Machine Building Division (Fabrication Shop)

MUKAND LTD.

MACHINE BUILDING DIVISION (KALWE,THANE)

OUR PRODUCTS
Our main product is EOT Crane (Capacity 5-500Ton)

INTRODUCTION OF MEMBERS
LEADER:- Mr. G.V.NAVELKAR Mr. S.R. MORE Mr.B.V.SHAH FACILITATTATOR GUIDE CO-ORDINATOR Q.C.C STARTED ON PROBLEM SELECTED ON PROBLEM COMPLETED ON Dy.-LEADER :Mr.S.J. AGASHE Mr. C.G. CHALKE MR.S.L. WANI :Mr.Y.C.HAMAND :Mr..J.G.RATHOD :Mr. B.S.MARATHE :01/04/1991 : 04/11/2006 :17/02/2007 MEMBERS

NUMBER OF MEETINGS

:16

STEP-1:

IDENTIFICATION OF PROBLEM
IDENTIFIED PROBLEMS BY BRAIN-STORMING 1. Distortion control. 2. Delay in starting work at the beginning of the shift. 3. Rework on items received from vendor. 5. Taper burning of electrodes 6. Distortion in rope drum. 7. Crane availability for handling.

4. Defects occurring while welding with gas metal arc welding (GM

8. Oil leakage in shearing machine.

9. Difficulties in structural assembly Similarly there are 56 problems.

STEP-2: SELECTION OF PROBLEM

ABCANALYSIS A Minimum involvement of other department in solving the problems. B Involvement of other department is a necessity. C Management sanction may be needed in implementing the solution. Problems under category A 1. Distortion control. 2. Defects occurring while welding with gas metal arc welding (GMAW) process. 3. Cutting gas availability. 4. Helper not available

Problems under category A 5. Defects occurring while welding with submerged arcwelding (SAW) process. 6. Improper match marking.

7. Notches during gas cutting.

8. Bolt threads getting damaged. 9. Improper identification of testing weights. 10. Wing nuts on trolley getting damaged. 11. Rework on girder during crane assembly.

SELECTION OF PROBLEM
(BASED ON CRITERIA)
a. Repetitive jobs and rework require in each jobs. b. Rework resulting into more cycle time and lower productivity. c. Only skilled manpower can carryout actual manufacturing and rework. d. Rework to maintain dimensions results in variation in material properties. e. Rework resulting in to losses in other department.

CHECK SHEET
(For showing Relationship between Criteria and Problems)
PROBLEMS

TOTAL

1 2 3 4 5 6 7 8 9 10 11

2 3 0 0 2 2 4 2 1 0 5

SELECTION OF PROBLEM

BY BAR GRAPH
6 5

TOTAL

4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11

PROBLEMS

Based on criteria & and their impact on problems

REWORK ON GIRDER DURING CRANE ASSEMBLY

PROBLEM SELECTED IS

MILESTONE CHART(BEFORE)
Quality Circle Name : RESEARCH Department : MBD Guide : J.G.Rathod Facilitator : Yogesh Hamand Date: 11/11/2006 Members Name G.V. Navelkar S. J. Agashe S.L. Wani C. G. Chalke B. V. Shah S. R. More
17 18 19 Target 1 1 1 2 2 2 1 2 2 2 2 1

Project :Rework on Girder during Crane assembly. Project No. 15 Meeting Day : Saturday
Sr No 1 2 3 4 5 6 7 8 9 10 11 12 Week Activity Identification Of Problems Selection Of Problem Defining Problem Analysis Of Problem Finding The Causes Root Cause Analysis Data Analysis Developing solution Foreseeing Probable Resistance Trial Implementation & Checking Performance & Results Regular Implementation
Follow-up/ Review &Recurrence Prevention

Date of beginning : 04/11/2006 Time : 01:30 pm to 02:30 pm

1 2 3 4 5 6 7 8 9

Date of completion : As per plan No. of Projects completed : 16

10 11 12 13 14 15 16

TOTAL

19

STEP- 3: DEFINITION OF PROBLEM

To study the problem in details, girder was selected. (As shown in photograph-1).

