Mahindra & Mahindra Ltd.

Automotive Sector, Mumbai

Press Shop - Body Product Unit
Presented by Mr. Parag Desai

Kaizen Theme
To reduce cost by Improving Yield of Bolero Cowl side outer Panel
Circle Mentor Team Leader Team Press Shop High Bay Area Mr. Sachin Sawant Mr. Wahid Abdul Mr. S.S. Amberkar Mr. P.S. Gamre Mr. P. A. Desai Mr. U. K. Meher Mr. Y. D. Kamble Mr. V. P. Patil Mr. G. S. Patel Mr. D.R. Yadav Mr. R.B.Bagwe Mr. A.N.Shete Mr. C.S. Borges
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Dept/ PU: Body PU- Press Shop

Team Performance
Meetings held Ideas generated 12 169

Ideas implemented
PQC Percentage

169
68 %

Press shop

Resources 1000 T DA press 1200 T press 600 T press

PU/Dept:

300 T press
May 2010

200 T press 100 T press

Press Brake Shearing press

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315 T press

250T press

Outline of Kandivli Press Shop

Press shop 4 lacs parts/month

1.4 lacs parts/month

Nasik Plant

2.0 lacs parts/month

Kandivli Plant

0.6 lacs parts/month

Zaheerabad Plant
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Product- Bolero Model

Bolero Pick UP

Bolero Camper

Bolero Refresh
PU/Dept: May 2010
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Bolero Cowl Side Outer selected to be in-warded in Kandivli Press Shop From Vendor Due to capacity Issue.

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Dies transferred from Vendor of Nasik

Blank Die Draw Die Trim Die

Form Die

Pierce Die

Slot Pierce Die

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Problems inwarded along with Bolero Cowl Side Outer

Low Yield Problem

output weight Yield = Input Weight

Problem 1 : Yield Analysis on Raw Material

Yield of Bolero Cowl Side Outer in Blanking is 83.34%

Raw material

Blank

How Scrap ???

Scrap Wastage is 16.66%

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Target Taken
Target To improve the yield is 88.34 %
Improve Yield By 5%

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Conventional ideas for Blank Size Optimization!!!

Shifting Locating pins in Draw operation to optimize

blank holding area.

No scope for shifting of location pins in draw operation

Optimizing bridge in the blanking operation.

No scope for optimizing bridge
Bottom Die Shoe Bottom Die Shoe Top Die Shoe Top Die Shoe
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NO!!! for Mahindra

Mahindra always tries to work conventionally in an

unconventional manner.
In Mahindra NO stands for

N - Next O - Opportunity!!!
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New Idea of 2 In 1 !!!

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Blank Layout Analysis

1340 mm

Yield Improved By 1.03 % 3.67

2665 mm 2560 mm

1000 mm

BEFORE

1000 mm

AFTER
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Fatigue Problems
Weight of new sheet is 20.20 kg.

Fatigue in lifting and sliding the sheet in the die.

Lot of bend and arise activity for the operators for

each stroke. Ergonomics SSES was showing this in red zone.

Hydraulic Scissor Table

Hydraulic Scissor Table was required for

supporting the sheet and rotating it by 180 degrees. Cost of the table 2 Lacs
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Idea : Why to invest 2 Lacs ???

Why not we make something Innovative !!!
With the Help of In-house Manufacturing Skills some improvement done with Die
Die was suitably modified for ease in set-up and production. Position and Location Of Die Changed and Slot of Die Modified. New Poka Yoke Pins added in Die. Rollers Fixed on Die to easy location and Removal. Riser Fixed on Bottom of the Die.

Ingenious Idea of Providing a rotating table (made from scrap) with a ball bearing implemented.
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Rotating Table
The operator fatigue was totally eliminated.

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Benefits
Increase in Yield by 3.67%
BETTER

3.67%

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Benefits
Reduction in Cost of Blank by Rs. 20 per Vehicle
4.5%
Rs.

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What Next ???

Still How to Improve Yield ???
How Reach the target of 5%

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Problem 2 : Yield Analysis on Scrap ( In process)

This is a scrap coming out from Blank

Scrap

So we found a Part Which is coming from this Scrap This part is coming From Reliable Vendor

Slush Protector

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How To Make it ??? We require new Tooling For this part. 1. Time Period given for new Tooling is 6 Month. 2. Cost of the tooling is 6 Lac Rupees.

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In-house Tool manufacturing

One Idea clicked..
Why not to make in house tooling with our team work and skills by using obsolete die material

PU/Dept:

May 2010

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Identified : Obsolete Old Die Set

PU/Dept:

May 2010

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New Die Made from scrap material

Slush Protector Blanking & Flange die made in house Old die New die

Die made from Obsolete material Saving = Rs. 5 Lacs

PU/Dept: May 2010
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New Die Made For The Part

Use of Bolero Cowl Side outer Scrap for making Slush

Protector for XL Fender Assembly.

Die made from Obsolete material Saving = Rs. 5 Lacs

Slush Protector
Total Savings Rs. 17 Lacs

Annualized Savings = Rs. 12 Lacs

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By This way Yield Improved

Yield Improved From 83.34% to 90.65%

Yield Improved By 7.31 %

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Total Savings!!!
Blank Size Optimization

Validated from Account Dept

Saving of Hydraulic Scissor Table

Scrap Utilisation In House Die

= = = =

Rs. 32 Rs. 2 Rs. 12 Rs. 5

Lacs Lacs Lacs Lacs

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So We

Three

Target taken is 5% But crossed the Limit and We accepted the challenge achieved 7.31% to remove operator fatigue Can Say WeScrap to make a Worked Towards Utilized it positive to make Pillars part Mahindra Rise of from In-house operator skilled Die

...

Accepting No Limit Driving Positive Change Alternative Thinking

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THE E - Effort N - Never D - Dies