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QCC PRESENTATION OF MAINTENANCE DEPARTMENT

INTODUCTION OF QCCA quality circle is a volunteer group composed of workers (or even students), usually under the leadership of their supervisor (or an elected team leader), who are trained to identify, analyze and solve work-related problems and present their solutions to management in order to improve the performance of the organization, and motivate and enrich the work of employees. When matured, true quality circles become self-managing, having gained the confidence of management.

Quality circles were first established in Japan in 1962; Kaoru Ishikawa has been credited with their creation. The movement in Japan was coordinated by the Japanese Union of Scientists and Engineers (JUSE). The first circles were established at the Nippon Wireless and Telegraph Company but then spread to more than 35 other companies in the first year. By 1978 it was claimed that there were more than one million quality circles involving some 10 million Japanese workers.

QUALITY CONTROL CIRCLE NAMEZERO BREAK DOWN

QCC THEMEDevelop key machines list and their system of preventive maintenance.

Sheet9QCC REGISTRATION FORMMaintenance IHamid KhanDepartment:Section:Zero Break Down29.01.2013Circle Name:Date :Theme Name :SAFETYDevelop key machine list and their system of Preventive Maintenance. (Target Date: 31.03.2013).QUALITYCOSTPRODUCTIVITYOTHERS1) PROMOTION LEADER ( Head of Department)Mr. Hamid Khan.2) ADVISOR/COORDINATOR (Director Prod. & Tech.)Mr. Ahsan-ul-Haq3) FACILITATORMr. Ameer Khusroo4) CIRCLE/ THEME LEADERMr. Junaid Zeb Ghouri.Signature Circle LeaderSignature Head of DepartmentCIRCLE MEMBERS (6~10 Member)Sr.Member NameTitleSr.Member NameTitle1Mr. Ayoub Ahmed(Foreman)62Mr. S. Shahid Ali(Supervisor)73Mr. Abdul Raheem(Sr. Electrician)84Mr. Nazeer(Electrician)9510QCC Department use onlyTHEME REG. NO._________________________REG. DATE:_________________________QCC (T/L) Sign :________________

&LProcon Engineering Pvt. Ltd&RQMS Department

Sheet5Procon Engineering (Pvt.) Ltd.Approved byPrepared byDateTHEME SELECTIONTHEME SELECTION CRITERIASr. #Proposed ThemeWill it make the work easier ?Can the circle solve it by themselves ?Can they complete it on time ?What will happen if the problem is not solved now ?What will the benefit for company ?Total1Develop key machines list and their system of preventive maintenance.55455242Renovation of Heat Treatment Oven.44544213Hyd. Press of Tool & Die modification.3333315

&RQMS Department0105040203Very LowLowAverageHighVery High

Machine ListKEY MACHINE LIST FOR MAINTENANCEUP DATED: 15/4/13S/NOMACHINE NAMECODESDEPARTMENTREMARKS1SHEARING MACHINE (MECHANICAL)O25502DECK ASSEMBLY2PIPE BENDING MACHINEO33801WIRE SHOP3PIPE CUTTING (AUTO)O37103WIRE SHOP4ZIG ZAG SPRING MACHINEO33301WIRE SHOP5WIRE CUTTING MACHINE (AUTO)O33101WIRE SHOP6HANGING SPOT WELDING MACHINEO43901WELDING SHOP7HYDRAULIC PRESS 330 TONO50204SEAT PRESS SHOP8SHEARING MACHINE # 02O55502SEAT PRESS SHOP9STEAM GENERATOR BOILER104701CUSHIONING 4 WHEEL10OVEN147801PAINT SHOP11OVEN147802PAINT SHOP12LAMINATION PLANT (FLAME)155102LAMINATION13LAMINATION PLANT (GLUE)155101LAMINATION14SEALING MACHINE 01 KW191601CUTTING & STITCHING15PNUEMATIC PRESS (MORI) 250 TON214914RECLINER16HUDRAULIC RIVETING MACHINE224002CHASSIS ASSEMBLY17PLASMA CUTTING MACHINE224801CHASSIS ASSEMBLY18LONG MEMBER PRESS 3600 TON220201CHASSIS ASSEMBLY19FIRE PUMP DIESEL176601GENERAL20FIRE PUMP ELECTRIC176602GENERAL21COOLING TOWER173605HEAVY PRESS SHOP22HOIST (LIFT)178205COIL CUTTING AREA

