1. LEAN ACTIVITIES AT TVONE –
QUARTER ONE REPORT
Gaurav Bijlani
Manufacturing Engineer
April 2014

2. ACTIVITY BASED - NUMBER OF KAIZEN
EVENTS - 1
Test area Kaizen event. Test area has
several bottle necks, Operator training,
equipment availability, Failures and also
spof (Single point of failure). After meetings
and data gathering, project objectives have
been established. This is a Manufacturing
based activity.
Number of participants – 6
Project started mid-February. Completion
target date, end of June 2014.

3. NUMBER OF KAIZEN EVENTS
Training provided:
5S audits and criteria
5S training for core team members
7 + 1 Wastes (TIMWOODS)
SMED (Single minute exchange of Die)
Value Stream Mapping
Process Mapping

4. RESULT BASED
Safety – With cables neatly tucked away
(Tie-wrapped) and neatly arranged,
extension leads raised off the floor and at
accessible height, tripping hazard is
eradicated.
Delivery: Lead time reduced. Test operators
suggested carrying out Testing products in a
batch process rather than in smaller batch
or individual units. This reduced setup time.

5. RESULT BASED
Employees trained in Lean fundamentals:
% of BU trained in Lean Fundamentals – 20%
Original figure, 16%.
% of BU participating in Kaizen : 12%. This is
the first time Kaizen event is taking place at
tvONE.

6. Q1 SUCCESS STORY
5S activities implemented, Lean initiatives
board in place, OTD and FTP monitored,
programming capability in Test area
increased 100% and batch processing
introduced.
Aim is to complete Test area Kaizen event
by the end of the second quarter and start
Production area Kaizen, Process mapping
Production area and initiating SMED in SMD.

7. Q2 TRAINING AND PROJECT PLANS
SMED and OEE training booked for 8th May.
5S basics for all Production employees – In
house training planning in progress.
Cost, Quality and Delivery training booked –
9th April.

8. 2014 TARGETS
Carry out Process Mapping of at least 2
areas in the Production area and remap the
area.
Improve Quality by measuring processes at
every stage.
To continue 5S activities and complete at
least 2 Kaizen events in the year.
Actively include every individual in Process
improvements.