Kaizen Star - Plant 1
Aakash Reddu
April - 2024
Total1
| Sr. No | Kaizen No | Kaizen Theme | Initiator | Team | Before Situation |
After Situation |
Month | ||
| 1 | LCIK - 36358 |
Training Room Direction signs |
Mustak Ansari , 51009729 |
direction signs hanged for training room because of which new joining manpower's are confused on daily and asking to others that where is training room, Also new staff is same faced |
|
07/2022 | |||
| 2 | LCIK - 40562 |
Training Provided To line operator regarding TPM implementation. |
Vinay Shekhar , 59429 |
Ravi Prakash Yadav , 51010012 Prakash , 51009675 |
Line operator is not following the TPM and equipment cleaning activity due to unawareness of process. | Now Training is going to provided all stage operator to maintain 6S at same stage and aware about system process. | 05/2024 | ||
| 3 | LCIK - 43020 |
Training New Operators from Packing to Assembly |
Ravi Prakash Yadav , 51010012 |
Anil Kumar chaursiya , 51010623 Kunal Upadhyay , 51010611 |
Newly hired operators were assigned only to packing tasks without formal training in assembly work. This created a skill gap, limited workforce flexibility, and caused frequent manpower shortages on the assembly line. These issues led to delays, decreased productivity, and low operator engagement due to repetitive work and lack of growth opportunities. | A structured training program was introduced where experienced trainers guided new operators through assembly processes, providing hands-on learning until proficiency was achieved. Operators were gradually cross-trained in both packing and assembly tasks, enabling them to switch roles as needed. Assembly line downtime due to manpower shortages decreased by 30%. * Overall production output increased by 15%. * Operator versatility improved, with 85% of new operators able to work confidently in both departments within the first month. * Employee satisfaction scores rose by 20%, reflecting higher engagement and motivation. *Next Steps for Continuous Improvement:* * Implement periodic refresher training to maintain and enhance operator skills. * Establish a mentorship system where experienced operators support new hires. * Monitor productivity and quality metrics regularly to identify further training needs. * Explore cross-training in additional areas to increase operational resilience. | 08/2025 | ||
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