Company .

Name JBES
E.Code - Loss : Quality KAIZEN SHEET
DEPT. Production
KK JH QM PM HSE OTPM DM E&T Bench Mark -
Change the design of R/G gauge as per Target -
Kaizen Theme : To improve the quality of Frame-R Kaizen Idea:
fitment of part in HMSI. Start date 12/5/2015
component
Finish date 15/5/15

Problem/Present Status : Floor gap issues observed from customer end

HMSI.Now no checking method available in R/G gauge of Floor gap. Now
part check in R/G gauge in horizontaliy lay down position.
Problem Reported at : HMSI tapukera
Countermeasure:- Now we have change the design of R/G and parts
check in vertical position as which Frame-R radius and mandrel gap has
Team Members : VISHNU PATHAK
been reduce , and added a pin to check the position of pipe , that is right or
wrong.

Problem related to : Fitment problems in HMSI

Before After Benefits in P Q C D S M

Q
Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15

NO FLOOR GAP Sustenance Plan :

S.N. Activity Resp Frequency Remarks

HORIZONTAL VERTICAL 1
POSITION POSITION

1. Why - Change the design of R/G gauge Result : Horizontal Deployment :

2. Why - Floor gap observed at customer end 1 Till now no issued observed S.N. Area Resp Target Date Status

3. Why - No provision available in R/G gauge to check floor gap 2 1

4. Why - R/G not design as per to check this point 3

5. Why - This type problems not observed that time 4

Company .Name JBES
E.Code - Loss : Quality KAIZEN SHEET
DEPT. Production
KK JH QM PM HSE OTPM DM E&T Bench Mark
One side of bock should be fixed and second should Target
Kaizen Theme : To reduce the change of welding postion shift and Kaizen Idea:
be movable. Start date 8/5/2015
length variation of pipe in bottom bridge in k-38
Finish date 8/5/2015

Problem/Present Status : Both blocks are movable and welding torch

position has been fix and blocks controlled by phenumatic cylinder as which
bottom bridge position has been shifted and welding position out and Countermeasure:- One block has been fixed and second are movable as
Team Members : HIMANSHU SHARMA
welding done on pipe. which parts welding position has not been shifted.

Problem Reported at : K-38 bottom bridge line

Problem related to : Quality problems

Before After Benefits in P Q C D S M

Q
Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15

Sustenance Plan :
S.N. Activity Resp Frequency Remarks
Both block are Movable
movable
Fix Block Block 1

1. Why - One side clamping position of bottom fixed and other side movable Result : Horizontal Deployment :

2. Why -bottom bridge position has been shifted and welding position out
1 Improved the quality of bottom bridge S.N. Area Resp Target Date Status
and welding done on pipe.

3. Why - Welding torch position fixed but bottom bridge pipe position
2 1
movable.
4. Why - Bottom bridge pipe clamped by phenumatic cylinder 3

5. Why - Welding position shift in bottom bridge k-38 4

Company .Name JBES
E.Code Loss : KAIZEN SHEET
DEPT. Production
KK JH QM PM HSE OTPM DM E&T Bench Mark
Earthing sensor should be provided in stopper in Target
Kaizen Theme : To reduce the chance of variation of flaring height of Kaizen Idea: flaring machine. Start date 5/5/2015
stearing head k-38
Finish date 6/5/2015

Problem/Present Status : Flaring height not maintain as per specification

because of the manual intervention of operator pipe position has been vary
during operator keep the part in die, so that flaring height vary as per
spec.Now provided a stopper in die, part should be touch this stopper but
some times 100 % not sure that part touch or not so that pipe flaring height Countermeasure:- Earthing sensor provided in machine and interlink with
has been chnaged as per spec. stopper. When operator touch the pipe to stopper then machine run and if
Team Members : AMBUJ PANDEY
operatot not touch part completely then machine operation will not do. So
possibility of height variation has been reduced.

