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Improving Safety in Die Handling
Mini Kaizen#83

Improving Safety in Die Handling

During die transportation, the die was lifted and moved by the forklift forks from underneath. This created a risk of the die tipping during transportation.To maintain balance, the transportation proc...

24 September 2026
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KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:
A

BEFORE

State before kaizen

  • The die was lifted from underneath using forklift forks.
  • The die could become unstable during transportation.
  • There was a risk of the die tipping over.
  • Transportation had to be performed slowly to maintain balance.
  • The slower process increased transportation time.
  • The existing method created an unnecessary safety risk.
  • Approximate cost: ₺200/die.
CostTRY 200.00
A forklift is transporting a heavy die by lifting it from underneath with its forks. Because the die is not securely connected to the forklift, maintaining balance requires slow and careful movement. Main message: Unstable load handling creates both safety risk and time loss.
Caption: A forklift is transporting a heavy die by lifting it from underneath with its forks. Because the die is not securely connected to the forklift, maintaining balance requires slow and careful movement. Main message: Unstable load handling creates both safety risk and time loss.

AFTER

State after kaizen

  • Suitable steel channels were installed on the upper section of the die.
  • The forklift forks can engage with these channels.
  • The forklift can establish a more controlled connection with the die.
  • The risk of tipping during transportation was eliminated.
  • Die transportation became safer and faster.
  • Approximately 1.5 hours/week of transportation time was saved.
  • Approximately 78 hours/year of time were saved.
  • Annual financial benefit was approximately ₺13,600.
GainTRY 13,600.00
A die equipped with dedicated steel channels that allow the forklift forks to engage with the die in a more controlled and stable manner. The improved connection reduces tipping risk and enables safer, faster transportation. Main message: A controlled connection makes die handling safer and faster.
Caption: A die equipped with dedicated steel channels that allow the forklift forks to engage with the die in a more controlled and stable manner. The improved connection reduces tipping risk and enables safer, faster transportation. Main message: A controlled connection makes die handling safer and faster.

Kaizen Impact

Total savings/gain

+TRY 13,400.00

Problem Statement / Theme

During die transportation, the die was lifted and moved by the forklift forks from underneath. This created a risk of the die tipping during transportation.

To maintain balance, the transportation process had to be carried out more slowly. This not only created a safety risk but also increased transportation time.

As a countermeasure, suitable steel channels were installed on the upper section of the die so that the forklift forks could engage with the die in a more controlled way.

This connection improved the stability of the die during transportation and eliminated the risk of tipping. As a result, the transportation process could be performed more quickly and safely.

Results:

  • Approximately 1.5 hours/week transportation time saved
  • Approximately 78 hours/year time saving
  • Approximately ₺13,600/year financial benefit

Lean principle:
A small change in how a load is handled can improve both safety and flow at the same time.

Team Formation

A

Ahmet DEMİR

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