S/O -11532

PERIOD OF MGF. NOV-2006

FLOW DIAGRAM
A
START CHECKING/RECTIFICATION GIRDERS STRAIGHTNESS

GIRDER MARKING &CUTTING PLATFORM BRACKET TACKING & WELDING FITTING OF L.T PLATFORMS E/CS POSITIONING FOR ASSEMBLY E/Cs SPAN AND DIAGONAL PLACEMENT OF GIRDER

TAKING GIRDERS CAMBER READING FITTING OF RAILS & CLAMPING ARRNGEMENT PACKINGS BETWEEN SOLE & TOP PLATE SOLE PLATE, RAIL CLAMPS & STOPPERS WELDING RECTIFICATION CHECKING CAMBER

NOT OK

CHECKING/RECTIFICATION GIRDERS VERTICALITY

OK
END PLATE TACKING & WELDING

A
END

IMPORTANT ACTIVITIES
Girder is an important part of EOT crane. If girder dimensions are as per drawing requirements, difficulties during crane assembly is less. But for manufacturing/fabrication of girder, gas cutting and welding is required to be done, because of which variation in dimension are observed whish are as follows: 1. 2. 3. 4. Variation in verticality. Variation in girder straightness. Reduction in girder camber. Gap between girders top plate and sole plate.

Rework/rectification is required to remove above-mentioned variations.

Crane assembly can be done only if the entire dimensions are maintained as per the drawing.

IMPORTANT ACTIVITIES

VERTICALITY STRAIGHTNESS CAMBER

IMPORTANT ACTIVITIES

Putting packing between sole plate and top plate of girder

DATA COLLECTION
(For One crane, No. of girder 2) To find out time required for these activities we collected data, which are as follows.
Date: 11/11/2006 Period:07/11/20006 To 11/11/2006 SR. NO . 1 2 3 4 Activities Checking/ Rectification verticality for Leveling of Girder Checking/ Rectification Girders Straightness. Putting Packing between sole plate and top plate of Girder. Checking & Rectification of camber as per drawing requirement Total Collected By: Chalke, Wani S/O: 11532 Time in hrs 2 4 4 10 No. of Workers 2 3 2 4 Mandays 0.5 1.5 1 5 8

PARETO DIAGRAM
8 7.5 7 6.5 6 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0
92.75% 81.25% 62.5%

100 90 80

MANDAYS

60 50 40 30 20 3 1 ACTIVITY 2 4 10 0

Pareto diagram indicates that time taken for activity no.3 i.e., checking & rectification of camber as per drawing requirement is maximum (62.5%). Therefore our group decided to concentrate on checking & rectification of camber, as per drawing requirement.

PERCENTAGE

70

STEP- 4:

ANALYSIS OF PROBLEM
Data for finding out camber Reading
Date: -16/11/06 Collected By: S.R.MORE Camber reading before fitting & welding of rail clamping arrangement 18 16 20 14 13 Camber reading after fitting & welding of rail clamping arrangement & keeping girders on E/C 7 4 6 6 5

SR. NO.

S/O NO.

Date

Required Camber

1 2 3 4 5

11458 11530 11342 11512 11532

10/11/06 12/11/06 12/11/06 14/11/06 15/11/06

10-20 10-20 12-24 8-16 8-16

From the data it is observed that camber get reduces after welding of rail clamping arrangement.

PHOTOGRAPH -3 GIRDER BOTTOM PLATE HEATING

For Bringing back decreased Camber to its original Position, two gas cutters are required on either side of the girder for heating.

STEP 5:

FINDING THE CAUSES

We conducted brainstorming and got the following causes for camber rectification of girder:
1) Unskilled fitters, welders & gas cutters. 2) Poor quality of Raw material & Welding electrodes. 3) Shielded metal are welding (SMAW) process 4) Improper profile cutting m/c. 5) Improper gas regulators. 6) Improper shearing m/c. 7) Improper pug cutting m/c. 8) Gas cutting Torches. 9) Excessive welding. 10) Rusty surface. 11) Material with scales. 12) Improper method of sole plate welding. 13) High current, low current and spatter loss. 14) Fluctuation in speed and jerk in action of pug cutting machine. 15) Taper cutting during shearing. 16) Electrodes with improper flux. 17) Electrodes with moisture.

CAUSE AND EFFECT DIAGRAM

MAN
Fitters

MATERIAL
Electrode with Moistures

Material with Scales

Poor quality Of electrodes

Electrode with Flux

Gas cutter

Poor quality of raw Material

Welders Rusty Surface

High & low current Improper SMAW m/c Spatter loss

Excessive speed

Regulators
Fluctuation

Gas Cutting Torches Excessive Welding

Rectification of Girders camber

in

Speed Pug m/c

Profile Cutting M/C

SMAW Process
Spatters Improper sole plate welding

Improper shearing m/c

Taper CUTTING

MACHINE

METHOD

STEP- 6:

ROOT CAUSE ANALYSIS

TESTING OF THEORIES CHECK SHEET (Welders)
SMAW Process

A)MAN 1) Unskilled welders:SR. NO. 1. 2. 3. Name

Period :Oct2006 to Dec.2006 Qualification certified by Q.A.

