A project on

INNOVATIONS
EKC Ltd.
By, Nishad Khamkar Sonia Mirajkar Shashank Palande Shailaja Patil Ashwini Pokharkar Aseem Halani

About EKC
Established in 1978 8 Manufacturing units around the globe.

Restructured to public limited in 2001.

Capacity to produce 500000 cylinders around the globe. All major markets covered.

Major competitors
Rama cylinders Bharat forge CPI industries USA Hi Tech industries Japan

Photos of some plants

Products

Products

Products

Products

Kaizen idea generation.

Activity

KK P

JH Q

QM C

PM D

SH S

OTPM M

DM

ET

Kaizen Idea Sheet

Shop: Spinning Section

Result Area

Defect Type

Pipe Cutting I / II /III m/cs Reg. No: 004 / 2010 Kaizen Idea : Providing Automatic Timer to cut off power Kaizen Theme :- Elimination of while M/c. is running for Idle .

M/C:

Unwanted Running of Hyd. Power pack.

Problem/Present Status:

Countermeasure:

Bench Mark Target Kaizen Start Kaizen Finish

To be calculate

Machine is running and there is not having mistake proofing for switching off the power when running in idle condition . Unnecessary Running of elect. Motor of Hyd. Power pack.
Analysis: Unnecessary Running of elect. Motor of Hyd. Power pack
Why Why Analysis

Providing Automatic timer / Relay to cut / switch off electrical motor ( 2 HP), while Machine is not in Use And Hyd. Power pack is on
This is applicable for All Conventional Machines
Result:1 )Reduction in Energy consumptions 2 )Safe running of machine . 3) Optimum use of machine elements . 4 ) Oil temp. will be in controlled zone , less oil leakages * E xact calculations are to be done for saving

10% Saving 15/6/10

Team Members :Mr. Amol Pawar , Mr. Jadhav , Mr. V Sharma, Mr. Umesh Meher Team Leader : M H Thakur

Benefits:1) Mistake proofing for avoiding loss due to Operators oversight. 2) Energy saving in safe practices
N o
1

Continuous Running Elect. Motor .

M/cs. Running continuously without stopping Hyd. Motor. Forget / Fail to switchOff in idle / no load condition.

M/C

T/date

Res.

Status

PC1

15/7/1 0 15/7/1 0 15/7/1 0

Mr. Amol Mr. Amol Mr. Amol

PC2

PC3

Why why analysis.

My car will not start.

1.
2. 3. 4.

Why? - The battery is dead

Why? - The alternator is not functioning. Why? - The alternator belt has broken. Why? - The alternator belt was well beyond its useful service life and has never been replaced.

5.

Why? - I have not been maintaining my car according to the recommended service schedule.

OLD LAYOUT

Benefits of proper layout

Plays a major role in cost reduction Time reduction Continuous flow Maximum utilization of available space

Flexibility as per predicted future demand

New Layout

Achievements through layout changes

Smooth uninterrupted flow of cylinders Increase in productivity

Maximum utilization of machinery

Cost reduction from 360 to 210 per cylinder Flexibility in producing any size of cylinders

Spinning and furnace

Before change
Causes of negative variances
PRODUCTION Capacity

Previous Month

Achieved

Variance Major loss of hours Total

Setup

B/d

Any other N/L No plan, N/M

Lost Hours

Productio n Qty

Lost Hours

m/c 1 Spinning m/c 2

11000

4280

6720

72.2

224.5

81.25

378

9690

181.25

12000

6700

5300

81

80.5

129.25

290.75

8549

239.75

m/c 3

8000

5404

2596

85.2

44.5

201

330.75

5156

259.5

m/c 4

12000

7083

4917

91

85.2

89.2

265.5

7051

281.75

23467

19533

30446

After change
Causes of negative variances
PRODUCTION Capacity

Previous Month

Achieved

Variance Major loss of hours Total

Setup

B/d

Any other N/L No plan, N/M 11.25

Lost Hours

Prodn Qty

Lost Hours

m/c 1

15000

9015

5985

62.2

174.5

248

8546

235.75

Spinning
m/c 2 15000 9874 5126 62.7 125.2 20.25 208.2 8916 222.25

m/c 3

8000

328

7672

55.5

69.25

320.5

445.2

240

473.75

m/c 4

15000

6237

8763

124

139.2

61

324.2

6507

249.5

m/c 5

15000

8394

6606

95.2

54.25

73.25

222.7

9809

181.75

33848

34018

Process Flow
Tube cutting Bottom forming Neck forming operation Heat treatment Neck machining Internal cleaning Hydraulic test Tightness test

Innovations in processes
Capable to develop pull type of production Line balancing Transportation
Lead time reduction Automation

Elimination of unwanted processes Continues flow (no WIP) Ergonomics achieved