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    Kaizen-Continuous Improvement

    Uploaded by

    Aminul Islam
    The document discusses the concept of continuous improvement (Kaizen) through small, incremental changes. It provides an overview of Kaizen principles such as reducing waste, eliminating unnecessary processes, and focusing on continuous, incremental change. Examples are given of Kaizen improvements made at a cooling tower, including modifying the gear box breather system and developing a way to check intermediate shaft float. The benefits of these changes included saving money by reducing maintenance costs and manpower. Overall, the key aspects covered are the Kaizen philosophy of continuous improvement and examples of its implementation.

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    © All Rights Reserved
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    Kaizen-Continuous Improvement

    Uploaded by

    Aminul Islam
    1K views43 pages
    The document discusses the concept of continuous improvement (Kaizen) through small, incremental changes. It provides an overview of Kaizen principles such as reducing waste, eliminating unnecessary processes, and focusing on continuous, incremental change. Examples are given of Kaizen improvements made at a cooling tower, including modifying the gear box breather system and developing a way to check intermediate shaft float. The benefits of these changes included saving money by reducing maintenance costs and manpower. Overall, the key aspects covered are the Kaizen philosophy of continuous improvement and examples of its implementation.

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    Kaizen-Continuous Improvement

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    The document discusses the concept of continuous improvement (Kaizen) through small, incremental changes. It provides an overview of Kaizen principles such as reducing waste, eliminating unnecessary processes, and focusing on continuous, incremental change. Examples are given of Kaizen improvements made at a cooling tower, including modifying the gear box breather system and developing a way to check intermediate shaft float. The benefits of these changes included saving money by reducing maintenance costs and manpower. Overall, the key aspects covered are the Kaizen philosophy of continuous improvement and examples of its implementation.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    1K views43 pages

    Kaizen-Continuous Improvement

    Uploaded by

    Aminul Islam
    The document discusses the concept of continuous improvement (Kaizen) through small, incremental changes. It provides an overview of Kaizen principles such as reducing waste, eliminating unnecessary processes, and focusing on continuous, incremental change. Examples are given of Kaizen improvements made at a cooling tower, including modifying the gear box breather system and developing a way to check intermediate shaft float. The benefits of these changes included saving money by reducing maintenance costs and manpower. Overall, the key aspects covered are the Kaizen philosophy of continuous improvement and examples of its implementation.

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    .

    Continuous Improvement

    Prepared by
    Md.Aminul Islam
    Reliability Engineer
    SADAF-SABIC
    Email: aminulju@gmail.com
    ..tool is KAIZEN
    Japanese business philosophy of continuous improvement ..
    ...by Everybody! Everyday! Everywhere!

    KAIZEN is a problem solving process with existing resources.


    Find root causes of problems and solutions.

    Kaizen works by reducing waste (Muda- waste) & eliminating


    work processes that are overly difficult (Muri- overburden).

    Kaizen focuses on applying small, daily changes that result in


    major improvements over time and long-term profit.

    Kaizen emphasizes that the process is the target and


    employees can provide improvements .

    Kaizen is an on-going, a never-ending improvement process.

    It's a journey rather than a destination


    Identify an
    opportunity
    for
    improvement
    Plan for the
    future/sustain Collect all
    relevant data

    Find any scope


    for horizontal
    deployment and Cycle Analyse the
    process /data

    of
    deploy if
    applicable.

    Standardize the
    solution
    KAIZEN Find root cause of
    the problem &
    through proper develop an
    documentation optimal solution

    Study the
    Implement the
    results and
    solution /
    quantify
    kaizen
    benefits
    Replace conventional fixed ideas with fresh ones.
    Think positive dont say cant
    Think, Rethink and then attempt kaizen, with 100% clarity and understanding
    Grasp the current situation, speak with data, manage by facts

    Start by questioning current practices and standards. Ask why ? How?....


    Seek the advice of many associates before starting a Kaizen activity.
    Better the wisdom of 5 people that the expertise of 1

    Dont make excuses. Make execution happen.


    Use only appropriate tools, while implementing.
    Do not seek perfection. Implement a solution right away, even if it covers
    only 50 % of the target.
    Correct mistakes as soon as they are found

    No blame - treat others as you want to be treated


    According to M. Imai, a guru in these management philosophies and practices, the three
    pillars of kaizen are summarized as follows:
    1. Housekeeping/5S 2. Waste elimination (7 type of
    wastes)

    3. Standardization.
    Top Management commitment

    Top Management commitment

    Top Management commitment

    Setting up an organization dedicated to promote Kaizen

    Appointing the best available personnel to manage the Kaizen


    process

    Conducting training and education

    Establishing a step-by-step process for Kaizen introduction.