Mr.Prabhakar Desai Mr. Suhash Agashe Mr. S. L. Wani

Qualified welders are used for welding.

2) Unskilled Fitters & Gas Cutters:Similarly, Qualified & Skilled fitters & gas cutter are used for girder fabrication and crane Assembly

Hence this theory is INVALID.

TESTING OF THEORIES B) MATERIAL:Poor quality electrodes of raw material & welding

Raw material & welding electrodes used for manufacturing girder and crane assembly are duly inspected & tested by Quality Assurance department as well as by clients inspector (as applicable) prior to its clearance for usage.

Hence this theory is INVALID.

TESTING OF THEORIES C) MACHINE: CHECK SHEET (For Confirming Calibration) Period: Oct.2006-Mar2006
SR. NO. 1. MACHINE NO. SMAW R53 WELDER SJA CALIBRATED Yes No

2.
3.

SMAW R32
SMAW R59

PD
SLW

From the above data it is clear that machines used for welding are calibrated. In Similar manner periodic calibration of profile cutting m/c and gas regulators are done. Hence this theory is INVALID.

TESTING OF THEORIES
C) MACHINE: b) Improper Shearing, Pug Cutting M/C & Gas Cutting Torches: Periodic checking & maintenance is being done by user dept. & is confirmed by maintenance department. CHECK SHEET (Data For Confirming Periodic Checking)
Date: -30/10/2005 Collected By: - S. J. Agashe
SR. NO
.

MONTHS (YEAR2005)
Apr May June July

Shearing M/C CHECK

YES NO

Pug cutting M/C CHECK

YES NO

Gas cutting Torches

YES NO

1. 2. 3. 4.

Above data shows that m/c & torches are in good working condition. Hence this theory is INVALID.

TESTING OF THEORIES
D) METHOD Improper method of sole plate welding We collected data of camber reading taken before and after sole plate, rail clamps & stoppers welding.
GIRDER TOP AFTER SOLE PLATE, RAIL CLAMPS & STOPPERS WELDING

100

100 IN DRAWING ALL DIMENSINOS ARE IN MM

TESTING OF THEORIES
Girders Camber Reading
Date: 16/11/06 Period: 10 /11/2006 to 15/11/2006 Collected By: Mr.S.R.More
Camber Before sole plate, rail clamps & stoppers welding (mm) Camber After sole plate, rail clamps & stoppers welding (mm) 7 4 6 6 Required camber (mm)

SR. NO.

S/O NO.

Girder NO.

11458

1 2 1 2

18 16 20 14

10-20

11342

12-24

From the data it is observed that camber get reduces after welding of rail clamping arrangement.

TESTING OF THEORIES
USED OF 5W&1H ANALYSIS S/O No. What Where On Girder During Crane Assembly On Girder During Crane Assembly When After sole plate, rail clamps & stoppers welding Why Who How Improper method of sole plate welding Improper method of sole plate welding

11458

Camber Reduced

Excessive Welding

Welder

11342

Camber Reduced

After sole plate

Excessive Welding

Welder

Earlier mentioned data & 5W-1H analysis shows that, problem is due to Improper method of sole plate welding Hence this theory is VALID.

TESTING OF THEORIES
Incorrect selection of electrodes: Selections of electrodes are done by qualified welding engineers in consultation with process planning department and is approved by Q.A. department. Proper welding procedure specification (WPS), procedure qualification record (PQR) are prepared and is approved by Q.A. department / client inspection (as applicable) Electrodes are selected after completing the above-mentioned necessary formalities. Hence this theory is INVALID.

TESTING OF THEORIES

Conclusion:Based on the above analysis, the valid theory is as follows. After subsequent brain storming on valid theory, group concluded that root cause of our problem is

Improper method of sole plate welding.

STEP-7: DATA ANALYSIS

After finding out root causes we collected data of girders for the period Aug 06 to Nov 06 in which camber rectification was carried out.

Camber Rectification data

Period: Aug 06 To Nov 06 Collected By: Mr.G. Navelkar

Sr. No. Period of Manufacturing No. Of crane Time taken for camber rectification (Mandays) 40 42 27 30
Time taken in Mandays (Ref. Sample Girder selected for Case Study)

1. 2. 3. 4.

