12/16/2016

AVTEC LTD.

KAIZEN SUMMARY SHEET

KAIZEN
NO.

AREA

Fork lift

Fork Lift

Fork Lift

Shaft Line

Tooth
Rounding

Hard Cell

OPERATION

AFFECTED
COMPONENT

BEFORE

BENEFITS

AFTER
SAFETY

QUALITY

PRODUCTIVITY

DATE

TEAM

COST

Small fork used to lift the material & machine

Large (long) fork developed.

12/06/08

Bihar Khan

Input Shaft

Position of locating pin at the centre of gear

Position locating pin locate at the portion where

rounding to be done.

12/01/09

Ghanshyam,
Randhir, Dhigata

OD Grinding

Input Shaft &

Lay shaft

Marpose flagging sensor tip with round nos

Marpose Flagging sensing tip modified, and can

take ref from grooves

22/01/09

Ashutosh, CSM

Round Gear

Tooth
Chamfering

Sleeve /
Synchro Ring

End Milling cutter used for tooth chamfering

Insert type end Milling cutter used for tooth

chamfering.

24/01/09

M.Muralidhar,
Manoj Vijay, Bihar.

Round Gear

OPD
Inspection

All Round Gears Pin ( Roller ) used for OPD / OBD inspection.

Ball used for OBD/ OPD inspection

12/02/09

Dhigata, Randhir,
Vishal, Sahoo.

Round Gear
& Shaft Line

Deburing &
Chamfering

All round Gears

No entry chamfer provided in cutters.
& Shaft

Provide cutter entry chamfer for safe entry

03/02/09

Balmukund, Vipin,
Manoj vijay

Round Gear

Tooth
Chamfering

Shifter Sleeve & Tooth chamfering machine was opened by hitting Developed suitable C spanner which has
Synchro ring the nut which damages the collet
eliminated the damage of Collet

09/03/09

Bihar Khan

Round Gear

Key way
broaching

Screw direction changed to upword , - no needs

to open complete fixture for locating pinn
adjustment.

14/03/09

Bihar Khan,
Shaoo
Shymal

Round Gear

Tooth
Chamfering

Shifter Sleeve Internal Spline damage in clamping.

2 Teeth locator change to full spline collet.

19/03/09

UK Shaoo, Bihar
Khan

10

Round Gear

Deburing

Synchro Ring

Deburring machine introduced in line

24/03/09

M.Muralidhar, M.
P Joshi , Bihar
Khan

11

Shaft Line

Turning 1st
setup

Steady rest provided for component resting

18/04/09

Manoj, Sahoo,
Shymal Myati.

12

Round Gear

Tooth
Chamfering

Shifter Sleeve

Burr removal required for second face tooth

chamfering

Resting face inner diameter increased, which will

not foul on burrs generated in 1st setup

11/05/09

Bihar Khan,
Balmukund

13

Shaft Line

Inspection OBD

Lay Shaft

Span Measurement perform

OBD Measurement implemented in place of span

14/05/09

Randhir, Shymal,
NLR

14

Marking
Machine

Identification
Marking

Engine Gear

Pin type clamping pin over the fixture.

V shaped clamping support provided

14/05/09

Randhir, Manoj
Vijay

15

Shaft Cell

Facing &
Centering

Input Shaft

Chance of Wrong loading of component

Block provide to resist wrong loading

17/05/09

Shymal,
M. Muralidhar

16

Shaft Line

Material
Movement

Input Shaft

2 Operator required to run 3 machine ( Shaping- Machine Layout Change - All m/c put together
2 & Rounding)
face to face - operated by single operator

22/05/09

Amiya, M.
Muralidhar
Maintenance &
Bihar

17

Marking
Machine

Identification
Marking

FDG

18

PDI

Groove Length
Inspection

Input shaft

19

Shaft Line

Material
Movement

20

Metrology
Lab

Inspection
-Mandrel
handling

21

Shaft Cell

Shaping Rounding

Engine Gear

Locating pin holding screws provided to bottom

side , needs to open complete fixture for
adjustment

Deburring on lathe machine at tool room.

Input shaft/ Lay

Manual Holding of component for quill clamping
shaft

Possibility of wrong side marking

Cavity provided, which will not allow to wrong

Loading

22/05/09

Rejent Thakur,
Shymal

Height Gauge used check Groove length

Length Checking Gauge Implemented for L 28.95

24/05/09

Randhir, Harshal,
NLR, Shymal

Input Shaft / Lay 3 Operator required to run 4 machine. & More

shaft
operator fatigue.

Machine Layout change for single piece flow Operated by 1 operator

28/05/09

Amiya, M.
Muralidhar
Maintenance &
Bihar

All Round Gears Mandrels Kept in component empty bins

Mandrel Stand Provided with cavity and label for

mandrel selection

06/06/09

M.Muralidhar,
Milton

All three machine interlock for single piece flow.

14/6/2009

M. Muralidhar,
Sandeep Das

Input Shaft

No interlinkage between three operations.

