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Improving Safety in the Cable Winding Mechanism
Mini Kaizen#81

Improving Safety in the Cable Winding Mechanism

In the cable winding area, the metal mechanism holding the bobbin was exposed during operation. This created a safety risk for operators.The exposed mechanism could come into contact with the operator...

24 September 2026
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KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:
G

BEFORE

State before kaizen

  • The metal mechanism holding the bobbin was exposed.
  • The moving mechanism could be accessed directly during operation.
  • The operator's hands could potentially come into contact with the mechanism.
  • Clothing or hair could potentially become caught in the moving parts.
  • Personal items could also come into contact with the mechanism.
  • The exposed mechanism created an unnecessary workplace safety risk.
A cable winding machine with the metal mechanism holding the bobbin exposed. The moving mechanism is directly accessible to the operator, creating potential risks related to hand contact, clothing or hair entanglement, and contact with personal items. Main message: Exposed moving parts create avoidable safety risks.
Caption: A cable winding machine with the metal mechanism holding the bobbin exposed. The moving mechanism is directly accessible to the operator, creating potential risks related to hand contact, clothing or hair entanglement, and contact with personal items. Main message: Exposed moving parts create avoidable safety risks.

AFTER

State after kaizen

  • A protective cover was added around the bobbin mechanism.
  • The cover can be opened when changing the bobbin.
  • The cover remains closed during machine operation.
  • The moving mechanism is physically separated from the operator.
  • The risk of contact with moving parts was reduced.
  • The work environment was made safer without complicating the operation.
The same cable winding machine with a protective cover installed around the bobbin mechanism. The cover can be opened for bobbin replacement and closed during operation, creating a physical barrier between the operator and the moving mechanism. Main message: A simple physical barrier can eliminate an unnecessary point of contact.
Caption: The same cable winding machine with a protective cover installed around the bobbin mechanism. The cover can be opened for bobbin replacement and closed during operation, creating a physical barrier between the operator and the moving mechanism. Main message: A simple physical barrier can eliminate an unnecessary point of contact.

Problem Statement / Theme

In the cable winding area, the metal mechanism holding the bobbin was exposed during operation. This created a safety risk for operators.

The exposed mechanism could come into contact with the operator's hands, clothing, hair, or other personal items while the machine was running.

To eliminate this risk, a protective cover was designed and added to the mechanism. The cover can be opened when the bobbin needs to be changed and closed during operation.

This simple improvement physically separates the operator from the moving mechanism and reduces the risk of contact-related injuries.

Lean principle:
When a risk can be eliminated at its source, the safest solution is often a simple change in the process or equipment.

Kaizen image

Team Formation

G

Gözde YILMAZ

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