Aug 2006 September 2006 Oct 2006 Nov 2006

8 9 6 7

5 4.67 4.5 4.28

LINE GRAPH
((Indicates reduction in time taken for camber rectification of girder) )
6 5.8 5.6 5.4

MANDAYS

5.2 5 4.8 4.6 4.4 4.2 4 Aug-06 Sep-06 'Oct-06 Nov-06 PERIOD OF MANF.

OBSERVATION:From the above-mentioned data and graph it is observed that reduction in time taken for camber rectification of girder over the period is very less by existing method of manufacturing girders.

STEP: 8

Welding Of Rail Clamping arrangement as per drawing is carried out by following procedure. 1) Rail clamp tacking. 2) Sole plate tacking. 3) Rail fitting. 4) Stopper tacking.

DEVELOPMENT OF SOLUTION (P.D.C.A.)

5) Welding.

Date: -16/11/06 Period: 10 /11/2006 to 15/11/2006 Collected By: Mr.S.R.More, Mr.G.V.Navelkar S/O NO. Girder NO.
Camber After sole plate, rail clamps & stoppers welding (mm)

SR. NO.

Required camber (mm) 10-20

11458

1 2 1 2

7 4 6 6

11342

12-24

DEVELOPMENT OF SOLUTION PDCA I

To develop alternative welding sequence. Excessive distortion (i.e., reduction in camber) of girder is observed. Therefore cycle time for camber rectification is increased. To carry out sole plate full welding throughout the length of girder (To keep Fillet size of 3mm) along with rail clamp & stoppers Welding done as per plan.

S/O NO.

Girders No

DATA AFTER SOLE PLATE WELDING (ONE CRANE) Date: 19/01/2007 Collected By: Mr.C.G.Chalke Camber reading after sole Required plate welding camber (mm) (mm)

11454

1
2

7
5

12-24

DEVELOPMENT OF SOLUTION PDCA II

To develop alternative welding sequence. To omit sole plate welding.

Gap is observed between girder & sole plate.

Rail clamp arrangement is done without sole plate welding.

RAIL

GAP TOP PLATE

SOLE PLATE

DEVELOPMENT OF SOLUTION PDCA III

To develop alternative welding sequence. Resulted in camber rectification of girder to be done twice Hence cycle time increased. To carry out welding of sole plate as specified in drawing before fitment of rail clamps & stoppers Fitment / Welding done as per plan.

DATA COLLECTION
S/O NO. Girder No. Camber After sole plate welding (mm) 11

Date: 29/01/2007 Collected By: Mr.G.V. Navelkar Camber After rail clamps & stoppers welding (mm) 8 12-24 Required camber (mm)

1 11517

10

DEVELOPMENT OF SOLUTION PDCA IV

Still it is required to carry out camber rectification therefore group decided to develop another solution. To do sole plate welding,as per design given below along with rail clamps & stoppers & to provide packing below girder at center & to put weights at both the ends

It is observed that camber get reduces after welding of rail clamping arrangement.

Welding done as per plan.

100

100

100

100

DEVELOPMENT OF SOLUTION

DATA AFTER SOLE PLATE WELDING (ONE CRANE) Date: 02/02/2007 Collected By:Mr.B.V.Shah S/O NO. Girders No

Camber reading after sole plate welding (mm)

11

Required camber (mm)

1
11472 2

14-28 12

1) Camber rectification is required only once. Hence cycle time is reduced. 2) Distortion (i.e., Reduction in camber) is minimized.

DEVELOPMENT OF SOLUTION PDCA V

New design & improved method of welding found to be useful. To do sole plate welding as per design given below along with rail clamps & stoppers.

Observed camber after sole plate welding is within required range.

Welding carried out as per plan.

100

100

DEVELOPMENT OF SOLUTION

NON-WELD AREA WELD AREA

DATA AFTER SOLE PLATE WELDING (ONE CRANE/TWO GIRDER) Date: 07/02/2007 Collected By:Mr.S. J. Agashe S/O NO. Girders No Camber reading after sole plate welding (mm) Required camber (mm)

1 10952

21 12-24

20

STEP NO. 9 FORSEEING PROBABLE RESISTANCE

SR. NO. PROBABLE RESISTANCE ACTION TAKEN

1.

Shop floor khalasis, fitters and welders were of the opinion that suggested method of keeping weights on top and putting packing below the girder would be unsafe and time consuming.

Practical demonstration made to explain about safe working condition with new method and also explained that time taken for this activity is very less.