Problem Reported at :

Problem related to : Flaring height not maintain

Before After Benefits in P Q C D S M

Earthing P
sensor
Q
Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15 May-15

PICTURE NOT AVAILABLE D

Sustenance Plan :
S.N. Activity Resp Frequency Remarks

1. Why - Result : Horizontal Deployment :

2. Why - 1 Now flaring height problems not observed in pipe. S.N. Area Resp Target Date Status

3. Why - 2 1

4. Why - 3

5. Why - 4
 Kaizen Month/ Status
S.No Resistered Name Problems Kaizen(Countermeasure) Benefit
Month
15-May

Front fork Dim 192.8 +/- 1.5 mm not maintain after final welding due to Make a block to hold the legs of pipe and block has been made the close
1 Mar-15 Udham singh Quality improved OK
welding distortion. tolerence of the pipe and specification of fork dimensions.

To observed the complaint from customer Hmsi , holder Dim. Spec. 31 +0.5 Make a new block in which added a outside block where with controlled the
2 Mar-15 Udham singh Quality improved OK
maximum limit (31.5) size not maintain . dim 31 +0.5mm.

At stem insertion operation after six month die wear out and make again new
Now make a saperate bush as which after 6 month wear out the die then
3 Mar-15 sadhu ram die for insertion . New die cost was Rs approx. Die cost saved OK
only we can change only bush so that we save the cost of die.

Flaring height not maintain as per specification because of the manual

Earthing sensor provided in machine and interlink with stopper. When
intervention of operator pipe position has been vary during operator keep the
operator touch the pipe to stopper then machine run and if operatot not
4 May-15 Ambuj pandey part in die, so that flaring height vary as per spec.Now provided a stopper in Flaring height maintained OK
touch part completely then machine operation will not do. So possibility of
die, part should be touch this stopper but some times 100 % not sure that part
height variation has been reduced.
touch or not so that pipe flaring height has been chnaged as per spec.

Both blocks are movable and welding torch position has been fix and blocks
One block has been fixed and second are movable as which parts welding
5 May-15 Himanshu sharma controlled by phenumatic cylinder as which bottom bridge position has been Quality improved OK
position has not been shifted.
shifted and welding position out and welding done on pipe.

Floor gap issues observed from customer end HMSI.Now no checking method Now we have change the design of R/G and parts check in vertical position
6 May-15 Vishnu pathak available in R/G gauge of Floor gap. Now part check in R/G gauge in as which Frame-R radius and mandrel gap has been reduce , and added a pin Quality improved OK
horizontaliy lay down position. to check the position of pipe , that is right or wrong.

Hole miss part Outflow , No provision to ensure Hole miss

Locating pin provided in Receiving gauge
7 Feb-15 sadhu ram Quality improved OK

Earthling sensor provided in fixture if pin not guide in hole machine can't run
8 Feb-15 Kamlesh hingwe Hole miss part Outflow , No provision to ensure Hole miss Pokayoke OK

Hanger rod position shifted, No provision to guide Rod position

Guide provided in welding fixture
9 Feb-15 Nand kishore Quality improved OK

Thread damage possibility in final welding fixture. F.F Assy . Final welding
fixture clamping position on stem thread position . Thread damage not possible in this operation.
10 Feb-15 Umesh singh Quality improved OK

11 Feb-15 Hole miss part Outflow IN K-38 Earthling sensor provided in fixture if pin not guide in hole machine can't run Quality improved Pokayoke not effective
Birju / Sonu / Kamlesh
Hingwe

12 Nov-14 Laxmi Stem rod piece reject due to stem rod pin hole out(not To provide the sensor with automation. To ensure the stem NG piece not send to OK
qualify) and NG piece send to assembly line rod hole is ok assembly line.
Company .Name JBES Loss :
E.Code KAIZEN SHEET
DEPT.
KK JH QM PM HSE OTPM DM E&T Bench Mark
Kaizen Idea:
Target
Kaizen Theme : Countermeasure:- Start date
Finish date

Problem/Present Status :

Team Members :
Problem Reported at :

Problem related to :
Before After Benefits in P Q C D S M

Q
Jul-14 Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15

Sustenance Plan :
S.N. Activity Resp Frequency Remarks

1. Why - Result : Horizontal Deployment :

2. Why - 1 S.N. Area Resp Target Date Status

3. Why - 2

4. Why - 3

5. Why - 4