A small award winning Presentation....from M/S Perfect Industries, C65,Focal Point .Ludhiana..India--Mob no: -+91 75083-37007.Best Kaizen in New Product Design-------Thanks to the honorable JUdgES......

1. An ISO-TS 2001:16949 Company
Date:-24/12/13
We are manufacturing automobile fasteners & special
items as per customer requirement.
Presentation by:- Baldeep Singh
Prepared by:- Amandeep Singh

2. Title:- Improved Tooling Design
PART NAME :- Hex Screw M5×25
KAIZE
N
Company name :-Perfect Industries (India)
Tooling Design by: :- Mr. Maninder Singh
Before
After
Comments:1)
Comments :-
1. Burr observed after trimming process
2. Burr found more sharp after heat treatment.
3.Customer failed the screws due to burr
4. Screws are used in aluminum compressors after
tightening the screw , burr damaged the surface it
increase the risk of leakage of compressor.
1. Quality Improved no burr observed with new
designed tooling .
2. No need to trim hex at another machine.
3.Production increased.
4.Party approved the samples.
Benefits
:
cost
pro
quality
IDEA EXECUTE BY :- Design & Dev. Dept.
time
money

3. TITLE:- Improved tooling design
PART NAME :- Hex screws M5×25
Description
Before
KAIZE
SAVING
N
After
Daily
Production
100 ×8=16800
23120 ×8= 24960
Machines &
tooling used for
Bolt header +
trimming
machine
Multi Station Bolt
Forging machine
Electricity
Consumed
.746×3=2.23
units per hour
Machine Process
removed.
0 cost
Manpower Used
2.23units×8
hours=17.90
units
17.90×6=rs107/
2 nos.
Man hours Used
16 hours per day
8 hours per day
Rejection
5%
0.02%
(per day)
1 nos
Material Saved- .003gram(material saved from one
piece) .003×rs70=5250/
Trimming tooling saved=1400/
Electricity SavedDaily 17.90 units saved (17 .90×rs 6.00=107/)
Manpower Saved Rs.194x 7 =Rs.1358/
Rejection decreased from 5% to .
02%=9840/
TOTAL SAVINGS FROM A LOT OF 1 LAC
PIECES=
5250+1400+107+1358+9840=17955
KAIZEN INVESTEMENT
Skilled Operator salary =2800/7 days
Tooling =Rs.18000/
PAY BACK TIME – 1 .5 days
BENEFITS
1. Customer Satisfaction & zero complaint
2. QUALITY IMPROVED
3. PRODUCTIVITY INCREASE
4. LESS MANPOWER
5. MACHINE PROCESS SAVED
HORIZONTAL DEPLOYMENT- YES
3