2.

There was an objection from QA department that finally suggested design of sole plate welding is not sufficient for proper functioning of the crane.

Detailed analysis with all the readings of our case study submitted to our design department and our final suggestion of sole plate welding got approved based on proper design calculations. Approval from design department submitted to Q.A. department and their approval is also taken.

STEP: -10 TRIAL IMPLEMANTATION, CHECKING PERFORMANCE

The fabrication of two girders till one crane assembly is carried out with improved method. The data collected for finding out camber reading after implementation of improved method.
DATA AFTER SOLE PLATE WELDING (ONE CRANE/TWO GIRDER) Date: 07/02/2007 Collected By: Mr.S. J. Agashe S/O NO. Girders No Camber reading after sole plate welding (mm) 21 12-24 2 20 Required camber (mm)

1 10952

Observation: Camber after sole plate welding is within required range.

Comparision of camber reading

(Before & after implementation of improved method)
Condition S/O Required Camber (mm) Actual Camber (mm) Girder1 Girder2

Before implementation of improved method After implementation of improved method

11342 12-24 10952

21
(Reduction in camber)
REDUTION IN CAMBER (mm)
16 14 12 10

20

Above data indicates that reduction in camber was 15mm with earlier method of welding & it is zero with improved method of welding.

15

8
6 4 2 0 BEFORE AFTER

Data collection for finding out time taken for camber rectification for one crane (Two girders)

DATA COLLECTION

Date: 07/02/2007 Collected By: Mr.S. Agashe

Time taken in mandays For camber rectification Nil

S/O NO.

Period of Manufacturing FEB 07

Length of girder (mm) 34,000

10952

Time taken for camber rectification eliminated as against 5mandays earlier.

6 5 MANDAYS 4 3 2 1 0 BEFORE AFTER

Comparision Welding of rail clamping arrangement

(Before & after implementation of improved method)

Bar Graph (Time taken in mandays for Welding of rail clamping arrangement)

9 8 7 MANDAYS 6 5 4 3 2 1

0
BEFORE AFTER

For welding of rail clamping arrangement only 4 mandays are required as against 8 mandays earlier.

Hence saving of 4 mandays in welding.

Total saving of mandays (For one Crane)

5 Mandays in rectification of girders camber 4 Mandays in rail clamping arrangement welding 1 Mandays for resurface preparation & repainting at final painting stage.

Total saving of 10 mandays (For one Crane)

Cost saving
Total saving of mandays (For one Crane)
1) 5 Mandays in rectification of girders camber

2) 4 Mandays in rail clamping arrangement welding

Total

saving of 9 mandays (For one Crane)

i.e, cost saving of Rs 17,625.60

3) 1 Mandays for resurface preparation & repainting at final painting stage. Rate: Rs. 200/Total saving of mandays (For one Crane) Rs17,825.6

Saving in consumables (For one Crane)

Saving in electrodes, cylinders ( O2 & C2H2), Polish grinding wheels &
red oxide paint

i.e Total saving in consumables ( for one Crane) is Rs 2205/-

Total saving (For one Crane) = Total saving in mandays + Total saving of consumables

Total saving (For one Crane) = Rs.20,030/-

STEP 11:REGULARIMPLEMENTATION
DETAILS OF JOBS (CRANE ASSEMBLY) CARRIED OUT WITH IMPROVED METHOD
Sr. No. Year Of Manufacture No. Of Cranes No. Of Girders Time Taken For rectification of Camber( Mandays)X Mandays available for Fabrication Y 909 1313 1010

Time Taken For rectification of Camber ( Mandays% ) (X/Y)*100

1.10 -0.49

1 2 4

MAR 07 APR 07 JUN 07

9 13 10

18 26 20

10 Nil 05

3
5

MAY 07
JULY 07

12
11

24
22

05
Nil

1212
1111

0.41
--

COMPARISON GRAPH
45 40 35 30 25 20 15 10 5 0 'AUG-06 'SEPT-06 'OCT-06 'NOV-06 'MAR-07 'APR-07 'MAY-07 'JUN-07 'JUL-07 MANDAYS

10

'AUG- 'SEPT- 5 'OCT- 'NOV- 'MAR- 'APR- 'MAY- 'JUN- 'JUL0 'MAY'JUN-07 06 06 06 06 06 06 07 'APR-07 070707 07 07 06 06 07 07

