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 – Press Shop High Bay Area
Mentor – Mr. Sachin Sawant
Team Leader – Mr. Wahid Abdul
Team 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
Slide : 2
Dept/ PU: Body PU- Press Shop
Team Performance
Meetings held 12
Ideas generated 169
Ideas
169
implemented
PQC Percentage 68 %
3
Press shop
Resources
1000 T DA press 600 T press 300 T press 200 T press Press Brake
PU/Dept: May 2010 Slide : 4
1200 T press 315 T press 250T press 100 T press Shearing 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
Slide : 5
Product- Bolero Model
Bolero Pick UP Bolero Camper
Bolero Refresh
PU/Dept: May 2010 Slide : 6
Bolero Cowl Side Outer selected to be in-warded in
Kandivli Press Shop From Vendor Due to capacity Issue.
Slide : 7
Dies transferred from Vendor of Nasik
Blank Die Draw Die Trim Die
Form Die Pierce Die Slot Pierce Die
Slide : 8
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%
Slide : 10
Target Taken
Improve
Yield By
5%
Target To improve the yield is 88.34 %
Slide : 11
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 Top Die Shoe
Bottom Die Shoe Top Die Shoe
Slide : 12
NO!!! for Mahindra
• Mahindra always tries to work conventionally in an
unconventional manner.
• In Mahindra “NO” stands for
N - Next
O - Opportunity!!!
Slide : 13
New Idea of 2 In 1 !!!
Slide : 14
Blank Layout Analysis Yield
Improved
3.67
By 1.03 %
2665 mm
1340 mm 2560 mm
1000 mm
1000 mm
BEFORE AFTER
Slide : 15
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
Slide : 16
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.
Slide : 17
Rotating Table
• The operator fatigue was totally eliminated.
Slide : 18
Benefits
Increase in Yield by 3.67%
BETTER
3.67%
Slide : 19
Benefits
Reduction in Cost of Blank by Rs. 20 per Vehicle
4.5%
Rs.
Slide : 20
What Next ???
Still How to Improve Yield ??? How Reach the
target of 5%
Slide : 21
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
Slide : 22
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.
Slide : 23
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 Slide : 24
Identified : Obsolete Old Die Set
PU/Dept: May 2010 Slide : 25
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 Slide : 26
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
Slide : 27
By This way Yield Improved Yield
Improved By
Yield Improved From 83.34% to 90.65% 7.31 %
Slide : 28
Validated from
Total Savings!!! Account Dept
• Blank Size Optimization = Rs. 32 Lacs
• Saving of Hydraulic Scissor Table = Rs. 2 Lacs
• Scrap Utilisation = Rs. 12 Lacs
• In House Die = Rs. 5 Lacs
Slide : 29
Target taken is 5% But
crossed the Limit and
We accepted the challenge
achieved 7.31%
to remove operator fatigue
So We Worked Towards
Can Say WeScrap to make a
Utilized it positive
...
to make
Three of from In-house
Pillars part Mahindra Rise
operator skilled Die
Accepting No Limit
Driving Positive Change
Alternative Thinking
Slide : 30
THE
E - Effort
N - Never
D - Dies