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    Quality Circle (Hindi) 14 - 05 - 2011 (Read-Only)

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    Atul Sharma
    The document outlines an internal training programme for total employee involvement in quality control. It includes an activity plan from March to June 2009 to address identified problems. The plan involves identifying the problem, analyzing probable causes, identifying the actual root cause through data analysis and a why-why analysis. Charts are presented showing rejection data and defects for components over three months. A cause and effect diagram and why-why analysis are used to validate the root cause of die temperature being less, which was found to be the reason for product unfill. Monitoring of effectiveness is also included.

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    © All Rights Reserved
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    Quality Circle (Hindi) 14 - 05 - 2011 (Read-Only)

    Uploaded by

    Atul Sharma
    2K views40 pages
    The document outlines an internal training programme for total employee involvement in quality control. It includes an activity plan from March to June 2009 to address identified problems. The plan involves identifying the problem, analyzing probable causes, identifying the actual root cause through data analysis and a why-why analysis. Charts are presented showing rejection data and defects for components over three months. A cause and effect diagram and why-why analysis are used to validate the root cause of die temperature being less, which was found to be the reason for product unfill. Monitoring of effectiveness is also included.

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    Quality Circle (Hindi)14_05_2011 [Read-Only]

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    The document outlines an internal training programme for total employee involvement in quality control. It includes an activity plan from March to June 2009 to address identified problems. The plan involves identifying the problem, analyzing probable causes, identifying the actual root cause through data analysis and a why-why analysis. Charts are presented showing rejection data and defects for components over three months. A cause and effect diagram and why-why analysis are used to validate the root cause of die temperature being less, which was found to be the reason for product unfill. Monitoring of effectiveness is also included.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2K views40 pages

    Quality Circle (Hindi) 14 - 05 - 2011 (Read-Only)

    Uploaded by

    Atul Sharma
    The document outlines an internal training programme for total employee involvement in quality control. It includes an activity plan from March to June 2009 to address identified problems. The plan involves identifying the problem, analyzing probable causes, identifying the actual root cause through data analysis and a why-why analysis. Charts are presented showing rejection data and defects for components over three months. A cause and effect diagram and why-why analysis are used to validate the root cause of die temperature being less, which was found to be the reason for product unfill. Monitoring of effectiveness is also included.

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    © All Rights Reserved
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    of 40

    Internal Training Programme

    Total Employee Involvement-QC


    1
    @yaaoM……?
    DoimaMga caË
    caË
    Activity Plan
    P=Plan
    Mar- 09 Apr-09 May-09 Jun-09
    Activity
    W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

    Identification of Problem P P P
    P
    L Selection of Problem P

    A Defining the Problem P


    N
    Analysis of Problem P P

    Identification of probable
    P P
    cause
    Identification of actual
    P P P
    D root cause

    O Data analysis P

    Developing solutions P P P P

    Foreseeing probable
    P P P
    resistance
    C Trial implementation &
    P P P P
    H check performance
    E
    C Regular implementation P P P P P
    K
    A
    C Standardization P P
    T
    5 15
    sadsya kI ijammaodairyaaM
    laIDr / iDPTI laIDr kI ijammaodairyaaM
    laIDr / iDPTI laIDr kI ijammaodairyaaM
    maUla karNa ka puYTIkrNa (ROOT CAUSE VALIDATION)
    vaa^ya vaa^ya ivaSlaoYaNa (WHY WHY ANALYSIS)
    Rejection Data of Last 3 Month
    Produced Rejected
    Component Dec-
    Dec- 08 Jan-
    Jan-09 Feb-
    Feb-09
    Qty. Qty.
    PPM

    Clutch outer KRMA 2840 2530 2720 96636 8090 83716

    Clutch Pressure Plate


    580 615 510 89705 1705 19007
    KTEA
    Clutch Pressure Plate
    410 380 350 71592 1140 15924
    KRMA

    Center Clutch K1 385 360 330 80677 1075 13325

    Center Clutch K2 358 310 255 50453 923 18294

    Clutch center KRMA 198 158 180 137876 536 3888


    REJECTION DETAIL

    3000 2840
    2720
    2530
    2500
    Qty.

