quanta qcc kiran assembly

8/8/2019 Quanta QCC Kiran Assembly

http://slidepdf.com/reader/full/quanta-qcc-kiran-assembly 1/47

An ISO 9001, TS 16949, EMS 14001, 5S CompanyAn ISO 9001, TS 16949, EMS 14001, 5S Company



Ownership

Public Limited Company estd. in 1990

A Joint venture between

Galla Family & JCI of USA

Manufacturing Locations

4 Plants in 165 Acres employing 3200people at Tirupati

The largest single manufacturing facility in

Asia

Our Innovative dynamism

Brought VRLA technology to India

Export of batteries to Japan

Exclusive Vendor to OE premium

segment Vehicles

Dr. Ramachandra N Galla

Founder and Chairman



Mangal Precision Products

Amara Raja Electronics

Amara Raja Power Systems

Galla Foods



To transform

our spheres of influence

and to improve the quality of life

by building institutions

that provide better access

to better opportunities, goods and services

to more people all the time.

To transform

our spheres of influence

and to improve the quality of life

by building institutions

that provide better access

to better opportunities, goods and

services

to more people all the time.



SECTION : MVRLA-ASSEMBLY



Muralikiran.SFacilitator

M.Neelavaram Naidu

Team leader

C.Y.SasiBhushan reddy

Member

G.Rajesh

Member

M.RadhakrishnaMember

G. RamakrishnaMember



PROJECT START DATE : 3rd Dec 2009

PROJECT COMPLETION DATE : 25th Feb 2010

NO. OF MEETINGS HELD : 12

MEETING SCHEDULE : Every Tuesday

DURATION OF MEETING : 1 Hour (3:00PM - 4:00PM)

Team Formed on 3-Dec09

Quality is a goal for usQuality is a goal for us Q CC is the way to achieveQ CC is the way to achieve

We participate with enthusiasm in quality circles for Self and MutualWe participate with enthusiasm in quality circles for Self and Mutual

development and organization developmentdevelopment and organization development

OUR QCC POLICY



1st 2nd 3rd 4th 5th 6th 7th 8th 9th 10th 11th 12th Attendance %

M.Neelavarnam Naidu P P P P A P P P P P P P 7%

C. Y.Sasibhusan Reddy P P P P P P P P P P P P %

M.Radha Krishna P P P A P P P P P P P P 7%

G.Rajesh P P P P P P P P P P P P %

K.Rama Krishna P P P P P P P P P P P P %

96.67%AVERAGE ATTENDANCE

Team Meetings and Attendance

Names



12-STEPS FOR PROBLEM SOLVING

STEP-1 IDENTIFICATION OF PROBLEMS

STEP-2 SELECTION OF THE PROBLEM

STEP-3 DEFINITION OF THE PROBLEM

STEP-4 ANALYSIS OF THE PROBLEM

STEP-5 IDENTIFICATION OF CAUSES

STEP-6 FINDING OUT THE ROOT CAUSE

STEP-7 DATA ANALYSIS

STEP-8 DEVELOPING SOLUTION

STEP-9 FORESEEING PROBABLE RESISTANCE

STEP-10 TRIAL IMPLEMENTATION & CHECK PERFORMANCE

STEP-11 REGULAR IMPLEMENTATION

STEP-12 FOLLOW UP/REVIEW



Step-1Identification of Problems



Step-1 Identification of ProblemsS.NO IDENTIFICATION OF PROBLEMS CAT:A\B\C

1 Separator getting damaged at folding area A

2 Post height variation C

3 More heat seal leaks in D-gray B

4 More time taking for bringing pallet trucks B

5 Alignment problem at cos loading B

6 Elevator sensor getting disturbed frequently A

7 Frequently COS mould flow problem C

8 Lead bars storage problem in line-3 B

9 No heat guards for line-3 cos lead pot B

10 Stacking m/c is lying high-tough to access B

11 Line-1 icw not rejecting splatters batteries B

12 Off set torch holders tough to remove or replace B

13 Stopper gate operation delaying at line-2 post burning B

14 Line-3 separator loading in to machine is tough A

15 Separator offset adjustment time delaying in BM A

16 Torches touching PB moulds during PB(m/c shutting down) A

17 More group rejection due to ejection problem B

18 ICW rails problem in line-1 A

19 Inserting is not properly doing for end groups(26ah) A

20 Numerator not functioning properly A

21 Stress marks identified at icw A

22 65 ah inserting jig to be modified A

23 More time taking for icw samplings A

24 Mounting height variation A

25 Poor lighting at work area B



Step-1 Identification of Problems

26 Post burning setup problem(Freqently) getting disturbed) A

27 Fresh air, dust collector systems getting vested during break times A

28 Improper tinning in ltne-3 B

29 Difficult to load plates in to scissor lifters C

30 Cycle time is more for 65 ah leak testing A

31 More type change time at post burning A

32 More post leaks A

33 Water falling around leak testing tub (housing) problem) B

34 Difficult to load lead bars in to lead pot A

35 Tough to align battery according to the leak testing jig at leak testing A

36 Frequently heating palters getting damaged B

37 Frequent failure of post burning moulds A

38 Difficult to replace electrodes in TBS icw machine B

39 Separator storage is difficult A

40 Battery height variation after heat sealing A41 High scrap due to lead rundowns A

42 Oxide explores is high at stacking area B

43 Tin pot getting contaminated frequently A

44 Timing change problem in BM stacker A

45 Feeder-3 not functioning properly in BM stacker A

46 Up right conveyor problem in TBS stacker B

47 Frequent failure of post burning torches A



PROBLEM CLASSIFICATION

By using brain storming technique,

47 problems on hand were categorized

as A, B and C.

