Kaizen Improvement Event (K-188) in an Automotive Industry – A Case Study

Kaizen Improvement Event (K-188) in an Automotive Industry – A Case Study

Department of Mechanical Engineering, Integral University Lucknow, INDIA

Abstract- This paper is a case study of an automotive industry in which the Kaizen improvement activity entitled K-188 is performed in the shop floor and the kaizen target are made. At the end of the kaizen event, several objectives are achieved such as introduction of work bench, 5S level improvement, Identification & traceability system of Dies implemented, Layout for shop floor made, kan-ban system implemented, Standard worksheet made available on shop floor, Poka Yoke for critical dimension for critical part made, Proper layout of the shop floor is prepared. Several targets are achieved which are tabulated at the end of the paper. The result and conclusion of the case study includes situation before and after kaizen, summary of kaizen titles fulfilled, pending kaizen titles and the target sheet. The Target or progress sheet contained the improvement percentage of the kaizen event.

1. INTRODUCTION

   Kaizen means a constant effort not only to maintain but also upgrade standards. It means continuous improvement. The word implies improvement that involves everyone. Both managers and workers and entails relatively little expense. The kaizen philosophy assumes that our way of lifeis it our working life, our social life, or our home life should be the focus of constant improvement efforts. The Kaizen improvement can also be done practically to achieve more productivity.

   1. Kaizen Application Examples

      Fig.1 Flow diagram of Kaizen roles & responsibilities

      • Customer complains about the process

      • End to end process not defines not understood

      • There is considerable amount of rework or defect in the process.

      • Process is not standardized

      • Process inputs/outputs are not error proofed or are of poor quality.

      • Process cycle time is lengthy

      • Low productivity

2. KAIZEN EVENT (K-188)

   The kaizen event was organised in an automotive industry by the kaizen team with its purpose of implementation to achieve kaizen target.

   1. Kaizen Targets

      • Reduction of customer complaints

      • Improvement in 5 S level

      • Reduction in PPM level

      • Material handling improvement

      • System improvement

   2. Quality Improvements

      Fig.3 Die Clamping machine

      Fig.4 Notching Process

      Fig.5 Cowl Mounting Bracket

      Fig.6 RUPD Mounting dimensioning

      Fig.7 RUPD Side support Bracket welding

      Fig.8 Welding Process if intercooler bracke

   3. Material Handling and Supplier System Improvement

      Fig.9 Quality and Inspection before Dispatch

   4. Improvement in 5S Level

      Fig.10 KANBAN

      Fig.11 Instruction board

      Fig.13 Inspection Room

      Fig.14 Plant Layout

3. RESULT & CONCLUSION

After Kaizen Event K-188, the following results were achieved which are as follows:-

TABLE-1: SITUATION BEFORE AND AFTER KAIZEN

TABLE-2: SUMMARY OF KAIZEN TITLES

TABLE-3: PENDING KAIZEN TITLES

TABLE-4: TARGET SHEET

REFERENCES

1. S. Ashley, Manufacturing Firms Face the Future, Mechanical Engineering, 119:6, June 1997, pp. 70- 74.

2. Chan, E.T.S., & Smith, A.M. (1994). Simulation approach to assembly line modification: a case study. Journal of Manufacturing Systems, 12, 239 245.

3. Cheser, R. (1995, April). Kaizen is more than continuous improvement. Quality Progress, 23 25.

4. Dugger, J. C. & Teegarden, J. (1997). Manufacturing and industrial technology: a beneficial alliance of the future. Journal of Industrial Technology, 14(1), 37-41.

5. Imai, M. (1986). Kaizen: The key to Japans competitive success. New York: Random House.

6. Womack, J. P. & Jones, D. T. (1996). Lean thinking. New York: Simon & Schuster.

BIOGRAPHY

Mohd Anees Siddiqui was born in Kanpur, India, in 1988. He received the B.Tech degree in Mechanical Engineering from Integral University, Lucknow, India, in 2011, and pursuing M.Tech in Production & Industrial Engineering from Integral University.

In 2011, he joined the production department, Technical Associates Ltd, Lucknow as a Trainee Engineer. In 2012, he became Development Engineer at Berrys Auto Pvt. Ltd. He worked as a Lecturer in Lucknow Institute of Technology, Lucknow. Presently, he is working as a Lecturer in Department of Mechanical Engineering, Integral University, Lucknow. He has undergone internships and training programmes in Tata Motors Ltd, Hindustan

Aeronautics Ltd and Research Development & Standards Organisation. He is a member of International Association of Engineers and other professional societies such as International Association of Computer Science & Information Technology, International Association of Engineers & Scientists. His area of interest is manufacturing, workshop technology, design & estimation and he has published several papers in International journals. He has attended several national & international conferences on mechanical engineering. He received

2nd Award in model presentation Geothermal Energy Exploration Plant on celebration of Rajiv Gandhi

Renewable Energy Day at Non-Conventional Energy Development Agency, Lucknow, in Aug, 2010.