Graph

Graph2010

HoursSHEARING MACHINE # 025502 (DECK ASSEMBLY)

Sheet321.500

HoursPIPE BENDING # 033801 (WIRE SHOP)

0000

SERIES3HoursPIPE CUTTING (AUTO) # 037103 (WIRE SHOP)

0000

SERIES4HoursZIG ZAG SPRING MACHINE # 033301 (WIRE SHOP)

1000

SERIES5HoursWIRE CUTTING MACHINE # 033101 (WIRE SHOP)

0000

SERIES6HoursHANGING SPOT WELDING MACHINE # 043901 (WELD SHOP)

1.5001

SERIES7HoursHYD. PRESS 330 TON # 050204 (SEAT PRESS SHOP)

0100

SERIES8HoursSHEARING MACHINE # 055502 (SEAT PRESS SHOP)

0000

SERIES9HoursSTEAM GENERATOR BOILER # 104701 (CUSHION 4 WHEEL)

14.500

SERIES10HoursOVEN # 147801 (PAINT SHOP)

0000

SERIES11HoursOVEN # 147802 (PAINT SHOP)

1.54.52.50

SERIES12HoursGLUE LAMINATION # 155101 (LAMINATION )

11.510

SERIES13HoursFLAME LAMINATION # 155102 (LAMINATION)

1000

SERIES14HoursSEALING MACHINE 1 KW # 191601 (STITCHING & CUTTING)

001650

SERIES15HoursPNEUMATIC PRESS (MORI) 250 TON # 214914 (RA RECLINER)

02.510

SERIES16HoursHYD. RIVITING MACHINE # 224002 (CHASSIS ASSEMBLY)

0.5000

SERIES17HoursPLASMA CUTTING MACHINE# 224801 (CHASSIS ASSEMBLY)

0000

SERIES18HoursLONG MEMBER PRESS 3600 TON # 220201 (CHASSIS ASEMBLY)

0000

SERIES19HoursFIRE PUMP DIESEL # 176601 (GENERAL)

0000

SERIES20HoursFIRE PUMP ELECTRIC # 176602 (GENERAL)

0000

SERIES21HoursCOOLING TOWER # 173605 [HEAVY PRESS SHOP (GENERAL)]

0000

SERIES22HoursHOIST (LIFT) # 178205 [COIL CUTTING AREA (GENERAL)]

S/NOMACHINE NAMEMONTHLY BREAK DOWN HOURSJan-13Feb-13Mar-13Apr-131SHEARING MACHINE (MECHANICAL)20102PIPE BENDING MACHINE21.5003PIPE CUTTING (AUTO)00004ZIG ZAG SPRING MACHINE00005WIRE CUTTING MACHINE (AUTO)10006HANGING SPOT WELDING MACHINE00007HYDRAULIC PRESS 330 TON1.50018SHEARING MACHINE # 0201009STEAM GENERATOR BOILER000010OVEN14.50011OVEN000012LAMINATION PLANT (GLUE)1.54.52.5013LAMINATION PLANT (FLAME)11.51014SEALING MACHINE 01 KW100015PNUEMATIC PRESS (MORI) 250 TON00165016HUDRAULIC RIVETING MACHINE02.51017PLASMA CUTTING MACHINE0.500018LONG MEMBER PRESS 3600 TON000019FIRE PUMP DIESEL000020FIRE PUMP ELECTRIC000021COOLING TOWER000022HOIST (LIFT)0000