QUALITY CIRCLE GROUP NAME

(e.g. ACHIEVERS)
DEPTT. / AREA
e.g. (WELD SHOP)
 ACHIEVERS TEAM
Group Members (With
Team Achievers
Photos) :
1. Facilitator
2. Team Leader
Any
3. Team Member 1 Photograph/logo
4. Team Member 2 for Team
5. Team Member 3
6. Team Member 4
Team Achievers
7. .................

Work Area - Weld Shop Model – G (Swift)

Total Members - 10 Nos
Age Group - 22-35 Years
Meeting Time - 3:30 –4:30 Pm (Every Tuesday)
Meeting Duration - 1 Hr.
Meeting Place - Production Meeting Room
 ACTIVITY CHART
Jun - 12 Jul - 12 Aug - 12 Sep - 12
Activity PDCA
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4

Q.C. Theme Selection

- Major Concerns List
- MSQCD Evaluation
P
- Theme Definition

Data Collection & Analysis using Pareto

D
- Max. Contributors in BOP rejection
Identification of Root Cause –
Brainstorm (for Potential Causes) , 5
Why Analysis & Fishbone Analysis D
(Probable Causes) & Validation of
Causes (Simulation

Selection of Countermeasures D

Implementation of Countermeasures D

Monitor Effectiveness of
C
Countermeasures

Horizontal Deployment A

Hold the gain (Improvement) & Sustain A

 THEME SELECTION
 Brainstorm & Identify (All Members) Major Concerns where improvement is required
 Evaluate the impact (All Members) of Major Issues on MSQCD parameters
1- Lowest Impact, 5 – Highest Impact
 Select the Issue with Highest Score

M S Q C D
(Man) (Safety) (Quality) (Cost) (Delivery)
Total
Theme
Operator Potential (M+S+Q+C+D)
chances of Rejection Rejection cost Weld Loss
fatigue Accident

Reduction in PDI Defects 1 1 5 3 3 13

Productivity Improvement
1 1 3 4 3 12
(Reducing TAKT Time)

Reduction in Internal 2
(100% Incoming 1 4 5 3 15
Rejection Inspn & Rework)

Achievers Q.C. Theme

REDUCTION IN INTERNAL REJECTION
LET US APPLY PDCA TO SOLVE PROBLEM

 PLAN
A P
 DO

C D  CHECK

 ACT

AIM IS CONTINUAL IMPROVEMENT

 INTERNAL REJECTION TREND
200 Rejection (No. per Month)

150

113
Nos. / Month

109
103 103
96
100
79

50

Act Cum 12-

Tgt 12-13
2011 - 12

May'12

Jun'12

Jan'12
Oct'12

Nov'12

Dec'12
Apr'12

Aug'12

Sep'12

Mar'12
Feb'12
Jul'12

13
FACT FINDING …

TIME PERIOD :
Apr – Jun 12.

REJECTION :
103 Nos / Month
 REJECTION PARETO (Apr – Jun 12)

200 120%
98% 99% 100%
93% 95%
90% 100%
85%
150 79%
80%
69%

Cumm %
DEFECT (NOS.)

100 45% 60%

59 40%
50 31
20%
13 9 6 4 3 3 2 1
0 0%

RNF. PTN SIDE STAY

RET DR STRIKER
BRACE HOOD LOCK
EXT. SIDE BODY OTR

MBR PTN FR SIDE - LH

SUPPORT JACK BKT

BKT TRUNK LTD STRIKE

STAY BODY MTG

BKT BACK DR STRIK

BRACE PTN SIDE LWR

NOS CUMM %

Extn Side Body Otr (YP8) - 45% (of Total rejn) selected for QC Circle
 EXTN SIDE BODY OTR (YP8) DEFECT PARETO
(Apr – Jun 12)
90 120
100
DEFECTS(NOS) 85 100

CUMM. %
60 80
49 60
30 29 40
21
9 20
0 FLANGE 0

FLANGE

CRACK
HEIGHT

HEIGHT
MORE

LESS
1st FLANGE

FLANGE HEIGHT MORE 2nd FLANGE

(29)

FLANGE HEIGHT LESS

(21)

CRACK
(9)

DEFECTS
 PROCESS FLOW DIAGRAM
NG NG
PROCESS PROCESS

Datum Hole (Dia 4)

Blanking Drawing Trimming
punching

Inspection Datum Hole (Dia 8)

final punching Bending
 ISHIKAWA DIAGRAM
FLANGE HEIGHT UNEVEN (MORE OR LESS)

MAN METHOD

Process Parameter
Inadequate Not Defined
Locating of
Training
Blank NG

Improper Process Set

Placement Up NG

FLANGE HEIGHT
UNEVEN

Blank Size Process

Variation Parameter NG Datum
Hole Shift Gauges
Raw Material Worn Out
Excess Oil Tool Guide Pillar
Properties NG
on Blank Clearance Excess
Insufficient
Locating

MATERIAL MACHINE

Potential Causes Probable Causes

 VALIDATION OF POTENTIAL CAUSES
5W 1H Technique

S Identified probable
Who When Where How Results Conclusion
no Causes ( Why )

