Innovators (cost Reduction)
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Company Logo
2nd CII National Kaizen Circle Compétition 2019 A Kaizen Presentation By
(SANDEN VIKAS INDIA PVT. LTD., FARIDABAD) On: 11 & 12th June -19
Venue : India Habitat Centre , New Delhi
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Profile
Company Logo
INTRODUCTION :-SANDEN VIKAS INDIA PVT. LTD. Sanden Vikas, Faridabad Sanden Vikas, Bhagola
Sanden Vikas, Ballabgarh
36 Years of Partnership
Sanden Vikas, Neemrana
Total Group Company : 12 nos. Total Manpower : 3500 nos.
Sanden Vikas, Pune
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Product & Customers
Company Logo
Clutch
Clutch
Variable Compressor
Variable Compressor
Fixed Compressor
Fixed Compressor
Fixed Compressor
HVAC
HVAC
HVAC
Injection Molding
Injection Moulding
Injection Moulding
Injection Moulding
Hose & Pipe
Hose & Pipe
Hose & Pipe
Hose & Pipe
Mil/Annum
Capacity :
STR
Hose & Pipe 1990
1992
1995
2008
2012
NEW BUSSINESS
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Kaizen Theme
Company Logo Kaizen Theme
Cost Reduction Implemented Area
Variable Compressor Assembly Line (SDV-2) Implementation Team:
Nakul (Team Member)
Aayushi (Team Member )
Diksha (Team Member)
Bharat Verma (Team Member)
Ashok Deshwal (Team Facilitator )
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Problem / Present Status
Company Logo
High Manufacturing Cost Factors Manufacturing Cost COST
In-Direct Cost
Direct Cost
Material Cost Labour Cost
Reduce 2 Manpower by 1.Work Re-balancing 2.Layout Modification 3.Cycle Time Study
Indirect material Cost Indirect manufacturing Cost FUTURE CUSTOMER FORECAST FREQUENT COST REDUCTIONS
Focusing On Labour Cost
FLUCTUATING CUSTOMER DEMANDS
INCREASED CUSTOMER REQUIREMENTS
NEW INVESTMENT
IMPROVE EXISTING
NEW INVESTMENT NOT REQUIRED FOR UPCOMING PLAN
SCOPE OF IMPROVEMENT
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo
Lip Seal Assy Lot No. stamping Angle Setting
Return spring Assy PP Straightening C.B. & PP Assy.
Total Processes :- 51 Total Manpower :- 39
Cycle Time Study
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo
20 Sec
12.9 Sec 18.5 Sec
14.2 Sec
17.6 Sec
12.3 Sec
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo 2
Improvement 1
Manpower Deployment at Stations 03 Manpower at 3 Machine
Return Spring Assy.
1.Return Spring Assy.-1 M/P 2.PP Straightening M/C-1 M/P 3.Pp & CB Assy.-1 M/P PP Straightening M/C
PP & CB Assy.
1 Improvement 2
Lip Seal Assy.
Automatic Conveyor
Model Stamp
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
After Situation
Company Logo
03 Manpower at 3 Machine
1.Return Spring Assy.-1 M/P 2.PP Straightening M/C-1 M/P 3.Pp & CB Assy.-1 M/P
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Logo
After Situation
02 Manpower at 3 Machine 1.Return Spring Assy.-1 M/P 2.PP Straightening M/C 1 M/P 3.Pp & CB Assy.-
1
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
After Situation
Company Logo 20 Sec
THEN
21.3 Sec
12.9 Sec
18.5 Sec
23.1 Sec
NOW
\
18.6 Sec
THEN
14.2 Sec
NOW
17.6 Sec 20.9 Sec
12.3 Sec
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Benefits Achieved
Company Logo Qualitative:
1.Reduce Fatigue 2.Reduce Part Contamination 3.Improved Material Handling
Quantitative:
Productivity : Quality
:
Cost
:
Delivery
:
Safety
:
Morale
:
From 2.08
2.16
3,12,000 INR
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Kaizen Sheet Reactive
Proactive
Category: Innovative
Kaizen Title: Problem/Present Status: High Manpower Cost 1.(03 Machine placed in 03 locations, 03 Operator required to operate) 2.(03 Machine placed in 03 locations, 03 Operator required to operate)
Company Logo
Company
MM/YY
Sr.No
Sanden Vikas India Pvt. Ld.
05/19
01
Implemented Area : Variable Before Improvement:
1
Compressor Line
Implemented by: Aayushi Diksha
Result/Benefit: (a) Qualitative1) Improve Material handling 2) Reduce Contamination with covered conveyor
Root Cause Identification:
After Improvement:
(b) Quantitative 01 Reduce Manpower
1. 2. 3.
