**5.5 Result and Kaizen done in first iteration**

In this way all the wasteactivities which has found in first iteration completely eliminated. The major result achieved by this exercise is that by eliminating all waste activities which are acting as a hindrance to convert the internal activities in to the external activities can now be taken up in second iteration. By doing the first iteration of the reducing set up time cycle the total 44 minutes have been saved.

Kaizen done: In this complete exercise following kaizen has been done which is listed as follows: **Kaizen 1**: As shown in **Figure 7**, cutter head angle is the responsible factor for wrong lead profile because during setup (first iteration) it was wrongly set as per the requirement to suit the shaving cutter. To solve this issue Cutter head angle is made mandatory check point in the standard operating procedure.

**Figure 5.** *Outline of process and equipment.*


#### *Single Minute Exchange of Dies: Classical Tool of Lean Manufacturing DOI: http://dx.doi.org/10.5772/intechopen.96665*



**Table 1.** *Changeover sheet.*

#### *Single Minute Exchange of Dies: Classical Tool of Lean Manufacturing DOI: http://dx.doi.org/10.5772/intechopen.96665*


#### **Table 2.**

*Identified waste activities.*

#### **Figure 6.**

*Major causes of high setup time.*

**Kaizen 2**: As shown in **Figure 7**, the poor operator skill of setup change procedure is responsible factor for the cause of this Kaizen. To solve this issue following improvement activities has been done:

a.One operator is made in charge of setup changeover and he has been given rigorous training for standardized operating procedure for the setup changeover and provided with written documents.

*Single Minute Exchange of Dies: Classical Tool of Lean Manufacturing DOI: http://dx.doi.org/10.5772/intechopen.96665*


#### **Figure 8.**

*Improvement plan and its implementation.*

