Kaizen Submitted by Dept: Planning Date:02.08.

22
Team members Name-Maan Singh
Kaizen Category: I (Innovation) Before Kaizen
(Photo / Sketch)
Kaizen Theme: Stand for barricading area with barricading tape

Kaizen Schedule: 02.08.2021

Problem before Kaizen: In front of lubrication room, workmen used to place machines and
drum in haphazard manner causing poor housekeeping

Kaizen Activities: Fabricated stand for barricading tape installation and storage area After Kaizen
(Photo / Sketch)

Benefits / Results:
1) Designated storage area
2) Improved housekeeping
 Kaizen Submitted by Dept: Planning Date:05.08.22
Team members Name-Pratik More and Maan Singh
Kaizen Category: C(Cost reduction)
Before Kaizen (Photo / Sketch)
Kaizen Theme: Diffuser installation before breather for its life enhancement

Kaizen Schedule: 02.08.2022-05.08.2022

Problem before Kaizen: We were facing very low life(15-20 Days) of breather in some
equipment due to absorption of system oil by breather Kaizen (Photo / Sketch)

Kaizen Activities: Installed oil diffuser before breather to avoid system oil mixing in
breather silica gel.
Replication of kaizen to be done for other equipment also on phase manner

Benefits / Results:
1.Breather life increased from 15-20 days to approx 1 month
2.1 breather costs around 10K so 50 % cost saving is there on single breather.
 Kaizen Submitted by Dept: Planning Date: 10.08.2022
Team members Name- Maan Singh
Kaizen Category: R (Reliability) P(Productivity) Before Kaizen (Photo / Sketch)

Kaizen Theme: Moisture removal from CM-4 Symmetro gearbox

Date Oil moisture result Comments

Kaizen Schedule: 10.08.2022-11.08.2022 Gearbox overhauled and oil
04.08.22 0.08%
top up done
10.08.22 0.39%
Problem before Kaizen: After 3 days of CM-4 gearbox overhauling, gear oil visually looks
to be moisture contaminated. Tested and found oil moisture 0.385% which is more than 22.08.22 0.18%
limit.Total sump quantity is 2730 ltr

After Kaizen (Photo / Sketch)

Kaizen Activities: Oil vacuum de-hydration machine designed for hydraulic oil is used
for gear oil application with changes in some machine settings. Rechecked oil moisture
after 10 days and found moisture is reducing. Latest reading is 0.18% .

Benefits / Results:
1) Increased gearbox gear life because of reduced oil contamination
2) Saving of possible oil replacement cost because of high moisture. (2730 ltr oil
costing around 5Lakh)
 Kaizen Submitted by Dept: Planning Date: 19.08.2022
Team members Name- Maan Singh, Pratik More
Kaizen Category: R (Reliability) Before Kaizen (Photo / Sketch)

Kaizen Theme: Offline oil filtration in R-HRP hydraulic

Kaizen Schedule: 18.08.2022-19.08.2022

Problem before Kaizen: R-HRP hydraulic oil in-house oil patch report indicating high
size contamination particles in oil.

After Kaizen (Photo / Sketch)

Kaizen Activities: Installed Hy-Pro make offline oil filtration machine with 149 micron pre-
filter and 5 micron main filter.

Benefits / Results:
1) Increased equipment reliability
2) Increased oil cleanliness and improved hydraulic system working