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Kaizen Theme : To eliminate customer Complaints About Damages & Paint Removal.

Kaizen Theme : To eliminate customer Complaints About Damages & Paint Removal. Supplier Name :M/s. ASHTA LINERS PVT LTD ASHTA V.Code : A0216 Location : Ashta , Dist. Sangli Tier I name : M/s/ SPICER INDIA. LTD. PUNE. . Team Information. Team photo.

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Kaizen Theme : To eliminate customer Complaints About Damages & Paint Removal.

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  1. Kaizen Theme :To eliminate customer Complaints About Damages & Paint Removal. Supplier Name :M/s. ASHTA LINERS PVT LTD ASHTA V.Code : A0216 Location : Ashta , Dist. Sangli Tier I name : M/s/ SPICER INDIA. LTD. PUNE.

  2. Team Information Team photo

  3. Problem Definition Part Name : BRAKE DRUM (0602AB0020N) Model : Xylo Brief description of Problem:- Br. Drum Damages In Transport. What : Brake Drum Damage, Dents mark & removal of paint. When: During Transport. Who: Parts gets in direct contact to each other. Where: On road Damping of parts. Which: Metal to metal contact of Outer portion. How: Complaints from customer.

  4. Damages Dents mark Kaizen Photograph

  5. Analysis of the Problem : Open space between parts is cause to create Damping in Transportation. Metal to metal contact creates dent & damages on part surface. Bottom layer of part having more weight load. Heavy damages cause to disturb geometrical parameters. Key Word :

  6. BEFORE AFTER Kaizen Photograph NO Provision in pallet to absorb Transit Damping.

  7. Result : Complaint Trend Jan- 11 To Jully-11

  8. Analysis of the Problem : No provision to absorb damping pressure on parts during travelling. At Initial loading stage operator put parts in Pallets. This stage cause to create heavy dents. Component to component contact causes paint scratch during travelling. Key Word :

  9. BEFORE AFTER Kaizen Photograph NO Provision in pallet to absorb Transit Damping. Provision of corrugated papers to absorb Transit Damping.

  10. Result:Complaint Trend Aug- 11 To Dec-11

  11. Analysis of the Problem : Painted Outer Portion rinsing to each other cause to remove paint layer. Corrugated Paper get Crack in Damping cause to create small dents. No Provision of Material to Sustain Damping Pressure. Key Word : To Provide Sustainable Material Which can Prevent Dents/Paint.

  12. BEFORE AFTER Kaizen Photograph

  13. BEFORE AFTER Kaizen Photograph Corrugated papers cuts/crack in Transit Damping. Not Reusable. Provided Partition Separator Tray Of Polypropylene Material. It Can Reused

  14. Result Complaint Trend Jan- 12 To Sept-12

  15. BEFORE AFTER Kaizen Photograph

  16. Complaint Trend Jan - 11 To Sept-12 Result:

  17. Benefits P Q Quality Improvement by Avoid Dents , Damages & Paint Disturbances. Reduced Customer Complaints from 10 to 0. C Corrugated Paper Box Cost 1.67 Rs/Pcs .Separators cost 0.60 Rs/pcs. D Safe transit delivery of material up to customer end. S M Improved Systematic approach.

  18. Sustenance Plan Horizontal Deployment

  19. Thanks

  20. Any Question ?

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