Continuous Improvement Application in an Excavator Assembly Line

Rayappa Mahale1, P. Rajashekar Reddy2, Shrinivas A. Kulkarni3

1Assistant Professor, Department of Mechanical Engineering, Dr. D. Y. Patil School of Engineering and Academy, Pune, Maharashtra

2Production Manager, Tata Hitachi Construction Machinery Company Limited, Dharwad, Karnataka

3Senior Manager, Paint Shop (Operations), Tata Hitachi Construction Machinery Company Limited, Dharwad, Karnataka

Kaizen 25

Abstract:

The study was focused on continuous improvement applications in an excavator assembly line of Tata Hitachi Construction Machinery Company Limited Dharwad, Karnataka. The plant builds hydraulic excavators and wheeled backhoe loaders.

The purpose of the study is to impart continuous process improvement application to reduce quality defects and improve cost efficiency. The study solves the problem of quality defects using Pareto analysis and Ishikawa Cause and effect diagram.

The study objectives were to minimize the various issues regarding quality defects and thereby increasing product quality and reducing waste. Kaizen has become a foundation for this study. Through constant study and revision of processes, a better product can result at reduced cost. 

Keywords:

Continuous Process Improvement (CPI), KAIZEN, Lean production, Pareto Analysis, FIFO and Why- Why Analysis.