IMPROPER DATUM
PUNCHING PLACEMENT OF BLANK NG VALID
1 PLACEMENT OPERATOR HOLE
PRESS IN TOOL CAUSE
PUNCHING

NOT VALID
BLANK SIZE BLANKING DURING
2
VARIATION TOOL BLANKING
BLANKING PRESS TRIM EDGE VARIATION X CAUSE

VALID
DURING PUNCHING INSUFFICIENT LOCATING
3 DATUM HOLE SHIFT OPERATOR CAUSE
PUNCHING PRESS BLOCKS IN PUNCHING TOOL

DURING SHUT HEIGHT & STROKE NOT VALID

4 PROCESS SET UP NG DIE SETTER
SET UP
PRESS M/C
SETTING NG X CAUSE

RAW MATERIAL BUYER PURCHASE RM SPEC NOT SPECIFIED NOT VALID

5
PROPERTIES NG (PURCHASE) ORDER
RM SUPPLIER
CLEARLY IN PO X CAUSE

TOOL GUIDE PILLAR MEASUREMENT & VISUAL NOT VALID

6
EXCESS CLEARANCE
DIE FITTER DURING PM TOOL ROOM
CHECK NG X CAUSE

Legend : Contributing Not contributing -- X

 FLANGE HEIGHT UNEVEN
WHY-WHY ANALYSIS

Q1 WHY? FLANGELESS OR MORE

A1 IMPROPER LOCATION OF BLANK IN PUNCHING TOOL

Q2 WHY? IMPROPER LOCATION OF BLANK IN PUNCHING TOOL

A2A DATUM HOLE IN BLANK GETS SHIFTED IN PUNCHING

Q3A WHY? DATUM HOLE SHIFTING

A3A BLANK POSITION SHIFT IN PUNCHING OPN

ROOT CAUSE 1.PIN GUIDE NOT OK

A2B BLANK SHIFTING IN PUNCHING OPERATION

Q3B WHY? BLANK SHIFTING IN PUNCHING

A3B LOCATING BLOCKS NOT SUFFICIENT

ROOT CAUSE 2.BLANK GUIDE BLOCKS NOT OK

 KAIZEN – DATUM HOLE PUNCHING – PART LOCATION IMPROVEMENT

KAIZEN ALBUM MONTH: Jul-12

KAIZEN BY: Nafe Singh

KAIZEN AGENDA: Ext. Side Body L (64522M83K00) DEPTT.

KAIZEN NO.: SM/KZ/01
REF/ M/C :- Punching Tool PRESS SHOP
BEFORE AFTER REDUCED LOSSES

1. EQUIPMENT FAILURE
2. SET UP TIME
3. DEFECT & REWORK
4. 5 S
5. MINOR STOPPAGE
6. MEASUREMENT AND
ADJUSTMENT
7. ECO FRIENDLY
Guide Pin 8. START UP
9. OPERATING Missing
10.LOGISTIC
Locating block 11.YIELD
provided
12.ENERGY
13.SAFETY
14.OTHERS

IDEA: AFTER COMMENTS: HORIZONTAL APPLICATION

AVOID SHIFTING OF DATUM HOLE POSITION BLANK LOCATION DONE BY GUIDE BLOCK TO YES
DURING PUNCHING AND AVOID FLANGE HEIGHT AVOID SHIFTING OF DATUM HOLE .
VARIATION RESULT
BEFORE COMMENTS :
DATUM HOLE SHIFTS BECAUSE OF BLANK
DATUM HOLE
SHIFTING DURING PUNCHING OPERATION
SHIFTING
AVOIDED
DURING
PUNCHING
 ISHIKAWA DIAGRAM
CRACK

MAN METHOD
Process Parameter
Not Defined
Inadequate
Loading of
Training
Blank NG Part Shift During
Operation

Improper Process Set

Placement Up NG

FLANGE HEIGHT
UNEVEN
Process
Parameter NG
Blank Size Gauges
Variation Worn Out
Cushion Pin
Pad Wear Out
Diff. in Cushion
Raw Material Bead Pin Height
Excess Oil
Properties Ng Worn Out
on Blank
Improper Guide/ Die Surface
Location Matching Ng

MATERIAL MACHINE

Potential Causes Probable Causes

 VALIDATION OF POTENTIAL CAUSES
5W 1H Technique

S Identified probable
Who When Where How Results Conclusion
no Causes ( Why )

DATUM
IMPROPER PUNCHING PLACEMENT OF BLANK NG VALID
1 OPERATOR HOLE
PLACEMENT PRESS IN TOOL CAUSE
PUNCHING

NOT VALID
BLANK SIZE BLANKING DURING
2
VARIATION TOOL BLANKING
BLANKING PRESS TRIM EDGE VARIATION X CAUSE

DURING SHUT HEIGHT & STROKE NOT VALID

3 PROCESS SET UP NG DIE SETTER
SET UP
PRESS M/C
SETTING NG X CAUSE

RAW MATERIAL BUYER PURCHASE RM SPEC NOT SPECIFIED NOT VALID

4
PROPERTIES NG (PURCHASE) ORDER
RM SUPPLIER
CLEARLY IN PO X CAUSE

CUSHION PIN HEIGHT DURING VARIATION IN CUSHION PIN NOT VALID

5
NG
DIE SETTER
SET UP
PRESS M/C
HEIGHT X CAUSE

DURING
INSUFFICIENT GUIDE /
PART SHIFT DURING TRIMMING VALID
6 OPERATOR TRIMMING PRESS LOCATING BLOCKS IN
TRIMMING OF EXCESS CAUSE
TRIMMING TOOL
MATERIAL

