Assignment 1 - KAIZEN
Assignment 1 - KAIZEN
Assignment 1 - KAIZEN
Assignment -1
TPM
KAIZEN
5
PDCA
WHY
INSTRUMENT OF QUALITY
CONTROL
Pareto diagram, reasons and results diagram (so
called Ishikawa diagram), histogram, scheme,
punctual diagram, check card most often with x-R
diagram,
DO
PLAN
ACT CHECK
•Then we act promptly to • By checking through
implement the changes Data check sheets and
though process graphical analysis we
standardization. were confirmed that plan
and action will bring
desired result.
STANDARD OPERATION PROCEDURE
A work part was placed on the cutting line table where the cut
pieces were to be inspected. Its lower part was plain and upper
part was about 150 inclined with respect to the table.
The vertical portion which was attached at rear end of the work
part was used for holding the defect board and instructions for
the Checking Personnel.
Two steel rods were attached with the vertical portion holding a
light stand. The work part is 4 and ½ feet long and 2 and ½ feet
wide
INTRODUCTION OF DEFECT
BOARD
A defect board containing small pieces of fabrics with defects
was placed in the vertical portion of the work part.
The board was precisely useful for the checking personnel to
identify the defects of the fabrics.
The green color specifies the minor defects that can be
accepted and the red color specifies the major defects to be
rejected.
OTHER IMPROVEMENTS
LIGHTING FACILITIES
A fluorescent tube light (40W-250V, 2800 lumen) was placed
above the work part. The high lighting facility gave the worker
more flexibility in identifying fabric defects.
PERFORMANCE BOARD
A board was hanged above the table measuring the performance
of the checking personnel. It also helped to identify the
percentage of rejected fabrics. The number of cut pieces of
fabrics checked
AFTER KAIZEN
The process had been observed for ten months for the
improvement result.
For the first four months the previous process was observed and in
the next six months when the new process had been implemented,
data of total rejection and fabric fault in final product had been
taken.
It has been observed that, in the beginning of the implementation
the rejection of final product due to fabric fault has been
increased though it was supposed to decrease.
But after three months, the fabric fault has been decreased in
about 50 percent than of the previous process, which has been a
milestone for the industry
FINAL READINGS
USAGE OF SHOULDER PAD
GADGET
Shoulder pad is a type of fabric-covered padding used in men's and women's clothing
to give the wearer the illusion of having broader and less sloping shoulders.
A shoulder pad gadget is equipment used for holding shoulder pads in a disciplinary
and worker friendly way. Shoulder pads are made in shoulder pad making section
according to the buyer order and Comes to sewing line when production starts.
During the old process, shoulder pads were kept in a transparent bag beside the left
foot of worker who joint the pads with processing garments like suits, jackets and
overcoats etc. The problems with this process are stated below:
Time dilation
Indiscipline in work place
Increased stress and fatigue of worker
Difficulty in size selection of shoulder pads
Error in size selection
Low work efficiency
Low production rate
More space required.
DEVELOPMENT PROCESS
Frame Making of A Shoulder Pad Gadget:
A frame was made for holding shoulder Pads. The frame was
made of steel having length of 27 inches, height of 40 inches and
width of 12 inches. There were three segments of boxes in the
frame where in each segment shoulder pads are kept according
to their size (small, medium, large). The capacity is 420 pair of
shoulder pads.
Air Filled Cylinder:
A cylinder filled with air was jointed with the frame
through a pipe. The cylinder was 40 inches in height
having a diameter of 10 inches. It had a piston in the top
for controlling air pressure.
There is a hanger box holder for holding the box right now.
Workers feel very comfortable in taking hangers and efficiency
is highly increased in the new process.
BOTTLE NECK MINIMIZATION