BENEFIT - KWPJ TAIL LAMP PRODUCTIVITY

BEFORE
AFTER

PRODUCTIVITY
59% MANPOWER
37%
250 OLD ; 1100 / 8 = 137 NOS. PER HEAD 9
NEW : 1100/5 = 220 NOS. PER HEAD 220 8
8
COST :
200 GOOD 7 BEFORE
6 AFTER
150 138 5
5
4
100
3
GOOD
50 2
1 SPACE
0 0
BEFORE AFTER BEFORE AFTER SPACE

PRODUCTIVITY IMPROVED FROM 137 NOS. TO 220 NOS. PER PERSON

FOR 1100 NOS./SHIFT-- 220 NOS. PER HEAD. (59%) MANPOWER REDUCED FROM 08 NOS. TO 5 NOS. PER SHIFT
FOR 900 NOS./SHIFT -- 275 NOS. PER HEAD. PER SHIFT (99%). FOR 1100 NOS./SHIFT ( 37.5%) & 4 NOS. FOR 900 NOS. PER SHIFT (50%).

MANUFACTURING COST SPACE 31%

2500000 2351232 30

25 24
2000000
37%
20
1500000 1469568
16.5 GOOD
15

1000000
10

500000
GOOD
5

0 0
BEFORE AFTER BEFORE AFTER

MANUFACTURING COST REDUCED INR 23,51,232 TO INR 14,69,568 PER YEAR SPACE BEFORE 24 SQ. METER
MANUFACTURING COST SAVING IN6 8,81,664 PER YEAR ( 37.5%). SPACE BEFORE 16.5 SQ. METER. SPACE SAVING 7.5 SQ. METER ( 31%).
DUCTIVITY : MANPOWER :
138 BEFORE 8
220 AFTER 5

FOR 1100 MANPOWER BEFORE MANPOWER AFT

BEFORE AFTER MAN COST TOTAL YEAR MAN COST
138 MANPOWER 2304000 1440000 16 12000 192000 2304000 10 12000
220 POWER 47232 29568 W/LIGHT TOTAL LIGHT WATT KWATT .@16 HRS UNIT/DAY UNIT COST COST/DAY
200 8 1600 1.6 25.6 25.6 6.15 157.44

BEFORE AFTER W/LIGHT TOTAL LIGHT WATT KWATT .@16 HRS UNIT/DAY UNIT COST COST/DAY
COST 2351232 1469568 200 5 1000 1 16 16 6.16 98.56

BEFORE AFTER
24 16.5

138 275 137

0.9927536231884

TOPIC OLD NEW

MANPOWER 2,304,000 1,440,000
POWER @ 6.15 47,232 29,568
TOTAL 2,351,232 1,469,568
SAVING 881,664
* ALL VALUES IN INR
MANPOWER AFTER
TOTAL YEAR
120000 1440000
COST/MONTH COST/YEAR OLD
3936 47232

COST/MONTH COST/YEAR NEW

2464 29568
Kaizen Thinking way: