Kaizen Project by Sanjay Humania

6/18/2016 1

KAIZEN PROJECT

DEPARTMENT : Training (Automation)

PROJECT NUMBER : 1

PROJECT TITLE :

Effective utilization of Hydraulic training

kit & Reduction of oil leakage/wastage.

Sanjay Humania [www.sanjayhumania.com]

6/18/2016 2

PROJECT NO : 1

TITLE : Effective utilization of Hydraulic

training kit & Reduction of oil leakage/wastage.

BENEFITS :

•Avoid extra time for searching components.

•Avoid wastage of time for placement of components.

•Maximum utilization of class duration.

•Reduce hydraulic oil wastage

•Saving electricity

SUMMARY OF COMPLETED PROJECT


3

OUR FUNCTIONAL TEAM

Sanjay

Humania

Mr. V.M Bankar Sir

(Sr. Engineer)

Yes! WE WILL..

Training (LCA)

Mr. Animesh

Kala

Mr. Vinod

SirMr. Gyan

Majhi

6/18/2016 Sanjay Humania [www.sanjayhumania.com]

6/18/2016 4

PROJECT PLAN

PROJECT START: NOV 2014.

PROJECT COMPLETED : JAN 2015.

(UNDER LIFE TIME VALIDATION CYCLE)


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WHY THIS PROJECT

• To reduce component searching time

• To increase student performance & practice

time

• To enhance proper handling & utilization of

components

• To reduce oil wastage during experiment

• To increase utilization of class room & lab

• To reduce class changeover time between

classes

• To reduce kit/system failures

• Quality improvements in learning & training


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1.1 PROBLEM IDENTIFICATION

• While starting an experiment, time taken in

component searching is more.

• Lack of proper documentation and data sheet of each

and every components for student, which indirectly

reduce student performance.

• Lack of proper instruction manuals to handle and

avoid wrong way of components use.

• Oil leakage during experiments.

• Lack of proper location of the training kit/system in

lab.

• Student grouping in class may reduce class

changeover time.

• Need to increase quality in learning & training


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1.2 SELECTION OF PROBLEM

1) Quality improvements in learning

& training

2) Component searching time

3) Student performance

4) Utilization of components

5) Oil wastage

6) Capacity of class

7) Class changeover time

8) Kit/system failures


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1.3 DEFINING THE PROBLEM

Due to misplacing or misarranging of component after

experiment complete,

o which indirectly increase searching time in next

experiments.

Proper documentation and data sheet of each and every

components is not available for student,

o which indirectly reduce student performance.

Proper instruction to operate the kit was not displayed,

o So primarily student start in wrong way.

More junction/joints in a circuit may indirectly,

o Increases oil leakage oil wastage.

Conducting theory & practical in two different class room.

o Student grouping in class should be done.

Quality in learning & training.


6/18/2016 9

Why Why AnalysisBrain Storming Sessions

1.4 ANALYSIS OF PROBLEM

TOOLS USED FOR ANALYSIS


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Brainstorming is a group or individual creativity

technique by which efforts are made to find a conclusion

for a specific problem by gathering a list of ideas

spontaneously contributed by its member(s)

Brain Storming Sessions

So we all group member discussed on the

above mentioned 1.2 SELECTION OF

PROBLEM & 1.3 DEFINING THE PROBLEM

And come to few conclusion and results. We

have also prepared a Project Plan /CHART

discussed in next slide.


6/18/2016 11

Project Plan /CHART

Collecting

Information of

present situation

Planning

Identify

Waste

Reality

CheckMake Changes Verify Change

Measure

Results

Make this

the Standard

Celebrate

Do It

Again

Results:

A new way of work

Start


6/18/2016 12

1.4.1 ANALYSIS OF PROBLEM

Component searching time due to misplacing of

components by students.

So by labeling & allocating a fix place for a component

will be the right solution.

Student performance hampered due to unavailability of

documents & data sheet of the components.

Proper data sheet should provide to improve

performance.

Oil wastage due to leakage, it is not possible to eliminate

100% leakage,

But by reducing joints we can minimize leakage.

It is not possible to conduct total batch practical class at

a time,

So grouping should be done & in rotation all should do

practical class.