BEFORE SELECTION OF PROBLEM FOR CASE STUDY AFTER IMPLEMETATION OF SUGGESIONS OF CASE STUDY

PERIOD

We checked all the Girders and crane assemblies carried out with improved method in detail and following results are observed in all the girders. 1. Minimum distortion. 2. Minimization of rework 3. Non conformity with drawing eliminated. 4. Minimum labourious work. 5. Simplicity in working. COST SAVINGS: Total No. of jobs manufactured are 55 crane assemblies , 110 girder (inclusive of one trial piece) RS. 20,030/ job 55 (No. Of jobs) = RS. 11,01,650/POTENTIAL OF CASE STUDY SAVING (PROJECTED SAVINGS):No. of EOT cranes manufactured per year at MBD 125 nos. (avg.) Total saving per crane = RS. 20,030/Therefore, saving can be achieved per year = 125Cranes X Rs20030/ Crane = Rs 25,03,750/year. Case study has potential of saving

Rs 25,03,750/

year.

Thus, projected saving per year is Rs 25,03,750/-

TANGIBLE GAINS
1. Reduction in cycle time of welding and rework.
* Total saving of 10 mandays. 2. Rework for camber rectification of girder is minimized * Resurface preparation, repainting of girder on heated area avoided, therefore cost of consumable of welding, grinding and painting got reduced. 3. Better quality of surface finish is achieved. 4. Distortion minimized: Reduction in camber is only 1-2mm as against 15 17 mm earlier. 5. Saving Rs. 20,030/(Per job) & Rs.11, 01,650/(for 55 jobs).

INTANGIBLE GAINS
1. We got solution to chronic problem of regularly produced job. 2. We received good recognition & appreciation from our top management.

3. Simplicity of working and minimization of laborious work.

4. Standardization:-Improved method, horizontally deployed in 55 cranes. 5. Improved method resulted in safe working condition. 6. QCC provided platform for manifestation of some unique inherent

qualities of team members.

STEP12: FOLLOW UP /REVIEW & RECURRENCE PREVENTION

We have fabricated 110 girders (55 crane assembly), with this improved method of manufacturing.
Sr. No. 1 2 3 4 5 No. Of Girders 18 26 24 20 22 Time Taken For Camber ( Mandays% ) 1.10 -----0.49 0.41 -----

Year Of Manufacture
MAR 07 APR 07 MAY 07 JUN 07 JULY 07

No. Of Cranes
9 13 12 10 11

Percentage of mandays spent for camber rectification

1.1 1 0.9 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 Mar-07 PERCENTAGE MANDAYS

Apr-07

May-07

Jun-07

Jul-07

PERIOD OF MANUFACTURE

MILESTONE CHART (AFTER)

Date: 11/11/2006 Quality Circle Name : RESEARCH Department : MBD Guide :
Mr.J.G.Rathod

Facilitator : Mr Y.C. Hamand

Project :Rework on Girder during Crane assembly. Project No. 15 Meeting Day : Saturday
Sr No 1 2 3 4 5 6 7 8 9 Week Activity

Date of beginning : 11/11/2006 Time : 01:30 pm to 02:30 pm

3 4 5 6 7 8 9

Date of completion : 25/02/2007 No. of Projects completed : 16

10 11 12 13 14 15 16

Members Name Mr.G.V. Navelkar Mr S. J. Agashe Mr S.L. Wani Mr C. G. Chalke Mr B. V. Shah Mr S. R. More

17

18

19

ACTUAL

Identification Of Problems
Selection Of Problems Defining Problems Analysis Of Problem 1 2 1 2 1 2 1

Finding The Causes

Root Cause Analysis Data Analysis

Developing Solution
Foreseeing Probable Resistance Trial Implementation & Checking Performance & Results Regular Implementation
Follow-up/ Review & Recurrences Prevention

10 11 12

2 1

TOOLS & TECHNIQUES USED

1. 2. 3. 4. 5. 6. 7. 8. 9. Brainstorming ABC Analysis Bar Graphs Milestone Chart Flow Diagram Data Sheet Pareto Analysis / Diagram Cause & Effect Diagram Check sheet 11. PDCA Technique 12. 4W&1H Analysis 13. 5W&1H Analysis

10. Line graph

FUTURE PLAN

Inventory Control & Standardization of Welding Pool Store

ACKNOWLEDGEMENTS
RESEARCH QCC takes this opportunity to express heartfelt thanks to
1. 2. 3. 4. 5. 6. C.E.-Machine Building Division Chief Engineer (Production) D C E (Fabrication) Business Excellence Group Q.C.C.Coordinator Concerned members of M.B.D.