    2000

    1500

    1000

    500 410 380 350 385 360 330 358 310


    255 198 158 180

    0
    Outer Clutch KRMA Clutch pressure plate clutch Center K1 Clutch center K2 Center clutch KRMA
    KRMA

    Jan-11 Feb-11 Mar-11


    80% samasyaayao 20%karNaaoM sao inai-
    inai-ma-mama-t haotI hOM.
    500 97 100 100

    88

    400 375 76 80

    C U M U L A T IV E % A G E
    300 60

    PPM
    57

    200 40

    128

    100 78 20
    55
    23
    0 0
    1 2 3 4 5

    TYPE OF DEFECTS
    BRAIN STORMING - 5W+2H

    WHO
    WHAT
    WHEN
    HOW
    MANY
    WHY

    HOW

    WHERE
    LIST OF POSSIBLE CAUSES DURING BRAIN STORMING - 5W + 2H

    Fatigue Diecoat leakage from spray header


    Skill Air entrapment
    Job Knowledge Less metal in die
    Experience Cast pressure less
    Training not proper High Speed length Variation
    Time Die temp. less
    Training content Plunger Jam
    Metal Temperature less Worn out plunger
    Excess Flash Water Leakage from Pipe in plunger
    Water Leakage from Pipe in die Die mis-matching
    More Internal Cooling in Die Insert worn out
    Mis-alignment of shot sleeve & sprue bush Platten parallelism NG
    Gap between shot sleeve & sprue bush Locking force less
    Metal sticking O ring damage
    Metal stick on level sensor Air vent not provide
    Intensification not Working Insert level down than block
    Machine encoder not working More spray pipe in specific area
    samasyaa kI phcaana krnao ko baad samasyaa ko saMBaaivat karNaao kao karNa evaM p`Baava
    ica~ (Cause & Effect Diagram) ko Wara sauinaiScat krto hO.

    karNa evaM p`Baava ica~ (Cause & Effect Diagram) @yaa hO ?


    iksaI BaI p`iËyaa (p`aosaosa) kao p`Baaivat krnao vaalao karNaaoM kao ica~$p mao
    saUcaIbaw krnaa.
    jaOsao maSaIna, saamaana, vyavasqaa, trIka, vyai@t, vaatavarNa Aaid
    Aaid ko karNa.
    karNa.
    [saI kao ifSa baaona Dayaga`ama va [saIkavaa Dayaga`ama BaI khto hO.
    maUla karNa ka puYTIkrNa (ROOT CAUSE VALIDATION)
    S.N Probable
    Photographs Who When Where How Qty Checked result Conclusion
    o Causes

    All the 100 shots Found


    Cast OK
    100
    Pressure Anjum After shot On machine Cast Pr. Req. = 700±.30 Not a Reason
    1 On 420t zitai. shots
    Less taken display Kg/Cm2 for unfill
    Cast pr. observed =
    698~708 Kg/cm2

    All the 100 shots Found


    OK
    High Speed High Speed length Req.
    After shot On machine 100 Not a Reason
    2 Length Anjum On 420t zitai. = 110±.5 mm
    taken display shots for unfill
    variation High Speed length
    observed = 108~109
    mm

    Plunger After shot 100 Not a Reason


    3 Pushpa On 420t zitai. Visual Plunger Movement Free for unfill
    Jam taken shots

    Die Temp. Check die 10


    Less After shot temperature shots
    4 Pushpa On 420t zitai. Temperature Found NG Reason for unfill
    taken by Touch Type
    pyrometer
    vaa^ya vaa^ya ivaSlaoYaNa (WHY WHY ANALYSIS)

    WHY ANSWER
    Die temperature less Excessive qty of die coat

    Number of Spray pipe


    Excessive qty of die coat more in( Specific area)
    spray header
    Number of Spray pipe General purpose spray
    more ( Specific area) header used
    General purpose spray
    Original with Machine
    header used
    Effectiveness Monitoring – Overall Rejection

    80000
    63400 N =7200
    60000
    PPM

    Target Achieved
    40000 3555132848

    20000
    PPM Target = 2000
    0 0 0 0 0 0 0
    0
    Feb-09 '10- 11-May- 30-May 3~ 9- 10~16- 17~23- 24~30- 1~7-Jul- 8~14-
    May-09 09 ~ 2- Jun-09 Jun-09 Jun-09 Jun-09 09 Jul-09
    Jun-09

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