Quality improvements in learning & training Sanjay Humania

[www.sanjayhumania.com]

6/18/2016 13

1.4.2(a) ANALYSIS OF PROBLEM

W

H

Y

W

H

Y

A

N

A

L

Y

S

I

S

Component searching

Misplaced during experiment

Lack of proper labeling

Lack of time

Need a systematic way

Quality improvements in

learning & training

why

why

KAIZEN

why

why

why

why

High strength of batch


Lack of proper design

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1.4.2(b) ANALYSIS OF PROBLEM

W

H

Y

W

H

Y

A

N

A

L

Y

S

I

S

Wastage of hydraulic oil

Oil leakage

Lack of documentation

Need a systematic solution

To eliminate oil leakage &

cost saving

why

why

KAIZEN

why

why

why

why

High strength of batch


6/18/2016 15

1.5 IDENTIFICATION OF CAUSES

SR.

NO. MAJOR ACTIVITY CAUSE

1) Time consumption Lack of proper arrangement

2) Student performance Lack of documentation

3) Oil leakage Lack of good design

4) Class room utilization Lack of management

5)Quality improvements in

learning & trainingLack of all the above topics


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1.6 FINDING OUT THE ROOT CAUSE

Need systematic & continuous

evaluating process for all problems

Lack of proper instruction,

documentation, design &

guidance.


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1.7 DATA ANALYSIS

Hydraulic Fluid Leakage Drowning

Our Profits?

To answer this question, the costs

associated with the following factors

need to be considered:

•Leakage fluid

•Cleanup

•Disposal

•Safety

*Information collected and compared with the data

provided at www.machinerylubrication.com Sanjay Humania


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1.7 DATA ANALYSIS

Fluid Leakage Drowning our Profits:

1. A single hydraulic leak of one drop per second is equal to

673.92 litre of oil in a 12 month period!!!

2. Consider a piece of hydraulic equipment losing six cubic

centimetres of oil per minute (1 centimeter³ = 0.001 litre).

3. Over 6 hours/day, the loss is 0.36 litres, which perhaps

is not a significant amount. But over a month this

equates to 9.36 litres, and 112.32 litres over the course

of a year.

4. Assuming a fluid cost of Rs 5020/20 litre, so Rs 251 per

litre, the annual cost is around Rs 28,192 approx.

* The currency data is compared with data provided at

Google search


6/18/2016 19

1.7 DATA ANALYSIS

Cost per 20 l

Hydraulic oil used

in FESTO kit


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1.7 DATA ANALYSIS

Cleanup

Where oil leaks occur, there are almost always

cleanup costs to consider, which include: Labour.

1. Equipment required to clean trays and degrease

machine surfaces such as detergents and

absorbent materials.

2. Assuming it costs Rs 200/- per week in labour,

equipment and consumables to clean the piece

of equipment discussed above,

3. The annual cleanup bill totals more than

Rs 200 x 48 weeks = Rs 9600 approx.

*Information collected and compared with the data

provided at www.machinerylubrication.com Sanjay Humania


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1.8 DEVELOPING SOLUTIONS

1.The first step in preventing a hydraulic fluid

leak is in proper circuit design.

2.Design a system/circuit with as few joint or

thread connections as possible.

3.Properly support the tubes, pipes and hoses

conveying the hydraulic fluid.

4.Vibration could result in leakage in joint or

connection failure .

5.O-ring failure could be the cause of leakage,

so periodically O-ring should be checked, if

damage the should replace.


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KAIZEN PROCESS

.

ACTION BY WHOM BY WHEN STATUS

Oil wastage is stopped by

using oil try

By Sr. Engineer

(Mr. V. M.

Bankar)

12-NOV-14Oil wastage

reduces upto 85%

Hose oil wastage is

checked by using oil

bucket

By Me &

Mr.Vinod

Wairagade

(Trainee)

25-NOV-14Oil wastage

reduces upto 80%

Component arrangement

& allocating fixed place

By Me &

Mr.Gyan C.

