एक कदम निपुणता की ओर

एक कदम निपुणता की ओर

एक कदम निपुणता की ओर

As all India has united to full fill dream of “स्वच्छ भारत”, we have dreamed of “निपुण भारत”, i.e. Efficient India. The Motto “एक कदम निपुणता की ओर“ is very important for Make in India campaign. More than 70 % of all working population works in small & medium scale enterprise which combines bottom of the pyramid of industrial structure. Efficient manufacturing is of outmost importance to move towards growth & sustainability for everyone.

5S is the most basic & very vital lean tool for bringing efficiency in industrial environment. we shall strive hard in inculcating 5S as a habit in our team. This is not a rocket science & can be easily understood by the bottom most team member. Off course, this needs a dedicated effort to yield result.

Just to put it in a simple way

  • Sort says, remove, what is not required from your work place.
  • Set in order says, put things orderly.
  • Shine says, make every thing clean.
  • Standardize says, Frame set of instructions or rule, so that each member of team works in same way.
  • Sustain says, work for long term effect.

These are very simple things, which are getting ignored due to many reasons. With focus on production & profit, companies do not pay attention to 5S. As a matter of fact, Implementation of 5S can increase production, by removing in-efficiency from the system.

5S makes procedures & process very simple to operate. This has amplifying effect on the company. few benefits are as under:

  1. Inefficiencies are removed.
  2. Set of instruction helps in standardizing the job
  3. Easy to train new member in team. Less expenditure in training
  4. Reduce wastage in time due to non value added activities
  5. Motivates team towards excellence.

To achieve dream of golden India, we have to strengthen our basic structure so that we cultivate the habit of working efficiently, thereby focusing on producing more from less with excellent quality.

Let’s take a pledge for taking the first step ie. 5S towards building a stronger india
” एक कदम निपुणता की ओर”

We support the motive of एक कदम की निपुणता ओर, & provide services in field of 5S auditing, consulting & training at very affordable prices. Contact us for any kind of support & partner us in building an Efficient India.

Lean Training Videos

Videos are the best way of self development. We are developing videos for supporting the zeal to learn.

The Egg Factory- Eliminate Waste

This video takes an example of a Boiled Egg company- ” The Egg Factory” to make you understand the various types of waste in a process. this also explains how to identify these wastes, so that actions plan for eliminating these wastes can be worked out.

 

Eight Lean Waste- Mr. TIMWOODS

There are many type is waste in any industrial process. These are categorized in 8 types. The training video tells about types of wastes in an industries & how to identify them.

Kaizen- The Lean Idea Management Tool

Kaizen is japanese term representing continuous improvement (KAI=Change, ZEN=GOOD). The kaizen training module tells about history, importance & process of implementing a kaizen system in any company. The video explanes kaizen in very simpler & easy way.

Multi tasking vs Single tasking

Single tasking is the new multitasking. Which is better Multi Tasking or Single Tasking? The Video will give you all your answers.

The Red Tag System

The Red Tag system is very important  for successful implementation of 5S-SORT process. This the first step of 5S, thus very important for successful implementation of complete 5S process. The Video explains how Red tag is to be used.

You can Buy red tags here.

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Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

Case Study – Frequent maintenance in Stack Analyser (Banish MUDA)

This is a beautiful case study resembling positive approach of the team towards finding solution.

A stack analyser was having very high frequency of maintenance. Being mounted in stack of incineration plant, the probe was exposed to dust & acidic gases, which were the main cause of probe failure.  Main Issues with the Analyser is:

  • High Frequency of Cell and heater failure.
  • Frequent chocking of cell assembly.
  • High time required for cleaning and cell replacement.
  • High cost of maintenance

The team took up the challenge to come out of the issue. The study done was a good example of usage of various reliability tools like RCA, Fishbone diagram, Brainstorming, etc. ,there is another angle to it, ie. Lean Management. The main objective of the study was to reduce the quantity of jobs performed on the analyser.

The team has recently gone through “7 Wastes-Mr. TIMWOOD “. They decided to identify the wastes in the activities on the analyser. All the activities were identified & written.

Each activity was studied and type wastes were identified.

Case Study- Frequent maintenance in Stack Analyser (Banish MUDA)

Analysis of the identified waste is as under:

  1. Transportation of probe to the repair location: Can the probe be repaired at the installed location?
  2. Motion of the workmen for steaming, hammering & temporarily electrical connections: Why Steaming, Hammering is required? Why temporarily connections are required?
  3. Defect during leak checking: What is the procedure for ensuring correct assembly?
  4. Inventory: How to reduce inventory required supporting the frequent maintenance?
  5. Waiting: Why can’t the warm up done at location?
  6. Over Processing: Why calibration & response check is required two times?

The next step was to find answer to these questions. The maximum time was consumed by removal of Cell & seal assembly. RCA tool, Why Why analysis was used to drill down to accumulation of the acidic dust at the cell as the root cause. A ceramic diffuser was prepared with OEM, to put in place of mesh, which is more capable of filtering dust. This small change after value engineering has resulted in substantial improvement in terms of time, cost, inventory, maintenance frequency, reliability & availability of the instrument.

Continuous Improvement

Cost of Modification: Rs. 25000

  • Total time of job was reduced from 8.8 hours to 4.3 hours.
  • No. of jobs reduced from 10/year to 4/year.
  • Material cost reduced from Rs. 1.8 Lakh to Zero.

Continuous Improvement

Experience of industries has been concentrated in different quality, Reliability & Lean tools. Correct knowledge & implementation of these tools is necessary for best results.

Check other case studies on Vanilla Ice Cream and Flight 5390 failure.
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Case Study- Frequent maintenance in Stack Analyser (Lean Tools)