Enhancing Machine Capabilities through Kaizen: A Success Story at Akij Resource
Problem: Inability to Meet Customer Sealing Gap Requirements
At Akij Poly Fibre Industries limited our heat sealing and cutting machine previously struggled to fulfill customer requirements due to its limited capability of maintaining a specific, default sealing gap. This limitation resulted in the machine being idle most of the time, unable to accommodate the varying sealing gaps needed for different products. A third-party company informed us that no further modifications could be done on this machine and recommended purchasing a new machine capable of providing different sealing gaps.
Solution: Innovative In-House Modifications
Undeterred by the third-party recommendation, a series of electrical and mechanical modifications were implemented to address this issue. By adding a device just before the sealing and cutting unit, we enabled the machine to adjust the sealing gaps according to customer requirements. This enhancement has significantly improved the machine's flexibility and usability, fulfilling the requirement of a new machine through our cost-effective in-house improvement.
Benefits:
Increased Productivity: The machine can now operate continuously, adapting to different sealing gap requirements without downtime.
Improved Quality: Ability to meet precise customer specifications, ensuring higher satisfaction.
Cost Savings: By modifying the existing machine at a cost of BDT 37,240, we avoided the high expense of purchasing a new machine, which would have cost BDT 3,951,039.60 (USD 36,000). This resulted in a substantial savings of BDT 3,913,800.
Cost Analysis:
New machine cost: BDT 3,951,039.60
In-House Modification Cost: BDT 37,240
Savings from In-House Development: BDT 3,913,800
Special recognition goes to Sadman Sabbir Sayek, Md. Maruf Hossain, Md Atikur Rahman, Nirmolendu sharma, Md. Ziaur Rahman, Sree ujjol Kumer, Md. Aminur Rahman and the entire team for their exemplary work on this project. We are dedicated to empowering our teams to solve problems and drive innovation. This project highlights our commitment to operational excellence and sets a benchmark for future initiatives.
#OperationalExcellence #Innovation #ContinuousImprovement #ManufacturingExcellence #Kaizen #EmployeeEngagement #Sustainability #CostSavings #QualityImprovement
Factory Director at Sohbi Craft Poland / Automotive Production Management / Metal Press Stamping products
3mo#sustainability #sohbicraftpoland Toyota Boshoku Europe N.V. We are proud to be recognized by You as sustainable developed partner, and it motivates us for constant improvement. Thank you!