TCF 1C SHOP

“KAIZEN” Event
On
Establishing 1S & 2S In Logistics Area For
Accomodating Super ACE & Venture Parts

FROM- 16th Oct – 28th Oct Responsibility :RAJAL GUHE

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Team List: TCF 1C TCF 1C SHOP

TEAM MEMBERS

MENTOR: Ravendra Singh Sayan

1. Rajal Guhe
2. Kanwarinder Singh Kochhar
3. Peter Chethalan
4. Faizi Raza
5. Nitish Rayal
6. Ashu Mawa
7. Kuldeep Cheema

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Team Members Participation: TCF 1C SHOP

AVG
ATTENDANCE =
98.9%

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TEAM MEMBERS PARTICIPATION TCF 1C SHOP

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 TCF 1C SHOP
REARRANGEMENT OF MATERIALS

FASTNERS

GANGWAY A/C
Plastic
Membrane
Heat Pipe
Shield

Cables
Door
Actuator
GALLERY

RGC
Seat Belt

Snorkel
Felt
Battery
Snorkel
Felt

Snorkel
Felt
29 28 27 26 25 24 23

GANGWAY

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Objective, Scope & Target TCF 1C SHOP

OBJECTIVE
- To Provide Proper Place for Venture & Super ACE Parts
- To Establish FIFO in Store
- To Establish 2 Bin System For Venture & Super ACE
-To Establish 1S & 2S Status

SCOPE :
- TCF 1C LOGISTICS AREA (C 27-29)
TARGET :
- 1s & 2s Audit Score Above 80%
-100% FIFO for all parts
--Minimise Material Movement

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Problem Definition:- Team 1 TCF 1C SHOP

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Activity Schedule: TCF 1C TCF 1C SHOP

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Kaizen for Second Row Seat Fitment TCF 1C SHOP

Name of employee: Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 Improper Storage Of Parts Removed To Specified 2 S Implemented

Parts Location

Before Kaizen After Kaizen

Excess
Material 2S
Implemented

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

WINDOW WINDING WINDOW WINDING GAUGE DESIGNED TO PROPER FITMENT

REGULATOR REGULATOR ANGLE ENSURE THE FITMENT OF WINDOW
FITMENT IN WAS NOT OK OF WINDOW WINDING WINDING
VENTURE REGULATOR AT 45 DEG. REGULATOR

Before Kaizen After Kaizen

GANGWAY GANGWAY
NOT MARKED MARKED

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Kaizen for Heat Insulation Hole Mismatch TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 Empty boxes placed in the Red tag area was defined Empty boxes were
store removed

Before Kaizen After Kaizen

Empty boxes
Empty boxes removed to red
placed tag area

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Battery There was no proper Place was defined for battery Reduced movement of
location defined for the closer to the station material and 2S
battery hence implemented
unnecessary movement
of material

Before Kaizen After Kaizen

Accessible
Battery was not and closer to
easily accessible
the station
and not in proper
location

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 No place defined for .Buffer area defined Excess material not
keeping excess material kept in the gang way
hence are placed in the
gang way

Before Kaizen After Kaizen

Buffer area not

defined for excess Buffer Area
material
defined

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For discussion only 13
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Cables Cables are not properly .Trolleys used to Keep the Proper storage of
stored in the cables cables and better
supermarket area hence quality
compromising the
quality

Before Kaizen After Kaizen

Improper
storage of Trolleys used
cables to store
without any
damage

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For discussion only 14
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Primary seal Difficulty in access of Trolley was used to store the Better accessibility
parts and improper parts in the super market
storage of parts

Before Kaizen After Kaizen

Better
accessibility

Part difficult
to access and
improper
storage

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For discussion only 15
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Cables Cables are not properly . .Trolleys used to Keep the Proper storage of
stored in the cables cables and better
supermarket area hence quality
compromising the
quality

Before Kaizen After Kaizen

Improper
storage of Trolleys used
cables to store
without any
damage

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For discussion only 16
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 No system to sort parts .Place defined for each part 1S & 2S implemented
or their arrangement

Before Kaizen After Kaizen

1S & 2S
implemented

1S & 2S not
followed

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For discussion only 17
Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 No 1S & 2S System .Part identification & 1S & 2S Implemented

maintained Arrangement is done

Before Kaizen After Kaizen

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

.
Pillar 29-28 No 1S & 2S System .Part identification & 1S & 2S Implemented
maintained Arrangement is done

Before Kaizen After Kaizen

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Wiper Pipes Improper Storage .

Bin Placed to store the parts 1S & 2S
Quality was
implemented
compromised

Before Kaizen After Kaizen

Unorganised Sorted
Part Storage Parts

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Wire Harness Improper Storage and Boxes are replaced by bins 1S & 2S Implemented
more time wasted for leading to better quality of
part identification parts & better part
identification

Before Kaizen After Kaizen

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

.
Pillar - 28 Improper Storage and Boxes are replaced by bins 1S & 2S Implemented
more time wasted for leading to better quality of
part identification parts & better part
identification

Before Kaizen After Kaizen

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

FELT Improper Storage For 3 FIFO racks modified for 1S & 2S implemented
Felts. Was Kept At Storage of all types of Felt
Pillar 25-24

Before Kaizen After Kaizen

Felt Was Kept in

1S & 2S
improper way
implemented

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Snorkel Storage Improper Storage For .

Trolley used for Storage of 1S & 2S
Snorkel. Quality was
Snorkel implemented
compromised

Before Kaizen After Kaizen

Snorkel Was
1S & 2S
Kept in
improper way
implemented

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Pillar 29-28 Excess material and no .Place defined for each part 1S & 2S implemented
system to maintain 1s and excess material removed
or 2s

Before Kaizen After Kaizen

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Bottom rail Cover Improper Storage .

Bin Placed to store the parts 1S & 2S
Quality was
implemented
compromised

Before Kaizen After Kaizen

1S & 2S
Unorganized implemented
Part Storage

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Kaizen for Wrongly fitted window winding regulator TCF 1C SHOP

Name of employee: CFT Ticket No: - Shop/Area: TCF 1C Line/Station:

Operation/Machine Problem Measure Taken Results

Heat Shield Improper Storage .

Bin Placed to store the parts 1S & 2S
Quality was
implemented
compromised

Before Kaizen After Kaizen

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 TCF 1C SHOP

RESULTS

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 TCF 1C SHOP

PARTS LOCATION FOR TRIM STATION 3

BEFORE AFTER

25-24 25-24
26-25 26-25
27-26 27-26
28-27 28-27
29-28 29-28

3 3

Proper Location
Improper Location

The circles show the space

b/w 2 columns i.e. 10 mts

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 TCF 1C SHOP

PARTS LOCATION FOR TRIM STATION 5

BEFORE AFTER
24-23 24-23
25-24 25-24
26-25 26-25
27-26 27-26
28-27 28-27
29-28 29-28

5 5

Proper Location
Improper Location

The circles show the space

b/w 2 columns i.e. 10 mts

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 TCF 1C SHOP

Excess Material Movement Reduction

TRIM - 3 TRIM - 5

120 160

140
100
120

Meters
Meters

80
100

60 S eries 1 80 S eries
60
40
40
20 20

0 0
BEFORE AFTER BEFORE
1 AFTER
2
1 2

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 TCF 1C SHOP

Thank You

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