“ Human Error Prevention ”

1. “Human Error Prevention” Problem Statement: Xylo Brake Drum low productivity problem. Machine Break Down Increased Supplier name : ASHTA LINERS PVT LTD ASHTA Tier I name : SPICER INDIA LTD PUNE What is the problem- Low productivity hence Unfullfilment of customer for Xylo Brake drum, Operator fatigue due to no. of Work stations, High cycle time. Who is affected- Customer Where location- Spicer(I) Pune. When Since – Feb.2011 Why is the problem –Conventional Lathes & Old CNC. How much- Insufficient Quantity supply to Customer. Training Date : Project Start Date : Sept11 Project Completion Date : March- 12 Quality Productivity Cost Safety

2. Human Error Prevention Part Name – Xylo Brake Drum. Part Number - 0602AB0020N. Model : Xylo. Process Stage : Operation Set Up Team members – 1. Team leader : S. S. Magadum 2. Member 1 : S. M. Attar 3. Member 2 : G. R. Japhale 4. Stage Operator(Must) : Anil Chavan • Low Productivity at Turning Operation. • More Materials Handling & Operator Fatigue.. • Poor Cost Increased. • Due to More operations Wide Tolerances Used. • High Br. Down %. • Rejection % Increased. • Labor Cost Increased. Disadvantages Of Conventional Machine Line : TOTAL : 08 NOS OPRATION

3. Analysis of the Problem :Why Problem is Generated Old Machine Cause to increase Br. Down Hours. Some of them are Conventional & old CNC Machines . Conventional Lathes Increase Operator Fatigue & Material Handling. More No. of Operations Cause to increased cycle time & Parameters Clearances. To Control Quality Parameters 70 % tolerances used. Old Machine Instability cause to increase Cost of poor quality. Key Word :

4. Solution Implemented: To adopt CNC machines instead of conventional machines for turning. Sustenance Plan for Actions : To replace old conventional machines and adopt Classic CNC machines of high speed-feed features & Suit To Compact For Space. Beneficial Targets Planed By Management : 1) To Increase productivity with fulfill of customer quantity requirement. 2) To Reduce human & quality errors with merging no. of operations. 3) Improve Quality Parameters. 4) Reduce Materials Handling. 5) Training plan for advance Classic LT-20 CNC Machines about Operating , Programming and its features.

5. Human Error Prevention MACHINE OLD SETUP OPR. NO:-150 TO 220 MACHINE NEW SETUP OPR. NO:-150 TO 200 BEFORE : AFTER : 06 Nos. OPERATION LINE TOTAL : 08 Nos. OPRATIONS LINE

6. Human Error Prevention OTHER AFFECTED PARAMETARS OTHER IMPROVED PARAMETARS BEFORE : AFTER : TOTAL : 08 Nos. OPRATIONS LINE 06 Nos. OPERATION LINE

7. Human Error Prevention Current Situation Trend Chart . (Detective part, problematic station etc) BEFORE : Trend Chart After Action Implemented. AFTER : TOTAL : 08 Nos. OPRATIONS LINE 06 Nos. OPERATION LINE

8. Human Error Prevention Check Sheet

9. BEFORE : AFTER :

10. AFTER-New CNC set Up BEFORE-Old Set Up Improvement Photograph

11. Benefits P Per Day Production Capacity Increased from 240 Nos. To 390 Nos. Q 50% Tolerance is used, Improved Cpk. C Cost Of Poor Quality Reduced from 0.34 Paisa To 0.17 Paisa. D Dispatch has been increased up to 390 Nos. Reduced Human Fatigue By Reduced Material handling With Improved Shop Lay out. S M Satisfaction about customer fulfillment.

12. BEFORE : AFTER : Future improvement plan Manual Process Manual Process Of Loading The Materials In Vehicle. Forecleap To be Provided For Loading The Materials In Vehicle To Reduce Human Fatigue. Time Limit Three months.

13. Movie (Optional)

14. Thanks

15. Any Question ?