Kobetsu Kaizen Zero Air Leakege Presentation
Kobetsu Kaizen Zero Air Leakege Presentation
Kobetsu Kaizen Zero Air Leakege Presentation
KOBETSU KAIZEN
( ZERO COMPRESSED AIR LEAKEGES)
200
174 174 Target- Industry best air losses - 30 cfm by march`05
180 Leading target - 10 cfm by mar`07
160
140 115
120
100 75
70
80 64
5353 51 25.2
60 51
43
24.7
24.5 24.5 23.5 23.2 22.3
29 29 24.5
40 29
20
24.5 23.2
0 apr`0 may`0 jun`0 sep`0 oct`0 nov`0 dec`0 jan`0 feb`0 M ar.0 M ay.0 June. Aug.0 Sep.0 Oct`0 Nov` Jan.0 Feb.0 M ar.0
jul`04 Jul.05
4 4 4 4 4 4 4 5 5 5 5 05 5 5 5 05 6 6 6
CFM 174 174 115 75 64 53 53 51 51 43 29 29 25.2 24.7 24.5 24.5 24.5 24.5 23.2 23.2 22.3
TPM Club India Jishu Hozen Pillar
LOADING 03.43.03
134
UNLOADING 03.45.17
45
LOADING 03.46.02
136
UNLOADING 03.48.18
45
LOADING 03.49.03
136
UNLOADING 03.51.19
45
LOADING 03.52.04
LEGRIS make air blow gun PILOT make air blow gun used
used - high consumption of - low consumption of air
air
TPM Club India Jishu Hozen Pillar
BEFORE
AIR BLOW GUN
AFTER
Air blow gun connected with Air blow gun connected with
jublee clamp - air leakages point leakproof quick fittings to .
TPM Club India Jishu Hozen Pillar
Air pipe connected with jublee Air pipe connected with leakproof
clamp - air loss point quick fittings to prevent air loss.
TPM Club India Jishu Hozen Pillar
Date-
QUICK RELEASE COUPLING 21.10.2004
BEFORE AFTER
Date-21.09.04
COMPRESSED AIR LINE
Air pipe connected with jublee clamp - Air pipe connected with thread joints -
air leakages point air leakages point
TPM Club India Jishu Hozen Pillar
Date-21.09.04
BEFORE AFTER
9
8 38818
7
6 40111 37791
34744
5
4
3
2
1
0
June'0
023 034 045 Apr.05 May.05 July05 Aug'05 Sep.05 Oct.05 Nov.05 Dec.05 Jan.06 Feb.06
5
Series1 7.72 4.8 3.72 3.38 3.57 4.12 3.73 3.49 3.17 2.67 2.98 3.3 2.65 3
TPM Club India Jishu Hozen Pillar
Series1 38.5 24 21.7 18.59 19.63 22.66 20.5 19.18 17.46 13.6 17.88 18.15 16.43 18.5
TPM Club India Jishu Hozen Pillar
600
500
400
300
200
100
0
APR.0 MAY0 JULY0 AUG'0 OCT`0 NOV.0
023 034 045 JUN.05 SEP`05 DEC.05 JAN.06 FEB.06
5 5 5 5 5 5
Series1 478 297 236 158 174 180 177 167 155 142 164 174 137 153
TPM Club India Jishu Hozen Pillar
Identification of air leakeges areas Reduction in mfg.var.cost(power) Saving of 182953 units (Kwh)
Esteblishment of real cause 2.92 Units /eq.eng in - 034 Saving of Rs. 10 - Lac
160 CFM - 30 kW
Before
Before
After
TPM Club India Jishu Hozen Pillar