Kaizen case study submitted by SRF Overseas Limited during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

1. Quality Month: Aug’11 Kaizen No Page No.:1
KAIZEN REPORT
Company logo Company Name Department: Section/Process:
SRF OVERSEAS LIMITED Manufacturing Team Engineering.
Improvement Title: In-house development of separator plates for TO5 twisting machines to reduce waste
Category: [√ ] Quality improvement [ ] Health & Safety [] Environment [√ ] Productivity [ ] Office processes
Before Situation Root Cause Analysis Improvement Measures After Situation
Sl. Problem Root Solution
No cause proposed
‘Why –Why’ Analysis identified
HB Since To put
1 waste there is no separator
Why waste is generated? is > 10% provision plates in
for any between
kind of two
separation spindles.
between
two
Waste is generated due to spindles it Separator
higher half bobbins in in is plates added
TO5 m/c resulting between the
into spindles
generation
of half
bobbin
waste.
Why half bobbin
generation is high in TO5
High half bobbin waste generation in TO5 machines ( twisting twisters? New separator plate fixed .
machines)
TO5- MONTHWISE HALF BOBBIN% TREND
TO5- MONTHWISE HALF BOBBIN% TREND
18.00
In TO5, if cord in one 18.00
17.00
17.00 spindle breaks, it also 16.00 Befo Afte
15.00 re r
16.00 breaks the cord in adjacent 14.00
14.60
15.00
14.00
14.60 side due to slashing. 13.00
12.00 12.20 11.90 11.87
13.00 11.00 10.90
12.20 10.00
12.00 11.90 11.87 9.00
11.00 10.90 8.00
10.00 7.00 7.01
HB %
9.00 Why does slashing take 6.00
5.00 5.33
8.00
7.00 7.01
place? 4.00
3.00
2.00 2.51 2.16
6.00 1.69
5.33 1.00
5.00 0.00
4.00
1 1 1 11 1 1 1 '11 '11 1 '11 '11
3.00 n-1 b- 1 r-1 r- y-1 n'1 ly'1 g p Oc
t'1 v c
Ja Fe Ma Ap Ma Ju Ju Au Se No De
2.00 Since there is no provision
1.00 for any kind of separation
0.00
between two spindles.
1 1 1 1 1 1 1
n-1 b-1 r-1 r-1 y-1 n'1 ly'1
Ja Fe Ma Ap Ma Ju Ju
Months
Benefits: Participation

2. 1- N. Centhil Kumar
1- Waste reduction from >10% to < 2% ( Saving: US$-50,000 per annum) 2- Biswajit Mallick
2- Increase is machine efficiency 3- T.B. Singh
4- Ahmed Raza
Standardization: Horizontal Deployment Opportunities (Replication):
Technical Standard developed for specification of separator plate and the process of fixing it on The stated improvement has been deployed in 4 out of 12 machines.
the Twisting machines Machine nos: TO5-2, TO5-3, TO5-4 and TO5-10,
Ref: MECH/TS/058
Single Point Lesson: Remark / Management Comments:
-
This is a very innovative solution, where in-house modification has been done by the engineering team
and which this improvement has given us lot of savings.
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
15th July 2011 2nd August 2011
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices.
Signed by Authorised signatory: _______________________Name:___M.N.Rathnam___________________________Designation:____Cheif Manager – MT
_________________________________ Date: _07___/_10___/_2011_______