REMARKS

12/16/2016

AVTEC LTD.

KAIZEN SUMMARY SHEET

KAIZEN
NO.

AREA

22

Round Gear

Hobbing

23

Round Gear

Material
Movement

24

Round Gear
Turning

Turning

All Round Gears

25

Material
Movement

Component
Handling

26

Shaft Cell

Centre Drilling

27

Round Gear

Handling

28

Hard Cell

OD Grinding

Lay Shaft

29

Heat
Treatment

Shot Blasting

All Gears &

Shaft

30

Round Gear

Shaving

31

Round Gear

32

33

OPERATION

AFFECTED
COMPONENT

BENEFITS

DATE

TEAM

22/06/09

M. Muralidhar,
Sandeep Das

Machine Layout change - Single operator can

operate 2/3 machine at a time.

04/06/09

Amiya, M.
Muralidhar
Maintenance &
Bihar

Inspection of length with the help of height

gauge & lever dial.

Comparator with master block installed for

height inspection

04/07/09

Randhir , Dhigata

FDG

Plastic bins use for handling of FDG (6 / plastic

bin)

Movable trolley with hanger design for handling

FDG .(100 / trolley)

05/07/09

M. Muralidhar,
Rajbinder Gill

Input Shaft &

Lay shaft

Gauges and Air Gun placed over the machine,

Needs to go to tool room for drill collet opening

Separate table for Gauges, Air jet and drill holder

clamping fixture provide to the machine

06/07/09

Ghanshyam

Oil Drain tray mounted over machine

07/07/09

Rajendra,

Dog Carrier Required to drive the shaft in 3rd

Setup of OD Grinding.

Holder with Internal Spline provided to drive the

shaft, Also the holder resist the entry of 2nd
setup not done

07/07/09

CSM

Fixture capacity for Round Gear - 115, Shaft 40 , FDG - 20 per batch

Fixture Modified & capacity increased as Round

Gear - 175, Shaft - 75 , FDG - 40 per batch .

12/07/08

Rajesh, Neel
Ratan, Uttam,
Manas

3 GLS / 4 GLS

Machine can runs with wrong side loading of

component

Tail Stock clamping sensing block modified to

differentiate clamping of tail stock in case of
Wrong loading,

14/07/09

M. Muralidhar,
Sandeep Das

Rounding

RIG, / Shifter
Sleeve 1/2

Two rounding machines for RIG and Shifter

Sleeve , kept separately on both side of Gang
way

Two Rounding machine kept together face to

face.

15/07/09

Vishal, Rajendra,
M.Muralidhar

Round Gear

Number
Marking

Engine Gear

Number Marking Machine was placed seprate to Number Marking Machine placed over broaching
broaching machine.
machine stand.

17/07/09

Vishal, Lilesh,

Round Gear

Timing
Marking

Engine Gear

Gear teeth not located - Fixture can not

differentiate in Crank & balancer type engine
gears.

17/07/09

Vishal, Lilesh,
Vipin, Shymal

21/07/08

Sandeep,
Lilesh,
M. Muralidhar,

22/07/09

Randhir

23/07/09

Randhir , Ajay

All Round Gears

BEFORE

AFTER
SAFETY

Cutting oil comes out with autoloader fixture and

Auto air purging provided over autoloader fixture
component

All Round Gear Single Operator Operates single machine.

All Round Gears No oil drain system for component comes out
& Shaft
from machine

1 GLS, 2 GLS , During Power failure - Welding missing

Laser Welding
3IPS & 4 IPS component passed to Ok component conveyer.

Gear teeth locater provided over the fixture.

As power resumes after failure, LBW machine
will not restart until the component without
welding is manually picked from the spindle of
work station
Change over procedure modified to open only
collet assy
Total Time = 5 minutes

QUALITY

PRODUCTIVITY

COST

34

Round Gear

35

Shaft Line

Facing &
Centering

36

Shaft Line

Turning

37

Shaft Line

Inspection OBD

Input shaft

Span Measurement perform

OBD Measurement implemented in place of span

25/07/09

Randhir, Shymal,
NLR

38

Hard Cell

OD Grinding

Lay Shaft

Formation of step at parting line of 1st & 2nd

Setup

Length position changed to bigger groove (width

4mm), Overlap in 4mm hence no step formation

05/08/09

CSM ,
M. Muralidhar

39

Round Gear

Key way
broaching

Engine Gear

Shaving Mandrel locating diameter was plain and Key Provide over the locating Diameter of
round.
mandrel.

07/08/09

Vishal, Lilesh,
Raju, Shymal

40

Round Gear

Shaving

All Round Gears

Shaving Mandrel Length short & knurling on one Mandrel Length Increased by 32mm and knurling
side.
provided on both side.

07/08/09

Vishal, Lilesh,
Raju, Shymal

41

Packing

Packing
Material
Storage

All

Lay Out Change & All packing material arranged

in Racks

07/08/09

Shivshanker
Rajbinder Gill

42

Round Gear

Length of Allen Key increased to safe handling.

