Factory transformation- kaizen

1
Discrete/ AssemblyLakshmi Machine Works Full
factory transformation
Assembly Stores - Before Kaizen
Logistics - After Kaizen
Suppliers connected by Milkrun concept
Internal logistics by Mizusumashi
Cluttered Assembly
Multi-storey stores overfull with Inventory
Mini Super Market in production
Inventory in open space
Results
Assembly Stores - After Kaizen
Organized Assembly
Supermarket Controlled Inventory
Reorder of items through Kanban
2
Discrete/ AssemblyMilton Plastics Full factory
transformation
Assembly Production - Before Kaizen
Production - After Kaizen
Improvement of machines
Large lot Production
Sitting operations in assembly lines
SMED Change over in 90 sec
Multiple Operators- Single function
Small lot production
Results
Assembly Stores - After Kaizen
Single Operator Multi-functional
Kanban Inventory reduced from nose level to
knee level
Standing operations in assembly lines
3
Discrete/ AssemblyBiocon Productivity
improvement in Manual packing line
Unbalanced line- Before Kaizen
Balanced line Rejection analysis for reducting
rejects
Activities which exceed Takt time (0.84 sec) is
managed by material handler effort to maintain
balance
Results
Re-arrangement of manpower by balancing the line
4
Discrete/ ProductionZydus Cadila Expansion of
Tablet facility (Cellular Flow Design)
Plan with Conventional Design (Old facility)
Paradigm Shift from Conventional Design to
Cellular flow design
Cellular flow design (For expansion of tablet
facility)
Results
5
Discrete/ ProductionZydus Cadila Full factory
transformation
Cycle time reduction (Lyophilization)
Increase of machine capacity

• Cycle Time
• reduction from 48
• Hours to 34 Hours
• Processing
• Capacity increased
• from 0.45 Million
• Vials to 0.81 Million
• Vials per month

Workstation for Vaccine R Packing line
Egg Processing Capacity Recovery
Before 85 doses/ man-hour After
120 doses/ man-hour Improvement 30
Old
New
6
Discrete/ ProductionMahindra Conveyors Early
Management for New plant layout
Early Management Event Structure 3 Phases
Capacity Planning Team designing the new Layout
Layout Pictures
Current State Mapping Future State Mapping
(Bucket Elevator Value Stream)
Results
FSM
CSM
7
Discrete/ ProductionReliance Industries
(Textile) Flow in Mending
Value Stream Map for improving the flow in Mending
5S at Maintenance room
Unnecessary items. Dirty work area
Very poor housekeeping
Before
Before
Space created, racks arranged
Proper arrangement - Tools belts
After
After
5S Quality tools (DOE) Reducing Spinning
Weaving rejections
Results
Before
After
5S in Reed storage area
Corrugated sheet not used while setting the
scrubber
Improper storage of reeds
Corrugated sheet leading to poor suction in
scrubber
Before
After
8
Discrete/ ProductionSandvik Implementation of
TPM
Machines Before Autonomous Maintenance
Improvisation of Hard to Clean, Lubricate,
Inspect Tightening areas
Feed carriage inside Hard to Clean
Use of special cleaning tool
After
Before
Belt drive Difficult to inspect
Annealing tank with abnormalities
Contamination - Splattering
Use of transparent door to inspect
Cellar area Untidy, Dirt etc.
After
Before
Machines After Autonomous Maintenance
Results
Annealing tank localized from Dirt/ Dust
Localization of Contamination
Clean cellar area