    KAIZEN + Innovation = Best Practice
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    Suggestion system

    KAIZEN system
    COOLING TOWER GEAR BOX BREATHER PROBLEM
    Before kaizen What is the problem ?

    Air trapped inside


    the oil indicator
    due to absence of
    vent hole

    Oil indicator
    Gear box with oil inlet line breather system
    chocked due to
    dust deposition
    in narrow hole.

    Excess oil filling


    due to wrong oil
    level indication in
    Motor with oil level indicator sight glass, which
    leads to oil seal
    failure & oil
    leakage.
    COOLING TOWER GEAR BOX BREATHER MODIFICATION
    After kaizen Countermeasure

    Made 10mm drill hole made at upper


    position to remove the trapped air
    during oil top up at gear box.

    Modified oil indicator

    Old breather cap


    Modified breather system at oil

    removed, side holes


    plugged ,6mm hole
    made at top face &
    S.S. bend tube
    welded
    indicator

    Complete oil level indicator


    COOLING TOWER GEAR BOX BREATHER MODIFICATION
    BENEFIT

    Before kaizen

    Oil seal damaged cost


    Rs = 1500/-*12
    Rs = 30,000/-

    After kaizen SAVING MONEY


    Oil indicator & breather Rs = (30,000 2000 )
    valve modification cost
    One machinist+ two
    Rs = 28,000/-
    finisher + 0ne welder
    Rs = ( 500+1000+500 )/-
    Rs = 2000/-
    COOLING TOWER GEAR BOX OVERHAULING PROBLEM

    Before kaizen What is the problem ? ( before kaizen )


    Gear box model number B232
    Manufacture - GREAVES
    Gear ratio 12.972 : 1

    This intermediate shaft standard floating


    This is the intermediate shat bearing
    =0.10mm . But there was no facility to check
    locking cover. There was no any
    the shaft floating. We checked from side
    shaft lifting scope to check the
    inspection door, which was not correct.
    bearing floating.
    GEAR BOX INTERMEDIATE SHAFT FLOTAING CHECK ARRANGEMENT
    After kaizen
    We are
    checking
    intermediate
    shaft floating
    by jacking
    method.

    Made 2 number drill hole with tap of M 16,


    80 mm PCD on the bearing cover.
    We ensure floating 0.10 mm at
    Now by Jacking the shaft towards bearing lock intermediate shaft bevel gear face
    plate with the help of 2nos M 12 bolt with through dial gauge.
    nut we can set the Floating.
    GEAR BOX INTERMEDIATE SHAFT FLOTAING ARRANGEMENT

    BENEFIT
    Before kaizen After kaizen

    There was no scope for set the Maintain the maintenance procedure
    floating at intermediate shaft perfectly.
    bearing.
    (Presently M 12 bolt installed at bearing
    cover).

    Two man engaged at 8 hours Two man engaged at 4 hours


    Two man power cost = Rs ( 125*2 *8 ) Two man power cost = Rs (125*2 * 4 )
    = Rs 2000 = Rs 1000

    Manpower cost saving = Rs (2,000 1,000 )/-


    = Rs 1,000/-
    Improve the overall culture of the company and
    increase employee retention
    Improve employee communication and
    cooperation
    Building excellent teamwork that work together to
    solve problems.
    Improve morale and employee satisfaction
    Show employees trust: Another way to help Kaizen
    succeed in a manufacturing environment is to show
    workers that they are trusted
    Increase plant/equipment efficiency
    Reducing Waste & cost
    Improving Safety standard
    Increase plant productivity & profit
    Simplifying work processes by eliminating difficult
    work
    Improve quality-related behaviour and
    achievements.

    It will also create a positive environment for


    various employees/ teams to compete against
    each other and these give a 'win-win' situation
    between the organization and employees.
    KAIZEN- Approach is one of the tools for quality improvement in the industry
    The one of important purposes of KAIZEN is to eliminate waste in work place
    Maximum utilization of existing resources
    Anyone can do it with: Little knowledge , Little dedication ,Little hard work
    and A very big positive attitude
    Our wisdom has no limitation
    Kaizen results can be measured in many ways as
    below:-
    Number of kaizen completed per employee per year

    Percentage participation level of employees

    Economic benefits in SAR/USD

    Qualitative benefits measured in terms of Near miss

    accidents

    Drop in ppm levels of quality

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