Legend : Contributing Not contributing -- X

 CRACK
WHY-WHY ANALYSIS

Q1 WHY? CRACK APPEARED ON TRIMMING EDGE

EXCESS MATERIAL HAVING CRACK NOT TRIMMED COMPLETELY

A1

WHY ? EXCESS MATERIAL NOT TRIMMED

Q2

A2 BLANK SHIFTED IN TRIMMING OPERATION

WHY ? BLANK SHIFTED IN TRIMMING OPERATION

Q3

BLANK LOCATION NOT PROPER IN TRIMMING TOOL

A3

WHY ? BLANK LOCATION NOT PROPER IN TRIMMING TOOL

Q4

A4 BLANK GUIDE BLOCKS NOT SUFFICIENT

Q5 WHY ? BLANK GUIDE BLOCKS NOT SUFFICIENT

ROOT CAUSE GUIDE BLOCK DESIGN NOT OK

 KAIZEN- GUIDE BLOCK DESIGN IMPROVEMENT IN TRIMMING OPERATION

KAIZEN ALBUM MONTH: 71/10/2010

KAIZEN BY: Manoj

KAIZEN AGENDA: Ext. Side Body R (64122M83K00) DEPTT.

KAIZEN NO.: SM/KZ/02
REF/ M/C :- Triming Tool PRESS SHOP
BEFORE AFTER REDUCED LOSSES

1. EQUIPMENT FAILURE
2. SET UP TIME
3. DEFECT & REWORK
4. 5 S
5. MINOR STOPPAGE
6. MEASUREMENT AND
ADJUSTMENT
7. ECO FRIENDLY
8. START UP
9. OPERATING Missing
10.LOGISTIC
Three side location has 11.YIELD
No location
provided and restrict the
provided to guide 12.ENERGY
improper movement of
the operator. 13.SAFETY
part during the notching
operation. 14.OTHERS

IDEA: AFTER COMMENTS: HORIZONTAL APPLICATION

GUIDE BLOCKS INCREASED TO PROVIDE 3 YES
IMPROVE BLANK LOCATION BY INCREASING
SIDE LOCATION
GUIDE BLOCKS
RESULT
BEFORE COMMENTS :
INSUFFICIENT GUIDE BLOCKS IN TRIMMING
TOOL PART GUIDE
IMPROVED,
CRACK PORTION
TRIMMED IN THIS
OPERATION
 DEFECT (NOS.) Nos. / Month

100
150
200

50

100
150
200

0
50
2011 - 12
SUPPORT JACK BKT 113

34
43%
Apr'12
103

BKT TRUNK LTD STRIKE

63%

16
BEFORE

May'12
109

8
BKT BACK DR STRIK Jun'12
96

73%
Jul'12
62

8
STAY BODY MTG
84%
AFTER

Aug'12
47

3
BRACE PTN SIDE LWR
87%

Sep'12
43

Oct'12
44

MBR PTN FR SIDE - LH

91%

Nov'12
3

BRACE HOOD LOCK

95%

Dec'12
Rejection (No. per Month)

JUL12

RET DR STRIKER Jan'12

97%

Feb'12
ZERO DEFECTS IN EXTN SIDE BODY OTR AFTER C/M
2
35% REDUCTION IN REJECTION

RNF. PTN SIDE STAY

AFTER C/M IMPLEMENTATION IN

100%

Mar'12
0

EXT. SIDE BODY OTR

100%

Tgt 12-13
79
COUNTERMEASURE EFFECTIVENESS VERIFICATION

Act Cum 12-

0%
20%
40%
60%
80%
72

100%
120%

Cumm % 13
 STANDARDISATION AND HORIZONTAL DEPLOYMENT

1. PIN GUIDE NOT OK

ROOT CAUSES
2. BLANK GUIDE BLOCKS NOT SUFFICIENT

1. GUIDE BLOCK ADDED IN PUNCHING

COUNTER MEASURE
2. GUIDE BLOCKS IMPROVED IN TRIMMING TOOL

EFFECTIVENESS ZERO DEFECT ACHIEVED TILL DATE AFTER C/M

VERIFICATION IMPLEMENTATION IN JUL- 12

COMPARISON OF LAST OFF PART OF PREVIOUS LOT, FIRST OFF

STANDARDIZATION PART OF CURRENT LOT WITH MASTER SAMPLE STARTED AS
PRACTICE TO ENSURE LOT QUALITY

HORIZONTAL DEPLOYMENT DEPLOYED ABOVE STANDARDISATION FOR ALL PARTS