JQM

Farm Equipment Sector

Kaizen Presentation

Farm Equipment Sector

Kaizen

Project : Set Up time Reduction of Emission Gas Bottle System

2nd November 2007

Organization
JQM

Market Leader Farm Equipment Sectorin Indian Tractor Industry since last 25 years Third position in Global Tractor Market Products Engines & Tractors

Organization Achievement
JQM

Farm Equipment Sector

JQM Award Oct 2007 Deming Award Nov. 2003

ISO14001 - 2003

TS-16949-2002
QS 9000 - 2000 ISO9001 - 1996

Mahindra is First Tractor company in the World to achieve JQM Award

Kaizen Group Information

JQM

Farm Equipment Sector Name :- Real Timers

Formation Product unit Facilitators :- Jun07 :- Testing & Evaluation (Product Dev Group) :- Mr. S.K.Raut & Mr. M Raja

Name of Members :Mr. Sameer Tambe Mr. Amol Berde Mr. Yogesh Kale

Meeting Frequency:- Weekly every Monday 2.00 PM (1 hr)

Contents
JQM

Farm Equipment Sector

Background

Old System set up Problem Definition Need of Kaizen Why Why Analysis Root Cause Methodology New System Set up Result

Benefits
6

Background
JQM

Farm Equipment Sector

Diesel Engine Exhaust Emission consist of major pollutants like NOx, HC, CO, & PM

Gases with various known concentration levels are being used in Emission analyzer

Background
JQM

Farm Equipment Sector

1. Operating gases - XL Grade O2, XL Grade Zero Air, XL Grade N2, H2 + HE - Continuously in use

2. Calibrating gases - Propane + N2, NO + N2, CO + N2, Co2 +N2 - One time use

*** Each Calibrating gas has two ranges of Concentration i.e. Low & high PPM levels

Old System
JQM

Farm Equipment Sector

Press. regu

Outside Control room

Control room

100 80 60 40 20 0

Gas Bottle Empty! !

Press. Regu panel

Gas bottle

Emission analyzer

Background
JQM

Farm Equipment Sector

Old System

Pressure regulator

Gas bottle with pressure regulator

10

Constraints of Old System

JQM

Farm Equipment Sector

- Consumption of operating gases are high when compared to calibration gases - Frequency of Replacing the gas bottle is once in 15 days or less depends on no of test/ projects carried out - Lead time for Gas bottle filling is high Minimum 5 Days

11

Problem Definition
JQM

Farm Equipment Sector - Location of the Gas bottles are away from the Lab
Corridor ( as per safety standard ) - Gas bottle getting emptied without any indication surprise to Engineer

LEADING TO..

Engine Emission test hold up due to

unavailability of analyzer gases

12

Need of Kaizen
JQM

Farm Equipment Sector Interruption of emission test

Unable to meet project time lines
Low utilization of test bed & Emission analyzer
Emission analyzer utilization
100 90 80

89 82 68 70 60 72

Avg. 73.5 %

% Utilization

70 60 50 40 30

20
10 0 Jan-07 Feb-07 Mar-07 Month Apr-07 May-07 Jun-07

13

Need of Kaizen
JQM

Farm Equipment Sector

Test Bed Utilisation

No man power 2%

Engine not received 3%

Break down 5% Gas bottles not received 17%

OEE 73%
No man power Engine not received Break down Gas bottles not received OEE

14

Need of Kaizen
JQM

Farm Equipment Sector Utilization Summary

Average % Utilization : 73.5 %

% Split up No man power : 2 % Engine not received : 3 % Break down : 5 % Gas bottles not available : 16.5 %

15

WHY WHY ANALYSIS

JQM

Farm Equipment Sector Test hold up

Why

Gases Not Available

Why

Not Ordered
Why

No Intimation
Why

No Early Warning
16

Root Cause
JQM

No Early Warning System Farm Equipment Sector

- Need was felt that the test engineer should have an

advance information on the status of each gas bottle pressure in order to. 1. Place order for gas bottle in advance 2. Achieve uninterrupted test

Design a Real time pressure indicating system for gas bottles

17

Methodology
JQM

Farm Equipment Sector

Concept development

Electrical system circuit developed

Selection of components

System set up

18

Real Time Pressure

Indication System
JQM

Farm Equipment Sector

Press. regu

Outside Control room

1 5

2 6

3 7

4 8

Control room

Accept Test Reset

Press. Regu panel

100 80 60 40 20 0

Alarm .
Gas bottle

Emission analyzer

19

Real Time Pressure

Indication System
JQM

Features Sector of New Pressure Regulator :Farm Equipment

- Single stage pressure reduction with Contact Gauge - Regulator is Suitable for Cyl up to 200 bar - Safety relief valve - Operating temp - 40C to +100C

20

Real Time Pressure

Indication System
JQM

Signal Box :Farm Equipment Sector

- Microprocessor based alarm - Announciator with inbuilt hooter - Std features like Test/Accept/reset

21

Real Time Pressure

Indication System
JQM

Farm Equipment Sector

New pressure regulator connected to the gas line

New pressure regulator connected to Cylinder

22

Real Time Pressure

Indication System
JQM

Farm Equipment Sector

- Set pressure for each gas bottle considering Lead time, utilization & no of tests
Identification no
1 2 3 4 5 6 7 8 Bottle Propane + N2 NO + N2 CO + N2 Co2 +N2 XL Grade O2 XL Grade Zero Air XL Grade N2 H2 + HE

Set Pressure
20 40 20 20 30 30 30 30

*** New bottle pressure 120 130 bar

23

Result
JQM

Farm Equipment Test Sector bed utilization improved by 11.5 %

Machine utilization 100 80

% Utilization

85.0 73.5

60 40 20 0 Before After

24

Tangible Benefits
JQM

Farm Equipment Sector

1. Place order for gas bottle in advance 2. Achieve uninterrupted Emission test 3. Cost saving

25

Intangible Benefits
JQM

Farm Equipment Sector

1. Meet project time lines 2. Enhance test bed utilization 3. Reduce operator fatigue

26

JQM
P.U.: R&D , CELL: For all Test Beds M/C : ETL, Loc 2

Farm Kaizen Equipment Sector Theme : Set up time Idea : Installation of Real time
reduction for Gas bottle system Problem / present Status: pressure indicating system Counter Measure:

KAIZEN SHEET
Kaizen No. : 35 Date : 29/06/07
Bench Mark Target Start Kaizen Finish Team Members : 1. Sameer Tambe 2. Amol Berde 3. Yogesh Kale 5 days 25/06/07 29/06/07

N.A

N.A

Benefits:

Place order for gas bottle in advance

Analysis :
Gas bottle getting emptied without any indication

Result :
1) OEE schedule adherance improv ed, 2) Achieve project timelines

Achieve uninterrupted emission test OEE schedule adherance improved, Achieve project timelines
PU R&D HORIZONTAL DEPLOYMENT M/C NO. STATUS PU M/C NO. LOC 2 Completed STATUS

27

JQM

Farm Equipment Sector

28