Extra Manpower for Machine Manual material transportation Operator Waiting time
1
2
Standardization: 1) 2)
Root cause-Layout Constraint
Idea to eliminate root cause:-Line Balancing, Cycle Time Study Counter-measure Gravity Conveyor @ 90°
Return Block cleaning frequency added in check sheet PP Dent Checking Frequency to be Added
How many places this Kaizen can be deployed horizontally No
2nd CII National Kaizen Circle Compétition 2019 A Kaizen Presentation By
(SANDEN VIKAS INDIA PVT. LTD., FARIDABAD) On: 11 & 12th June -19
Venue : India Habitat Centre , New Delhi
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Profile
Company Logo
INTRODUCTION :-SANDEN VIKAS INDIA PVT. LTD. Sanden Vikas, Faridabad Sanden Vikas, Bhagola
Sanden Vikas, Ballabgarh
36 Years of Partnership
Sanden Vikas, Neemrana
Total Group Company : 12 nos. Total Manpower : 3500 nos.
Sanden Vikas, Pune
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Product & Customers
Company Logo
Clutch
Clutch
Variable Compressor
Variable Compressor
Fixed Compressor
Fixed Compressor
Fixed Compressor
HVAC
HVAC
HVAC
Injection Molding
Injection Moulding
Injection Moulding
Injection Moulding
Hose & Pipe
Hose & Pipe
Hose & Pipe
Hose & Pipe
Mil/Annum
Capacity :
STR
Hose & Pipe 1990
1992
1995
2008
2012
NEW BUSSINESS
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Kaizen Theme
Company Logo Kaizen Theme
Cost Reduction Implemented Area
Variable Compressor Assembly Line (SDV-2) Implementation Team:
Nakul (Team Member)
Aayushi (Team Member )
Diksha (Team Member)
Bharat Verma (Team Member)
Ashok Deshwal (Team Facilitator )
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Problem / Present Status
Company Logo
High Manufacturing Cost Factors Manufacturing Cost COST
In-Direct Cost
Direct Cost
Material Cost Labour Cost
Reduce 2 Manpower by 1.Work Re-balancing 2.Layout Modification 3.Cycle Time Study
Indirect material Cost Indirect manufacturing Cost FUTURE CUSTOMER FORECAST FREQUENT COST REDUCTIONS
Focusing On Labour Cost
FLUCTUATING CUSTOMER DEMANDS
INCREASED CUSTOMER REQUIREMENTS
NEW INVESTMENT
IMPROVE EXISTING
NEW INVESTMENT NOT REQUIRED FOR UPCOMING PLAN
SCOPE OF IMPROVEMENT
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo
Lip Seal Assy Lot No. stamping Angle Setting
Return spring Assy PP Straightening C.B. & PP Assy.
Total Processes :- 51 Total Manpower :- 39
Cycle Time Study
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo
20 Sec
12.9 Sec 18.5 Sec
14.2 Sec
17.6 Sec
12.3 Sec
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Before Situation
Company Logo 2
Improvement 1
Manpower Deployment at Stations 03 Manpower at 3 Machine
Return Spring Assy.
1.Return Spring Assy.-1 M/P 2.PP Straightening M/C-1 M/P 3.Pp & CB Assy.-1 M/P PP Straightening M/C
PP & CB Assy.
1 Improvement 2
Lip Seal Assy.
Automatic Conveyor
Model Stamp
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
After Situation
Company Logo
03 Manpower at 3 Machine
1.Return Spring Assy.-1 M/P 2.PP Straightening M/C-1 M/P 3.Pp & CB Assy.-1 M/P
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Company Logo
After Situation
02 Manpower at 3 Machine 1.Return Spring Assy.-1 M/P 2.PP Straightening M/C 1 M/P 3.Pp & CB Assy.-
1
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
After Situation
Company Logo 20 Sec
THEN
21.3 Sec
12.9 Sec
18.5 Sec
23.1 Sec
NOW
\
18.6 Sec
THEN
14.2 Sec
NOW
17.6 Sec 20.9 Sec
12.3 Sec
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Benefits Achieved
Company Logo Qualitative:
1.Reduce Fatigue 2.Reduce Part Contamination 3.Improved Material Handling
Quantitative:
Productivity : Quality
:
Cost
:
Delivery
:
Safety
:
Morale
:
From 2.08
2.16
3,12,000 INR
2nd CII NATIONAL KAIZEN CIRCLE COMPETITION 2019
Kaizen Sheet Reactive
Proactive
Category: Innovative
Kaizen Title: Problem/Present Status: High Manpower Cost 1.(03 Machine placed in 03 locations, 03 Operator required to operate) 2.(03 Machine placed in 03 locations, 03 Operator required to operate)
Company Logo
Company
MM/YY
Sr.No
Sanden Vikas India Pvt. Ld.
05/19
01
Implemented Area : Variable Before Improvement:
1
Compressor Line
Implemented by: Aayushi Diksha
Result/Benefit: (a) Qualitative1) Improve Material handling 2) Reduce Contamination with covered conveyor
Root Cause Identification:
After Improvement:
(b) Quantitative 01 Reduce Manpower
1. 2. 3.
Extra Manpower for Machine Manual material transportation Operator Waiting time
1
2
Standardization: 1) 2)
Root cause-Layout Constraint
Idea to eliminate root cause:-Line Balancing, Cycle Time Study Counter-measure Gravity Conveyor @ 90°
Return Block cleaning frequency added in check sheet PP Dent Checking Frequency to be Added
How many places this Kaizen can be deployed horizontally No
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