TACL 110
Plant
TACL FARIDABAD
Narender Singh
Team Members
Date of Start
02.01.2010
Slide number: 1
Problem Statement
ID Closing
NA
Last manufacturing process stage where technically the problem can get
generated
182191KSP9300C
Splitting Problem
3.3 %
1 Presses
Annual Savings in Rs. Lakhs if the defect is made zero and horizontally
deployed to other part numbers
1.08 Lakhs
Response
Attribute
Slide number: 3
MAKE SHELL
ANNEALING
MAKE SHELL
ANNEALING
PACK GRAPHITE IN
COPPER SHELL
CLOSE OD
CLOSE ID
BLANK
INSPECTION
Slide number: 4
DEC2009
W1
W2
W3
JAN10
W4
W1
W2
W3
FEB10
W4
W1
W2
W3
W4
Define
Measure
& Analyze
Improve
Control
Phases
Planned Start
date
Planned
Completion
date
Actual start
date
Actual
completion
date
Status
Define
24.12.09
1.01.2010
2.01.10
11.01.2010
COMPLETE
Measure &
Analyze
4.01.2010
18.01.2010
12.01.2010
5.02.2010
Complete
Improve
Control
Slide number: 5
SHELL
SPLITING PROBLEM
GRAPHITE
LAYERS
ID CLOSING
ASSEMBLY
OD CLOSING
Slide number: 6
Average
Rejection=3.3%
Percentage Rejection
6.0
5.0
4.0
3.0
2.0
1.0
0.0
July'09
August'09
Sep'09
Oct'09
Nov'09
Dec'09
Months
22.6 % is the average rejection as calculated
from 3 lot inspection
Slide number: 7
824 Nos.
824 Nos.
NIL
Scrap cost/piece
7.75
Rework cost/piece
NA
0.064 Lakhs
NIL
0.064 Lakhs
1.08 Lakhs
Slide number: 8
Average
Rejection=3.3%
6.0
Percentage Rejection
5.0
4.0
3.0
2.0
1.0
0.0
July'09
August'09
Sep'09
Oct'09
Nov'09
Dec'09
Months
Slide number: 9
Forming Height
Burr
No of graphite layers
Closing Process
Slide number: 10
FF
VS
OBSER
MVA
CC
CS
PPS
PC
SSVs
MCS
HARDNESS
BURR
NO OF GRAPHITE LAYERS
CLOSING PROCESS
Legend: PC Paired Comparison, PPS Product/Process search, CS Component Search, MCS Modified Component Search, CC Concentration chart
MVA Multi-Vari analysis, OBSER Observation, VS Variable Search, FF Full Factorial
Slide number: 11
Slide number: 12
SSV 'BURR'
scale
RESPONSE
NOT OK
NOT OK
NOT OK
NOT OK
NOT OK
NOT OK
15
12
NOT OK
NOT OK
10
OK
11
OK
13
OK
14
OK
16
OK
OK
OK
OK
Slide number: 13
Slide number: 14
FORMING
HT.
RESPONSE
184
6.01
OK
291
6.03
OK
174
6.03
OK
176
6.03
OK
264
6.04
OK
272
6.04
OK
281
6.04
OK
163
6.04
OK
167
171
6.04
6.04
OK
116
6.19
NOT OK
223
6.2
NOT OK
25
6.21
NOT OK
293
6.22
NOT OK
249
6.22
NOT OK
315
6.24
NOT OK
137
6.24
NOT OK
209
6.25
NOT OK
33
6.25
NOT OK
333
6.26
NOT OK
222
6.26
NOT OK
237
6.27
NOT OK
OK
TOP COUNT=8
BOTTOM COUNT=8
TOTAL COUNT =16
Slide number: 15
Slide number: 16
No. Of Graphite
layers
RESPONSE
OK
15
OK
12
OK
13
OK
OK
OK
OK
OK
OK
11
OK
14
OK
OK
OK
10
Not Ok
16
OK
OK
Slide number: 17
Slide number: 18
Phase 3 - Improve
Validation of the Root cause(s)- B Vs C
1
Better Condition
Current Condition
Sample size
6B,6C / 3B,3C
Sample type
Pieces / Lots
Historic rejection
Lot quantity
Slide number: 19
Phase 3 - Improve
Validation of the Root cause(s)- B Vs C
Piece / Lot
Better ( B )
Current ( C )
1
2
3
4
5
6
Slide number: 20
Phase 3 - Improve
Data
Slide number: 21
Phase 3- Improvement
Analysis - B Vs C
1
Average of B
Average of C
Total count
Xb Xc (Amount of
Improvement)
Sigma (B)
Confidence level of
improvement
Number of iterations
done
Slide number: 22
Root cause(s)
Actions Planned
Planned
Completion date
Resp
Actual
completion
date
Status
Slide number: 23
Phase 3 Improve
Photograph of actions
Slide number: 24
Phase 3 Improve
Photograph of actions
Slide number: 25
Phase 3 Improve
Photograph of actions
Slide number: 26
Root cause
Variation
analysis done
Type of control
method decided
Status of implementation
Slide number: 27
Phase 4- Control
Analysis # 1
Objective:
Tool/technique used:
-
Slide number: 28
Phase 4- Control
Steps in Variation analysis
Step 1 : Identify the Parameter that requires Variation analysis
Parameter :
Slide number: 29
Phase 4- Control
Slide number: 30
Phase 4- Control
Data
Slide number: 31
Phase 4- Control
Data
Slide number: 32
Phase 4- Control
Multi Vari analysis - Conclusion
Part to Part variation
Time to Time variation
Stream to Stream variation -
Slide number: 33
PHASE - 4
CONTROL PHASE
Slide number: 34
PHASE - 4
CONTROL PHASE
Slide number: 35
PHASE - 4
CONTROL PHASE
Slide number: 36
PHASE - 4
CONTROL PHASE
Slide number: 37
PHASE - 4
CONTROL PHASE
Slide number: 38
PHASE - 4
CONTROL PHASE
Slide number: 39
Phase 4- Control
Analysis # 1
Objective:
Conclusion:
-
Slide number: 40
Phase 4 - Control
Results
Before
After
Slide number: 41
Phase 4- Control
Project Summary
Number of drill downs (funneling) done to reach the root
cause(s):
Number of predominant root cause(s) identified:
Time in months for completing the project:
Tools/Techniques used:
Slide number: 42
Phase 4 - Control
Benefits derived through the project
1.
2.
3.
4.
Slide number: 43
Phase 4 - Control
Current control plan
Slide number: 44
Phase 4 - Control
Proposed Control plan
Slide number: 45