning process should be done minimum

in 3 to 4 months.


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1.10 TRIAL IMPLEMENTATION AND CHECKING THE PERFORMANCE

“Hi, I am a faculty of ECAD, Pneumatics & Panel designing. Previously I was very frustrated with my PCs mouse. Maximum optical mouse was malfunctioning. After “Mouse cleaning kaizen project, 70% of my problem is solved. Thanks to Sanjay sir ! ”

______________________________

Mr. Sumeet Singh SamantaSanjay Humania


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1.10 TRIAL IMPLEMENTATION AND CHECKING THE PERFORMANCE

“Hello, I am a faculty of VLSI & PLC. Previously I was very much irritated with my lab PCs & mouse. 80% of optical mouse were faulty. After “Sanjay sirs kaizen project, all my problem is solved and mouse are working properly. Thanks to Sanjay sir ! ”

__________________Mr. Ashutosh Kumar


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1.11 REGULAR IMPLEMENTATION


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1.12. FOLLOW UP & REVIEW

1. Regularly we are maintaining all rules

implementation after kaizen.

2. Feedback are taken from every student after

complication of each batch.

3. Regularly I check, component list with tray list.


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2.00 RESULTS

1. Class room & Hydraulic kit is now 100%

utilized in its maximum usable time.

2. Student feedback is good.

3. Oil leakage reduced

4. Oil wastage reduced

5. Experiment time increase per individual

student

6. Less maintenance cost for hydraulic kit


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2. 1 TANGIBLE BENEFITS

1. Consider a piece of hydraulic equipment losing six cubic

centimetres of oil per minute (1 centimeter³ = 0.001 litre).

2. Over 6 hours/day, the loss is 0.36 litres, which perhaps is

not a significant amount. But over a month this equates

to 9.36 litres, and 112.32 litres over the course of a year.

3. Assuming a fluid cost of Rs 5020/20 litre, so Rs 251 per

litre, the annual cost is around Rs 28,192 approx.


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2.2 CONTRIBUTION TO GREEN EARTH

1. Less oil wasted so less pollution

2. Student are mentally less stress during theory & practical

class


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2. 3 INTANGIBLE BENEFITS

1. Saving time

2. Saving money

3. Increasing profit


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2.4 SPECIAL GAINS (LEARNINGS) FOR

MEMBERS

Developed the Kaizen approach of problem

solving

Developed a spirit of TEAMWORK

Developed enhanced environmental awareness


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2.5 FUTURE PROJECT PLANS

LIST OF PROJECTS

1) Effective utilization of Hydraulic training kit


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2.6 HORIZONTAL DEPLOYMENT


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2.7 ACKNOWLEDGEMENT

OUR SPECIAL THANKS TO

Mr. H.D Kapse Sir (M.D. Sir)

Mr. J.D Bagul Sir (Manager Sir)

Mr. V.M. Bankar Sir (Sr. Engineer)

For giving a chance to participate in training on

KAIZEN,

&

My group member

Mr. Vinod Sir

Mr. Avinash Sir

Mr. Gyan Sir

Mr. Animesh Sir

For helping me in my project..Sanjay Humania


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SUMMARY OF O TAGS AS ON DATE

No of O

tag raised

No of

O tag

implemented

No of

O tag

pending

NIL NIL NIL

Completed

In Process

SUMMARY OF O TAGS FOR CURRENT

MONTH

No of O

tag

raised

No of

O tag

implemented

No of

O tag

pending

NIL NIL NIL


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List of 0 tag pending for completion with PDC


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Thanks


Kaizen Project by Sanjay Humania

Leadership & Management

Transcript of Kaizen Project by Sanjay Humania