Majhi (Trainee)

27-NOV-14

Searching time

reduces upto

100%

Labeling, arranging and

preparing proper data

sheets for components

By Me &

Mr.Vinod

Wairagade

(Trainee)

02-DEC-14Quality increases

upto 90%

Making arrangement of

theory & practical classes

in same classroom

By Me &

Mr.Animesh Kala

(Trainee)

10-JAN-15Class room

utilization 100%

Dividing total class

strength in to groups

By Me &

Mr.Avinash

Khandagale

28-JAN-15Training kit

utilization 100% Sanjay Humania


6/18/2016 23

1.9 FORESEEING PROBABLE RESISTANCE

1.Availability of casual

2.Time apart from daily class schedule

3.Internet (needed for proper

documentation)

4.Implementing the solution for the

problem & checking the results is time

consuming


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1.10 IMPLEMENTATION PROCESS

Theory class & practical class

in same classroom


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Theory class & practical class

in same classroom


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Hose-hanger is

used now

BEFORE

AFTERSanjay Humania [www.sanjayhumania.com]

6/18/2016 27


Bucket

under the

hose

hanger

for short

hoses

BEFORE

AFTER


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Bucket under the hose

hanger for short hoses

BEFORE

AFTERSanjay Humania [www.sanjayhumania.com]

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Components are labeled and

fix place is allocated for each

and every components

Components are labeled and

fix place is allocated for each

and every components

AFTER

AFTER


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Labeling on

component

tray

AFTERBEFORE


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Tray is made for

collecting leakage oilAFTER

BEFORE


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1.10 TRIAL IMPLEMENTATION AND

CHECKING THE PERFORMANCE

1. After implementing all our solutions all working

perfectly.

2. Only waste oil tray need some modification.

3. Initially it does not have any drain pipe line,

further we have modified and attached a drain

pipe with main oil tank via filter.


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1.10 TRIAL IMPLEMENTATION AND CHECKING THE PERFORMANCE

BEFORE

AFTER

AFTERSanjay Humania


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1.11 REGULAR IMPLEMENTATION


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1.12. FOLLOW UP & REVIEW

1. Regularly we are maintaining all rules

implementation after kaizen.

2. Feedback are taken from every student after

complication of each batch.

3. Regularly I check, component list with tray list.


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2.00 RESULTS

1. Class room & Hydraulic kit is now 100%

utilized in its maximum usable time.

2. Student feedback is good.

3. Oil leakage reduced

4. Oil wastage reduced

5. Experiment time increase per individual

student

6. Less maintenance cost for hydraulic kit


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2. 1 TANGIBLE BENEFITS

1. Consider a piece of hydraulic equipment losing six cubic

centimetres of oil per minute (1 centimeter³ = 0.001 litre).

2. Over 6 hours/day, the loss is 0.36 litres, which perhaps is

not a significant amount. But over a month this equates

to 9.36 litres, and 112.32 litres over the course of a year.

3. Assuming a fluid cost of Rs 5020/20 litre, so Rs 251 per

litre, the annual cost is around Rs 28,192 approx.


6/18/2016 38

2.2 CONTRIBUTION TO GREEN EARTH

1. Less oil wasted so less pollution

2. Student are mentally less stress during theory & practical

class


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2. 3 INTANGIBLE BENEFITS

1. Saving time

2. Saving money

3. Increasing profit


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2.4 SPECIAL GAINS (LEARNINGS) FOR

MEMBERS

Developed the Kaizen approach of problem

solving

Developed a spirit of TEAMWORK

Developed enhanced environmental awareness


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2.5 FUTURE PROJECT PLANS

LIST OF PROJECTS

1) Effective utilization of Hydraulic training kit


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2.6 HORIZONTAL DEPLOYMENT


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2.7 ACKNOWLEDGEMENT

OUR SPECIAL THANKS TO

Mr. H.D Kapse Sir (M.D. Sir)

Mr. J.D Bagul Sir (Manager Sir)

Mr. V.M. Bankar Sir (Sr. Engineer)

For giving a chance to participate in training on

KAIZEN,

&

My group member

Mr. Vinod Sir

Mr. Avinash Sir

Mr. Gyan Sir

Mr. Animesh Sir

For helping me in my project..Sanjay Humania


6/18/2016 44

SUMMARY OF O TAGS AS ON DATE

No of O

tag raised

No of

O tag

implemented

No of

O tag

pending

NIL NIL NIL

Completed

In Process

SUMMARY OF O TAGS FOR CURRENT

MONTH

No of O

tag

raised

No of

O tag

implemented

No of

O tag

pending

NIL NIL NIL


6/18/2016 45

List of 0 tag pending for completion with PDC


6/18/2016 46

Thanks


Leadership & Management

Kaizen Project by Sanjay Humania