If You are an Innovator, We have something for you!!!

Are You an Innovator!!!

Innovations is no body monopoly. Rightly said, innovation can come from anyone, may be a road side hawker, a 5 year old child, an illiterate farmer, an engineer, a sales person, a student, a scientist. Innovation, knows no boundaries & limitation of education, age, profession, etc.

innovators

Innovation needs a “problem to be solved” & “dedication for finding the solutions”. Majority of the times, innovation is only small changes made in any environment, that may have a very large impact.

We have many ideas flowing all around, idea can yield results, only if they are implemented in systematic way. India has vast opportunities for innovation in all spheres of lives. We also have potential to tackle all challenges in simpler ways.

We are looking for such innovators, who want to make a impact by simple changes in lives of people. We invite such people to work with us.

  • Are you good at innovation?
  • Have you designed something creative?
  • Is you creation, need of the future?
  • Do you want to commercialize your innovation for benefiting the society?
  • We have a attractive a option for you!!!

Attention innovators!!!

  • Innovators, who have ready working model of their project should send synopsis of your project on rds@breval.co.in
  • Selected candidates will be called for further discussions.

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Introduction to 5S -The Super Organiser

5S Structure

 

Introduction to 5S – Super Organiser

The 5 steps of 5S – Super Organiser are as explained below:

Sort:

This process identifies the items that are required to perform work in the work areas. Clear (sort out) all other items from the work area. It has following benefits:

  • Efficient use of work space
  • Improved safety
  • Improved productivity
  • Improved utilization of materials, supplies, and resource
  • More visible work flow
  • Improved employee satisfaction
  • Improved quality

Set In Order:

Aplace for everything & every person at its place. This supports in ease for retrieval. It has following benefits:

  • Elimination of 7 wastes and ease effort needed to search for or retrieve tools and supplies.
  • Easy identification of any missing tools
  • Improved safety through an organized workplace
  • Increased productivity

Shine:

Proactive/preventive housekeeping to keep work areas, work surfaces, and equipment clean and free from dirt, debris, oil, etc. Benefits:

  • Cleaner and more satisfying place to work
  • Improved Quality standards
  • Maintenance issues exposed faster (planned downtime vs. unplanned downtime)
  • Improved safety (fewer accidents)
  • Improved work culture

Standardize:

Do things in a consistent and standard way. Formulate standardize procedures for activities, instruction, schedules, checklist for helping keep the workplace clean and organized. Standardize work area layouts and storage techniques wherever possible. Visual Management implementation for ease of maintaining standardisation.

Sustain:

Integrate 5S principles into the organization’s objectives in order to sustain new standards and continually improve the workplace.

Workshop on 5S

We have designed special products for 5S like Red tag, Posters, Lean Storage etc. Please visit our Online shop.

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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)