ET

HOSUR

VINSAR ELESTOMERS HOSUR

QUALITY IMPROVEMENTS KAIZEN 29 NOV’11

 Activity KK JH QM PM SHE OTPM DM ET
KAIZEN Loss No. /
IDEA- SHEET Step
HOSUR Result Area P Q C D S M

Kaizen No: 1
Work Place:Rubber Moulding
KAIZEN THEME:.Reduction of defects during Idea: Pneumatic removal
unloading
Bench mark
Cell :
Problem/Present status: Countermeasure : Target
Impurities of wooden remover Placing the mould in fixture of Kaizen Start 22-07-2011
sticks to the hot rubber components similar shape and applying Kaizen Finish 01-08-2011
making contamination pneumatic pressure can remove the Team Members:
components . 1. Karthik.V
2.A.Ramanujam

Benefits:
1.Avoids damages to mould
Why Why Analysis: or components
Q:why impurities sticks to Results : 2. Reduced rejection of
components? Mixing of wood impurities components while
prevented. removal
A:wooden remover gets damaged
due to pressure and sticks to hot Quality improved
rubber components.
Root cause : wooden stick
remover
 PHOTO ET

HOSUR

BEFORE AFTER
 Activity KK JH QM PM SHE OTPM DM ET
KAIZEN Loss No. /
IDEA- SHEET Step
HOSUR Result Area P Q C D S M

Kaizen No:V2

Work Place:Rubber Moulding

KAIZEN THEME:.To reduce air locks in components Idea:Using aluminium mould opener.
Bench mark
Cell :
Problem/Present status: Countermeasure: Target
Flat top mould plates does not allow Small holes drilled in top plates Kaizen Start 1.08.2011
air locks to get released. makes air locks get released easily
Kaizen Finish 05.08.2011
Team Members:
1. Karthik.V
2.A.Ramanujam

Benefits:

Why Why Analysis: Results 1.Internal NC parts % reduced

Q: why air gets trapped in mould? 1.Air locks are prevented from 4000ppm to
2.Quality of components is 1000ppm.
A: Because of deep cavity mould.
improved.

Root cause : Deep

Cavity
 PHOTO ET

HOSUR

BEFORE AFTER
 Activity KK JH QM PM SHE OTPM DM ET
KAIZEN Loss No. /
IDEA- SHEET Step
HOSUR Result Area P Q C D S M

Kaizen No: 3
Work Place: Final Inspection
KAIZEN THEME:.To improve inspection method Idea: Using magnifier for inspection

m Bench mark
Cell :
Problem/Present status: Countermeasure:. Inspection of Target
Inspection of finished components finished components through Kaizen Start 12.01.2011
visually . magnifier Kaizen Finish 16.01.2011
Chances of locating minor defects is Team Members:
less 1. Karthik.V
2.A.Ramanujam

Benefits:
Analysis: Results 1.Elimination of defective
Minor defects can be identified and components is easy.
Q:Why visual inspection is not 2.Quality is improved
effective? eliminated thus improving the
quality
A: Minute defects cant be observed
easily
Root cause : Normal visual
inspection
 PHOTO ET

HOSUR

BEFORE AFTER
 Activity KK JH QM PM SHE OTPM DM ET
KAIZEN Loss No. /
IDEA- SHEET Step
HOSUR Result Area P Q C D S M

Kaizen No:4
Work Place:Rubber Moulding
KAIZEN THEME:.To reduce tool and component
damage Idea:Using aluminium mould opener.
Bench mark
Cell :
Problem/Present status: Countermeasure: Target
Using steel mould opener damages Using aluminum mould opener Kaizen Start 11.05.2011
the tool and components
Kaizen Finish 13.05.2011
Team Members:
1. Karthik.V
2.A.Ramanujam

Benefits:

Analysis: Results 1.Mould damage is prevented.

Q:why tool gets damaged.?
A: Because of hard steel opener
1.Damages of mould and 2.Handling is easy
components are minimized 3.Mould life is increased
2.Quality of components is
increased

Root cause : steel opener

 PHOTO ET

HOSUR

BEFORE AFTER