10/08/09

Vishal, Kalyan

Centre Drill
Change

Complete Holder Assy required to open for

centre drill change Total Time = 45 minutes

Input Shaft / Lay Chuck clamping/declamping , Door Open / Close Chuck clamping/declamping , Door Open / Close
shaft
- done manually by foot paddle
- introduce in program

Packing Material kept on floor

Laser welding
Length of Allen Key was short to tight the screw
All Round Gears
-setting
during setting.

REMARKS

12/16/2016

AVTEC LTD.

KAIZEN SUMMARY SHEET

KAIZEN
NO.

AREA

43

Round Gear

Cavity Milling

44

Round Gear
Turning

Component
Storage

45

Shaft Cell

Spline Rolling

Lay Shaft

46

Heat
Treatment

Straightening

Input Shaft

47

Shop floor

Record
storage

All

48

Shaft Line

Shaping

Input shaft

49

Round Gear
Turning

Broaching

50

PDI

Inspection

All

51

Tool Room

Raw Material
Storage

fixtures

52

Hard Cell

Boring, Facing
& Cone OD
Turning

53

Hard Cell

54

OPERATION

AFFECTED
COMPONENT

BENEFITS

DATE

TEAM

Cavity guided fixture provided which allows

number marking only for the components having
3 cavities in ID

15/08/09

M. Muralidhar,
Shymal

Gap Between the racks increased up to walkable

width.

15/08/09

Rajbinder Gill

Fixture not design to resist wrong direction

loading of component

Modified the fixture by providing a block to resist

wrong side ( Gear side) loading.

16/08/09

Shymal, Randhir,
Ghyansham

After Straightening - Cross verification of PCD

R/o at bench centre. - per lot wise

Process flow change to single piece flow from

straightening & bench centre.

16/08/09

Neel ratan ,
Manas

No place for keeping inspection recorded at

machine

Inspection table modified with racks for keeping

Inspection and production records.

20/08/09

Amitesh ,
Ghamshyam

Manual Chip Cleaning from the fixture

Oil flow direction adjust to clean the chips from

the fixture.

20/08/09

Randhir, Mirnmay
Myati

Broach cleaning brush introduce on machine,

which cleans the broach during up-word motion.

21/08/09

Randhir, Sanjay
Tayde

Chance of mixing inspected and un inspected

components

Layout Change for single piece flow of Material

22/08/09

Lilesh Shukla

Material Place on floor

Trolley Provided for material storage

23/08/09

Raju K, Shymal

Round Gears

New CBN inserts consumed & sent to scrap.

Scrapped CBN inserts reused after resharpening.

15/06/09

Gaurav Mittal

Back Facing

Round Gears

Sandvik DCGW insert used for backfacing.

Sumitomo DCGW insert used for backfacing.

07/06/09

Gaurav Mittal

Hard Cell

Wheel
Dressing

Grinding wheels

13/04/09

Gaurav Mittal

55

Shaft Line

Turning

Input shaft

New shorter process at high cutting parameters

implemented.

10/06/09

Gaurav Mittal &

Amitesh Das

56

Shaft Line

Grooving

Input Shaft / Lay

Single form grooving insert used for grooving.
shaft

One standard insert used for rough grooving first

& then form grooving insert used for finish
grooving.

05/04/09

Gaurav Mittal

57

Shaft Line

Deep hole
drilling

Input Shaft / Lay

Fixture problem & poor drill design.
shaft

Fixture problem solved & drill design improved.

20/06/09

Gaurav Mittal &

Ghanshyam

58

Shaft Line

Turning

Kennametal TNMG insert used for roughing &

finishing.

05/06/09

Gaurav Mittal

59

Shaft Line

Grooving

Scrapped insert reused after edge formation on

2nd side

13/05/09

Gaurav Mittal

60

Round Gear

Roughing & finishing, both with WNMG

06/06/09

Gaurav Mittal

61

All Cells

Turning

All Gears &

Shaft

Large variety of unecessary inserts used.

Lesser variety of inserts used.

10/07/09

Gaurav Mittal

62

All Cells

Turning, Tooth
Chamfering

All Gears &

Shaft

High cost Sandvik & Iscar Toolholders & Boring

bars used.

Low Cost Widia Tool Holders & Boring Bars

used. Also local tool holder manufacturers
developed.

11/04/09

Gaurav Mittal

Shifter Sleeve

BEFORE

SAFETY

Simple OD clamp fixture at number marking

Machine

All Round Gears Racks place together with less gap in between

3/4 GLS, Shifter

Broach cleaning done manually by brush
sleeve

Lay Shaft

AFTER

Winter Fliese make blade type diamond dressers

Star make blade type diamond dressers used.
used.
Lengthy process at low cutting parameters used.

Iscar TNMG insert used for roughing & finishing.

Input Shaft / Lay Single edged form grooving insert used &
shaft
scrapped.

OD Turning &
Roughing operation with CNMG & finishing with
All Round Gears
Facing
TNMG.

QUALITY

PRODUCTIVITY

COST

REMARKS