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There is lag in production planning like to know the status of working
progress, Daily & Monthly production planning & Inputs like materials, men
and machines are efficiently used, Production control, Planning plant capacity
for future production, production schedules, grouping similar products /
process, Lead time, To avoid / reduce the scrap generation.
Have to develop production activities such as studying about cycle time of
process / machine / man, need clean & standardized shop floor, Labor
productivity, Utilization of equipment and space, Continuous improvement,
process Capability, to set benchmark, work instructions

Have to improve the activities in Quality such as line inspection, First off &
Last off report, Determine what parameter is to be controlled or critical ones,
Cost of Quality as well as cost of poor quality, Customer satisfaction, supplier
monitoring & Rating, Most importantly usage of 7QC Tools

Have to develop the Design & Development activities like detail drawings,
process drawings / stage drawings, control plan, Bill of material in respective
drawings itself, developments of tools, process & Gauges, analysis of failure.

Process flow of closing the gap (techniques):

Details Drawings,
Documents, Records &


Lean Manufacturing

7 QC Tools

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Machine, process, Tools

& Gauges

Details Drawings, Documents, Records & planning:

First of all, we need to develop the detailed drgs. Such as Assy drgs with
indication of child parts, child part drgs with components details.
Need to develop the Process / stage drgs. To avoid the discrepancy between
product and drgs. Prepared.
All the drgs. Should have tolerance at least in Fitment areas.
In the past, we have User manual for product. But now we not maintain it so
need to make it.
We need to develop control plan because it is document that sets the limits
within which the process should operate, give the details like product
characteristics, process characteristics, specification, which machines, tools &
gauges to use in respective operations, reaction plan & Corrective actions.
Grouping of process and their dimensions to convert from the job production
to batch production type which is reduce the scrap generation as well as flow
To prepare Daily & Monthly production plan.
Productivity per man power.
Planning outsourcing products with relation between our final product lead
time & components lead time like which one takes more time we have to
order that one first.
Need to make Quality planning report.
Have to prepare the cost of quality and cost of poor quality as well as process
Need to monitor supplier & need to rate him.
Have to prepare the status of working in progress for each order.

Why we need to maintain 5S ?
Remove unnecessary items and dispose them properly, Make work easy by
eliminating obstacles, Provide no chance of being disturbed with unnecessary
items, Prevent accumulation of unnecessary items

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Prevent loss and waste of time, Easy to find and pick up necessary items,
Ensure first-come-first-serve basis, and Make work flow smooth and easy.
Gives identification to tools, gauges, conformance & Non conformance

Lean manufacturing :
Why we need to implement Lean Manufacturing ?
We can use this tools / methodologies to aim for the continuous elimination of all
waste in the production process. The main benefits of this are lower production
costs, increased output and shorter production lead times.
Defects and wastage Have to Reduce the defects and unnecessary physical
wastage, including excess use of raw material inputs, preventable defects, costs








characteristics which are not required by customers;

Cycle Times Need to Reduce manufacturing lead times and production cycle
times by reducing waiting times between processing stages, as well as process

preparation times and product/model conversion times;

Inventory levels To Minimize inventory levels at all stages of production,
particularly works-in-progress between production stages. Lower inventories also

mean lower working capital requirements;

Labor productivity -Should Improve labor productivity, both by reducing the
idle time of workers and ensuring that when workers are working, they are using
their effort as productively as possible (including not doing unnecessary tasks or
unnecessary motions);
Utilization of equipment and space - Use equipment and manufacturing
space more efficiently by eliminating bottlenecks and maximizing the rate of
production though existing equipment, while minimizing machine downtime;
Flexibility - Have the ability to produce a more flexible range of products with
minimum changeover costs and changeover time.

Process flow of Lean Manufacturing:

1. Recognition of waste The first step is to recognize what does and does
not create value from the customers perspective / Final product. Any material,

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process or feature which is not required for creating value from the customers
perspective is waste and should be eliminated.
2. Standard processes Need to implementation of very detailed production
guidelines, called Standard Work, which clearly state the content, sequence,
timing and outcome of all actions by workers. This eliminates variation in the
way that workers perform their tasks.
3. Continuous flow we have to aims for the implementation of a continuous
production flow free of bottlenecks, interruption, detours, backflows or waiting.
When this is successfully implemented, the production cycle time can be
reduced by as much.
4. Pull-production this is need ed to produce only what is needed, when it is
needed. Production is pulled by the downstream workstation so that each
workstation should only produce what is requested by the next workstation.
5. Quality at the Source this is one of the important and basic one for
defects to be eliminated at the source and for quality inspection to be done by
the workers as part of the in-line production process.
6. Continuous improvement To improve our

perfection by continually

removing layers of waste as they are uncovered. This in turn requires a high
level of worker involvement in the continuous improvement process.

