Measurement & Adjustment Loss

Kaizen Theme:

To reduce measurement & Adjustment

Loss in C2 U2.
Problem / Present
Status

Measurement &
adjustment time is
more
54 Minutes/shift

Analysis
Enclosed

Root Cause

SUNDARAM BRAKE LININGS LTD.,

PADI, CHENNAI - 50.

KAIZEN IDEA - SHEET

Idea :

To reduce measurement and adjustment

time (From 54 Minutes to Zero)

Countermeasure

Current status

Ref kaizen sheet

Before
After
Sl.
Description
1 Adj.drill head pitch variation No dowel Dowel provided
2

Cradle shaft axial play

1.95 mm

0.02 mm

Jig base mtg. face taper

0.12 mm

0.03 mm

Positive stopper deflection

M10 Bolt M16 Bolt

54 Minutes / Shift
Target
Zero
Kai.
Kaizen start
10/06/03
KK-273 Kaizen finish
20/08/03
Team
Members
Fugai
Fugai

C.A.Badrinarayanan

KD.Saravanan
R.L.Rajmohan
KK-275 K.Kasinathan
5 Product crown with clamp 1.2mm
0.05 mm
M.H.Suresh
6 Bush holder bkt. disturbed No dowel Dowel provided KK-276 S.Sathyanarayanan
Expense
7 Cradle setting disturbance No stopper Stopper provided KK-277
Benefits :
KK-274

K.Nagarajan
P.Mallappan
D.B.Rangarajan
K.s.s.sundar
S.Esakki

REF. KAI
P
Q
8 Cradle setting disturbance Strapclamp L Clamp
KK-278 Performance rate
C
increased from
D
9 Hyd. Cyl. stud loosening
No grub.sc Grub screw lock KK-279 60 to 75%
S
M
11 Jig index bush loosening
No grub.sc Grub screw lock KK-280 Scope & plan for horizontal depnt.

12 Less index bush length

12 mm

17 mm

KK-281

13 Air pressure variation

No
reservoir

Reservoir

Fugai

14 Pitch distance variation

No fixed

Fixed drill head

KK-282

Enclosed

Machine Tar.Date

Resp. Status

Refer Kaizen sheet