sample project-quality circle
DESCRIPTION
Sample Project which help you to understand the conceptTRANSCRIPT
together we can Quality Circle!Operations U & A
QUALITY CIRCLE-COIL SHOP
PROJECT TITLE: To reduce leak from….. To ……SAMPLE
together we can Quality Circle!Operations U & A
INTRODUCTION
TEAM NAME :…XXXXX………………..
LEADER NAME :………ABCD……………..
PROJECT TITLE :To reduce the leak from .. To ..
AREA :…Coil Shop –Brazing Area
DATE :………starting date……..
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TEAM STRUCTURE
HOD/Supervisor
Quality coordinator Maintenance coordinator
Team leader
Sub leader
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Team Attendance
S.NO
Name Position in Team
WK- WK- WK- WK- WK- WK- WK- WK- WK- WK-
1 Koshik Leader P P P
2 XXXX Sub Leader
P P P
3 YYYY Coordinator
P P P
4 ZZZZ Recorder P P P
5 GGGG Data collector
P P A
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together we can Quality Circle!Operations U & A
GANT CHART
Phase WK-14WK-16
WK-18 WK-20 WK-22 WK-24 WK-26 WK-28 WK-30 WK-32
Define
Measure
Analyze
Improve
ControlSAMPLE
together we can Quality Circle!Operations U & A
DEFINE PHASE
SAMPLE
together we can Quality Circle!Operations U & A
DEFINE PHASE
What is the Problem : More leak in CAC-1 cause low production and affect quality
Where is the Problem : In CAC-1 all lines
How much is the Problem : Daily avg Yield rate of CAC-1 is 94%
Boundaries of the Problem:CAC-1 brazing area to leak testing area.
Define
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SIPOC
• SIPOC(Supplier, Input , Process , Output & Customer)Specific Process flow chart with SIPOC.
Define
SAMPLEFin press
LacingVE U bend
Brazing
Leak test
Foil,Power,Manpower
Collar crack,Gathering
Cu tube,fins
Cu bend,coil bend,damage
Coil assy with end plate
Flare crack,coil damage….
Cu tube with ring
Cross insert,dust,oil
Oxy,LPG,Torch
Defect,burn mark,leak
Coil,power,coupler
Leak,damage…
Inputs
Outputs
together we can Quality Circle!Operations U & A
DRILL DOWN TREE
Define
Company target
Our Project
Our target
What improve
……To reduce Leak……
From.. To ..
Yield rate will improve
Production target of 750 MSAR achieve
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Review-Define Phase
Phase Plan/Actual
WK-14 WK-15 WK-16 WK-17 WK- WK- WK- WK- WK-
Define
Plan
Actual
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MEASURE PHASE
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MEASURE PHASE
Line:CAC-1
Problem : High leak rate in CAC-1
Where/Area:In CAC-1/Brazing area
Current Level:Avg 94% yield/day
Measure
SAMPLE
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Data Collection
Last One year or minimum 6 month data need to collect.
Data collected for……6…………MonthsData Type : Continuous / DiscreteData format: ExcelReference Document ..Daily leak testing report
Measure
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Current Level and Target Level
Current Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000: (6/381)*1000000=15789
Sigma Level: Calculate from sigma table
Target Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:…3/381*1000000=7874
Sigma Level:Calculate from sigma table
Completion time:……Aug’13..
Measure
SAMPLE
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Cause & Effect(Leak reduction)
Man
MachineMethod
Material
Lacing Jig
Flare punch dimension Conveyor angle slide
Hair pin length mismatch Corroded/Dust lead
Brazing Skill
View of operator
Torch handling method
Lead Rod Storage
End Plate disturbance
Manual Flaring
Header feeder to coil mismatch
Gas mixing proportion
Pressure Gauge not visible
Gas flow low
Work Distribution
Communication
AwarenessReturn Bend dimension
Flare Crack
Dust/gloves burr in flares
Oil presence in flare
Return bend dust
Pinching tool
Measure
SAMPLE
together we can Quality Circle!Operations U & A
KPIV/KPOV
List Down the Cause Variables from C&E diagram
1. 9.2. 10.3. 11.4. 12.5. 13.6. 14.7. 15.8. 16.
