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MISSION

GEMBA @
MGSL

FROM THE DESK OF M.D


I would like to express our sincere thanks to Mr. Anuj
Kathuria ED SS at Ashok Leyland, for visualizing the need
of instilling the need of up gradation in our manufacturing
unit for facing the challenges of coming times by getting
organized through MISSION GEMBA.
We highly appreciate the enthusiasm with which the
Ashok Leyland Team members have exposed us to the
various contemporary practices adopted in the various
fields of manufacturing and also there patience and
persistence , while we faltered many a times.
With this we thank the entire team & look for continues
relations for all times to come.

THANKS TO ASHOK
LEYLAND BY MGSL
MGSL is hearty thankful to Ashok Leyland for
giving the Mission Gemba which helps us in
improving productivity and quality of our product.

OUR PRODUCT RANGE


Fabrication of Passenger & Commercial Vehicles likes

Buses
Truck Load Bodies
Containers
Tippers
Trailers
Tankers
Petroleum Storage Tanks
Ambulance
Mobile ATM etc.

Manufacture

of Sheet Metal Pressed, Welded &


Assembled Components for Automotive and General
Industries.

PLANT LAYOUT

STEP BY STEP
PROGRESS OF
GEMBA

Presentation of Mission Gemba By AL


Identification of GCC
GCC Inauguration
Formation of Steering committee
Identification of Different Zones
Gemba leaders and team member-Zone wise
Suggestion scheme implementation
Skill matrix
Red tag Area identification
Training of Workers.

ZONES LIST

1.Machine shop
2.KIT SECTION-1
3.CTTP/FET FABRICATION AREA
4.TOOL ROOM/ DOOR FABRICATION AREA/ KIT SECTION-2
5.FVDP FABRICATION AREA
6.TRANSFORMER RADIATOR
7.PAINT/ COMPRESSOR ROOM/BLASTING BOOTH
8.STORES / HYDRAULIC KIT AREA /RAW MATERIAL
STORAGE
9.OFFICE AREA
10.
MAINTENANCE ROOM
11.
CABIN FABRICATION AREA
12.
RAILWAY (LOCOMOTIVE)
13.
CAFETERIA/WASHROOMS
14.
GENERAL FABRICATION AREA/PRESS SHOP

ZONE MEMBER FOR


5S ACTIVITY

GEMBA
COMMUNICATION
CENTER

BENEFITS OF GEMBA
We have reduced our Rejection, and
rework.
We got better productivity and
delivery.
Through Problem solving board, we
have identified 20 concerns and out
of these 15 were completed.

1S ACTIVITY IN
VARIOUS ZONES
OF MGSL

WHAT IS 1S?
This activity involves systematic sorting out,
labeling and removal of all items not
needed in the work area so that only the
needed items remain.
Objective: Clutter reduction by clearly distinguishing
between what is needed and to be kept and
what is unneeded and to be discarded.
Red Tagging
Local storage area for a predetermined amount of time
Central storage area for a predetermined amount of
time
Throw away

ENTRANCE
BEFORE

AFTER

MACHINE SHOP
BEFORE

AFTER

TOOL ROOM & SORES


BEFORE

AFTER

CENTRAL RED TAG AREA

DEPARTMENTS INTIATED
RED TAG
S No.

Department

Item

Recovered
Value

Disposal
Action

Trailer Mounting
&Accessories

Transferred to
other unit

2.

Hydraulic Item- PTO,


PUMP, RAM etc.

Sold out

3.

Old MIG & Arc machine

Under
Repairement

Torch, Dial Indicator

Scrapped

Kit Section

Obsolete Fixtures &


Templates

Scrapped

Maintenance

Gas Cutter, Small


Armature

7.

Production

Plastic (200 Kg)

8.

Maintenance

Motor 2 HP

9.

Maintenance

1.
Stores

Maintenance
4.
5.

6.

Wiper Motor

Sold out
Sold out
Sold Out
Sold Out

RED TAG CAMPAIGN


25
60
50
40

50

20
41

15

30

10

20
10
0

5
Tag PutsTag Removed

0
Dec'11

Jan'12

Feb'12

Mar'12

2S ACTIVITY IN
VARIOUS ZONES OF
MGSL

WHAT IS 2S?
This activity involves developing a place
for everything and labeling it so that it
can be found quickly and put away when
not in use.
Objective: To ensure everything has a place, and
there is a place for everything needed.

Motion Economy
Layout maps
Sign boards
Outlines
Color Codes

2S IN DESIGN & Q.A


OFFICE

BEFORE

AFTER

2S IN PRODUCTION
OFFICE

AFTER

AFTER

SWITCH IDENTIFICATION
IN OFFICE

TOOL ROOM & GUARD ROOM

TOOL ROOM

GUARD ROOM

SELF ASSESMENT THORUGH SKILL


MATRIX
OF VAROIUS DEPARTMENT

THANK YOU

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