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Company Name: Bharat Forge Limited, a world leader in manufacture of forgings and supplier of machined automotive components to world leaders like Spicer, Meritor, Mercedes Benz, Toyota etc. |
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Project Objective: Reduction in rejection of crankshafts for a particular export line from 4% by 2%. |
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Effort: 2 persons for 6 months. |
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Project Result: On starting the project, it became apparent that the prevailing rejection was actually 5.9% (not 4%), thus increasing the challenge. On completion of the project the rejection dropped from 5.9% to 3.2% in six months. Average production level of this production line being 6300 crankshafts per month, it means a reduction in rejection of 170 crankshafts per month. As a result, rework reduced and productivity increased. |
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Financial Benefits: Financial impact of this is savings of Rs 2.3 million per annum. |
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Next Steps: It is proposed that a full blown Six Sigma deployment is undertaken. Initiation of Green Belt training and projects can help the company get full advantage of the initial success. |
Reduce incoming raw material inspection and testing cost by 20%