Category A : 27problems

Category B : 17problems

Category C : 03 problems

PIE-CHART

A-27

B-17

C-03



Step-2Selection of the Problem



Step-2 Selection of the Problem

Safety & Ergonomics

Quality & Productivity

Process Criticality

Yield

Cost Savings

Factors considered in selection of problem



Step-2 Selection of the Problem

Considering the ergonomics and safety as major criteria we selected below top5 problems

P1.High oxide explores at group stacking area

P2.Tough to align battery according to leak testing jig at leak testing area

P3.Difficult to load lead bars in lead pot

P4.Difficult to load plates in to scissor lifters

P5.No heat guards for line-3 COS lead pot

S.NO NAMES P1 P2 P3 P4 P5

1 Neelavarnam 7 8 8 7 7

2 Sasibhushan 6 9 7 7 6

4 Radhakrishna 8 7 8 9 76 Ramakrishna 4 9 7 7 4

7 Rajesh 4 7 9 7 3

34 50 44 45 36

4 1 2 5 3RANK

TOTAL

On the basis of priority

rating P2 was selected



PROJECT :Tough to align battery according to leak testing jig

START DATE: 03/12/09 END DATE: 25/2/2010

1 2 3 4 5 6 7 8 9 10 11 12

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

Plan

Actual

ACTIONPLAN

CHECK

DO

PLANIdentification of Problem

selection of problem

Define the problem

Analyse the problem

Identifying the Causes

Regular Implementation

Followup/Reviw

Finding out the root cause

Data Analysis

Developing Solution

Foreseeing probable

resistance

Trial Implementation

Check performance

ACT

WEEK STATUS OF P OG ESS



Step-3Definition of the Problem



Step-3 Definition of the Problem

Cast on strap

Envelop stacking

Post burning

Group insertion

Heat sealing

Inter cell welding

Leak testing



Step-3 Definition of the Problem

PROBLEM:

Tough to align battery according to leak testing jig

OBJECTIVE:

To reduce operator fatigue in aligning battery according to

leak testing jig

GOAL :

To reduce operator fatigue in aligning battery according

to leak testing jig from 250 times to zero times a day



Step-4Analysis of the Problem



Step-4 Analysis of the Problem

Problem analysis was carried out through

4W 1H Technique

WHAT - Tough to align battery according to leak testing jig

WHEN - At leak testing

WHERE - In MVRLA assembly

WHO - Assembly operators

HOW - By analyzing the causes and developing solution



Step-5Identification of Causes



Step-5 Identification of Causes

Men Machine

MethodMaterial

Tough to Align

battery

According to

Leak

Testing Jig

Improper movement

of feeding rollersUn skilled operator

Uneven setting of

Parts

movement variation

No measuring

scale

Improper Alignment

Improper cleaning of

Leak testing Part

Group index

variation

Worn out bearings

Cause and effect diagram

Worn out lug aligners

Stopper

Jigs

Improper Design

of Leak Testing



Step-6Root Cause Analysis



Tough and more time taking to

align battery according to leak

testing jig

Why

Why

No proper design

Due to no stopper/jig for

aligning the battery

Step-6 Root Cause Analysis



Step-7Data collection and Analysis



Step-7 Data collection and Analysis

We are colleted data for 1 month and found that246 batteries/per day are getting miss aligned



Step-8Development of Solutions



Step-8 Development of Solutions

Using Brainstorming

Providing the stopper to stop the batteries in correct position

Providing the jig for aligning the batteries

Problem discussed among all QC members for developing solutions.



Step-9Foreseeing Probable Resistance



Step-9 Foreseeing Probable Resistance

An awareness programme was

conducted for all the operators,

who are working in the Assembly

and explained them about the

solution and asked them to express

their views for trial implementation.

All Members felt that this solutions is acceptable



Step-10Trail Implementation & Check Performance



Step-10 Trail Implementation & Check Performance

BEFORE

Problem ImprovementNo jig for aligning the battery Jig provided for aligning

the battery

AFTER

Jig for aligning the battery



Step-10 Trail Implementation & Check Performance

BEFORE

Problem ImprovementNo jig for aligning the batteryJig provided for aligning

the battery

AFTER

Jig for aligning the battery



Step-11Regular Implementation



Step-12Follow Up & Review



Step-12 Follow Up & Review

GOAL:

To reduce operator fatigue in aligning battery accordingto leak testing jig from 250 times to zero times a day

Achieved:Eliminated the toughness to align he battery

according to leak testing jig



INTANGIBLE BENIFITS

Operator fatigue reduced.

Self confidence improved.

Job satisfaction increased. Team work.

Improved Knowledge on 7 Q C tools

Communication skills improved.



1. Brain Storming

2. Bar Graphs

3. Ranking Technique

4. Flow Diagrams5. 4W & 1H

6. Why - Why Analysis



Acknowledgement

On behalf of Quanta Quality Control circle

we thank our management for giving us thi s opport unity to present

our case st ud y.

Last but not the least our sincere thank s to the

aud ience for giving us a kind and patient hearing.

quanta qcc kiran assembly

Documents