What to eliminate from production?

Over production
Work In Progress (WIP)
Inappropriate processing
Excess motion or ergonomic problems
Defected products
Underutilization of employees

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How to conduct the study

Study of Current

Time Study

Plot Man & Machine

Target Setting

Waste identification
Machine cycle

Implement Kaizen

Man cycle
Non Cyclic

Implement Cyclic
Motion with single piece

Target Achieved
check measurable

Standardized work
chart material Flow

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7QC Tools:
Why we need to use 7QC Tools:
7QC Tools gives the clear datas, Graphical representative to understand
easier as well as to form the grouping, Most importantly to find in which areas of
process / product most of rejection / reworks happening based on this we can
take corrective / preventive action with helpful of Cause & Effect diagram or
Failure Mode and Effects Analysis, To get the relation between two things by
Scatter diagram or Characteristic Matrix and to determine the variation we can
use Control chat.

How to use QC Tools:

1. Check Sheet we need to prepare this in Line inspection, supplier rating
incoming inspection,, etc.., we can use this where we need to collect the data
for analysis, decide which data Is necessary, to determine who & how data
will be analyzed
2. Histogram / Charts To analysis the data by making the multi groups, it
must useful in studying patterns of distribution and in drawing conclusions
about the process based on the pattern.
3. Cause and effect diagram It is one of the most useful tool because of we
can analysis the problem by looking all perspectives like Man, Machine,
Method, Material & Measurement. We can use this for analyze Cause and
effect relationship, to search for solutions of related problems, to standardize
4. Pareto Analysis It is another most important tool which is very much of
helpful to diagnostic most of quality problem occurs area / process. So we can
take corrective action / preventive action / improvement based on this.
5. Stratification Analysis we need to use this for analysis data by grouping
in different ways. We can use this many areas like machine, supplier,
operators, tools, gauges. To which the study of variation is conducted for
diagnosis and possible control / prevention of variations.

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6. Scatter diagram we can make use of it for relationship between two

variables. we can use It in what happens to one variable when another
variable is changed. From this we can understand , why particular variations
occur and how they can be controlled.
7. Control Chart We can use this as process control, from this we can
observe the performance over the time of process. We can visualize the
process which is out of control .

Machine, process, Tools & Gauges improvements:

We need to looks more in the tooling improvements like clearance between
Top & Bottom tools for reducing burr as well as improve tool life.
We need to make error proofing fixtures for avoiding the gauges and line
We must to make welding fixtures to make accurate as well as to reduce the
man power in this area.
Need to make improvement in machine like need to go to punching instead of
drilling which is more time consuming one.
We are using plasma cutting, for this also we can make it in pressings.
Need to reduce the scrap generation in all the process and most importantly
in Shearing and cutting.
Need to make gauges for almost all the process which reduce the time also
ensure the effectiveness of the product.
We need to conduct process validation for all the process to check the
effectiveness range.
New product Development :
What all are things need to look before proceeding the new product in
trail run / production ?
1. Details Drawings / process drawings / child part drawings
2. Bill of material
3. Approved sources
4. Material identification
5. Requirements of tools
6. Requirements of gauges

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7. Special / critical characteristics

8. Needed of user manual
9. Initial Studies (if need)
10.FMEA (if need)
11.Lead Time.
12.Process flow diagram
13.Engineering change approval /documents
14.Trail Inspection report
15.Appearance conformation
16.List of checking aids
17.Feasibility study
From the observation, we have decided to stabilize the documents first
of all for get the data from respective department because of then only we can able
to analysis where is the lag in our process, machine, design, etc.., after this we need
to make our shop floor clean & standardize as possible to continuous flow, easy to
pick & drop, which is give the separate areas on conformance & Non Conformance
of products also separate areas for all of them. We are going to use lean
Manufacturing for study about the cycle time, identification of wastages / scrap of
value as well as non value of products, to maintain the inventory especially we
can able to identify the improvement need process / machine / tools, etc.., we need
to make use of 7QC tools for indentify the dominate area of rejection and reworks.
After making the analysis of all the above mentioned, then only we can go to
improve the machine, process, tools & gauges because of based on those datas like
we can find which is critical process, most of the rejection areas, etc., So after
getting like this point, we can fist of all improve on that preference since it is most
product affecting areas.

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