Measure
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FDM(Function Deployment Matrix)
Variables(x’s)Productivity
Low:3 Mid:5 Max:9Cost
Low:3 Mid:5 Max:9Quality
Low:3 Mid:5 Max:9Total Weightage
Work Distribution 6 4 6 6*5+4*5+6*5=80
Brazing Skill 8 6 8 8*9+6*5+8*9=174
Pressure Gauge not visible
,,
,,
,,
,,
,,
,,
,,
,,
,,
,,
,,Measure
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SELECTED CAUSE LIST-x’s
List Down the Variables(x) from C&E diagramList Down the Cause Variables from C&E & FDM diagram
x1.Work distributionx2.Skillx3.Hair pin lengthx4.XXXXXx5.YYYYx6.ZZZZx7.GGGGx8FFF
Measure
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together we can Quality Circle!Operations U & A
Review-Measure Phase
Phase Plan/Actual
WK-14 WK-15 WK-16 WK-17 WK-18 WK-19 WK-20 WK-22 WK-24
Measure
Plan
Actual
Measure
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ANALYZE PHASE
Analyze
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Data collection for small variables(x’s)
S.No x’s Variables Data type
Remarks
1 x1 Work distribution Continous
2 x2 Skill ,,
3 x3 Hair pin length ,,
4 x4 XXXXX ,,
5 x5 YYYY ,,
6 x6 ZZZZ ,,
7 x7 GGGG ,,
8 x8 FFF ,,
Analyze
SAMPLE
We can use pareto or other seven QC tools to analyze.
together we can Quality Circle!Operations U & A
PARETO CHART –x1
Problem(x1):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
x1 x1.Work distribution 15
x2 Skill 14x3 Hair pin length 8x4 x4.XXXXX 13x5 x5.YYYY 14x6 x6.ZZZZ 7x7 x7.GGGG 4x8 x8FFF 1
Conclusion:……………………………………………………………………………………………………………………………………
X1 X2 X3 X4 X5 X6 X7 X8
5
5
10
1515
14
8
13
14
7
4
1
96 90 84 81 79 X6 X7 X8
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PARETO CHART –x2
Problem(x2):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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PARETO CHART –x3
Problem(x3):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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PARETO CHART –x4
Problem(x4):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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PARETO CHART –x5
Problem(x5):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x6
Problem(x6):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x7
Problem(x7):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
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together we can Quality Circle!Operations U & A
PARETO CHART –x8
Problem(x8):…………………………………………………………….………………………………………………………………………………
Analyze
X’s Variables
Data
Conclusion:……………………………………………………………………………………………………………………………………
SAMPLE
together we can Quality Circle!Operations U & A
MAJOR CAUSE LIST-Y’s
Analyze
List the major cause list from pareto chart analysis(80:20 concept)Need to improve top 20% of cause so as to solve 80% of remaining problem.
Y1. Work distribution
Y2. Skill
Y3. Hair pin length
Y4. XXXXXSAMPLE
together we can Quality Circle!Operations U & A
Review-Analyze Phase
Phase Plan/ Actual
WK-14 WK-15 WK-16 WK-17 WK-18 WK-20 WK-22 WK-24 WK-26
Analyze
Plan
Actual
Analyze
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together we can Quality Circle!Operations U & AImprove
IMPROVEPHASE
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S.No Y’s Variables Improvement Action
Remarks
1 Y1 Work distribution for brazing
Distribution of work accor to
model and type of brazing
Finish date: W-22
2 Y2 Skill ;;
3 Y3 Hair pin length
4 Y4 XXXXX
5 Y5 ………
Data collection for Main variables(Y’s)
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Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
Before Problem description
Photo attachment Photo attachment
Solution to that Problem and advantage description
IMPROVEMENT-Y1
Improve
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Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y2
Improve
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Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y3
Improve
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Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y4
Improve
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Before Improvement After Improvement
Location:
Implemented Method:
Effect on implementation:
IMPROVEMENT-Y5
Improve
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Review-Improve Phase
Phase Plan/ Actual
WK-14 WK-15 WK-16 WK-17 WK-18 WK-20 WK-22 WK-24 WK-26
Improve
Plan
Actual
Improve
SAMPLE
together we can Quality Circle!Operations U & AControl
CONTROL PHASE
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S.No Y’s Variables Data type Remarks
1 Y1 Y1. Work distribution
2 Y2 Skill
3 Y3 Hair pin length
4 Y4 XXXXX
5 Y5 ………
Data collection for Main variables(Y’s)
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CONTROL CHART-Y1
Control
• Use Check sheet or other monitoring tool to standardize the process
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CONTROL CHART-Y2
Control
• Use Check sheet or other monitoring tool to standardize the process
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CONTROL CHART-Y3
Control
• Use Check sheet or other monitoring tool to standardize the process
SAMPLE
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CONTROL CHART-Y4
Control
• Use Check sheet or other monitoring tool to standardize the process
SAMPLE
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CONTROL CHART-Y5
Control
• Use Check sheet or other monitoring tool to standardize the process
SAMPLE
together we can Quality Circle!Operations U & A
Current Level and Target Level
Target Level Measurement:
DPMO(Defects per Million Opportunities)
(Total defect/total Production)*1000000:…3/381*1000000=7874
Sigma Level : Calculate from sigma table
Project Acheived Level:
Control
SAMPLE
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Review-Control Phase
Phase Plan/ Actual
WK-14 WK-5 WK-16 WK-17 WK-18 WK-20 WK-22 WK-24 WK-26
Control
Plan
Actual
Control
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Summary of the Project
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