TQM PROJECT TITLE

Additional shifting of finished goods resulting in higher cost due to extra work.

FACILITATOR & TEAM

Facilitator : Sh.Shantanu Daga ji

Team leader : Sh.P.C .Mittal Member : Sh.Rachhpal Singh Sh.Purshottam Singh

ATTENDENCE OF MEETINGSR. NO. DATE TOPICS P.C.M R.S P.S.

01 25/07/11 TQM MEETING (TEAM FORMATION) P P P

02 26/07/11 PROBLEM STATEMENT & MISSION STATEMENT P A P

03 27/07/11 PROJECT DISCUSSION P P P

04 05/08/11 BRAIN STORMING P P P05 07/08/11 FLOW DIAGRAM P P P06 09/08/11 EVALUATION ON BRAIN STORMING P P P

07 10/08/11 CAUSE-EFFECT DIAGRAM (FISH BONE DIAGRAM) P P P

08 15/08/11 GRAPH AND CHARTS P P P09 12/08/11 PROJECT REVIEW P P P10 15/08/11 HISTOGRAM AND PARETO DIAGRAM P P P11 02/09/11 DATA ANALYSIS P P P12 16/09/11 TEST THEORY P P P13 30/09/11 DATA ANALYSIS OF TEST THEORY P P A14 19/10/11 PROJECT REVIEW P P P15 04/11/11 PROJECT REVIEW P P P

TOTAL ATTENDANCE 15 14 14

PROBLEM STATEMENT

The finished goods are shifted from one place to another resulting in a loss of Rs. 20000/mth.

MISSION STATEMENT

To reduce loss incurred due to shifting of material to Rs.5000/month by 31 Mar,

2012

EXPENSES ON SHIFTINGMonths

EXPENSES ON SHIFTING

JAN. 113935

FEB. 118696

MAR. 117540

APR. 115775

MAY. 119455

JUN. 115934

JUL. 1112188

AUG. 119210

SEP. 11 6308

OCT. 116816

Nov. 118116

EXPENSES ON SHIFTING

JAN. 11 FEB. 11 MAR. 11

APR. 11 MAY. 11

JUN. 11 JUL. 11 ADG. 11

SEP. 11 OCT. 11

Nov. 11 0

2000

4000

6000

8000

10000

12000

14000

Series 1

AMOU

NT I

N R

s.

MONTH & YEAR

QC TOOLS USED

1.Process/Flow diagram

2.Cause & Effect Diagram

3.Stacked graph/Line graph

FLOW DIAGRAMStart

Packing Lifting of final yarn Godown

Space available In yarn godown

Final shifting to yarn Godown

Storage

Dispatch

Shifting in Deptt. Gallery

Stored in Deptt.

Re-check Space availability

BRAIN STORMING1. Insufficient space in godowns2. Wide dispatch fluctuations on daily basis.3. Godowns far off from packing deptt. 4. Manual movement to first floor of consumes time & labor. 5. Untimely dispatch advice.6. Unavailability of canter for material shifting7. Road congestion on the way to Godown IV.8. Difficulty in material identification due to poor lighting.9. Loading delays due to uncovered shed during monsoons11. Contractor workers – delay in work, delay in reporting, etc12. Labor less than requirement provided by contractor. 13. Stock stored inside department is damaged by workers.14. Stock at various places causes delays during loading – truck owners complain. 15. Delays in arrival of transport – container for export16. Repacking because sample is required after packing. 17. Pallet machine faulty.18. Uncovered shed cause delay in shifting during rain.

CAUSE EFFECT DIAGRAM

Additional shifting of FG resulting in

higher cost due to extra work.

LOCOMOTION

METHOD

CUSTOMERMAN

Lifts unavailabilityPallet lifting

Machine faulty

Shifting delay

Canter breakdown

Uncovered shed causes delay during rain

Internal movement

Small forklift unavailable

Manual shifting causes broken cases

Irregular dispatch

Stock

Excess form export/short wt.

Loading mistake

Reloading

Wrong loading

Rechecking

Undefined timings

Heavy work

Labour

Wage structureTired/sick

Contract labour irregular

Godown too farPacking at different places

Storage

Manual shifting & extra time

Canter availability

Production not as per plan

Poor planning

Advice delay

Vehicle not available

Ranking of brainstorming pointsS.No.

Description Data

1 Insufficent space in godowns. Available2 Fluctuations in monthly dispatch. Available3 Manual movement to first floor /basement of consumes time & labor Available4 Untimely dispatch advice. Not available5 Contractor workers-delay in work ,delay in reporting,etc. Not available

6 Unavailability of canter for material shifting. Available7 Labor less than requirment provided by contractor. Available8 Godowns far off from packing deptt. Not available9 Pallet machine faulty. Available10 Delays in arrival of transport –container for export. Not available11 Uncovered shed cause delay in shifting during rain. Available12 Difficulty in material identification due to poor lighting. Not available13 Road congestion on the way to godown IV. Not available14 Stock at various places causes delays during loading –truck owner

s complain.Not available

15 Stock stored inside department is damaged by worker.s. Not available16 Loading delays due to uncovered shed during monsoons. Not

available

PRIORITIZATION OF CAUSES Insufficient space in go-downs.Fluctuations in monthly dispatch.Manual movement to first floor of consumes

time and labor.Untimely dispatch advice.Contractor workers - delay in work ,delay in

reporting, etc.Unavailability of canter for material shifting.Labor less than requirement provided by

contractor.

LABOUR SHORTMonths Required Provided JAN. 11 240 158

FEB. 11 224 161

MAR. 11 240 193

APR. 11 248 199

MAY. 11 240 195

JUN. 11 240 193

JUL. 11 224 186

AUG. 11 240 189

SEP. 11 240 249

OCT. 11 248 200

NOV. 11 240 214

LABOUR SHORT

JAN. 11

FEB. 11

MAR. 11

APR. 11

MAY. 11

JUN. 11

JUL. 11

AUG. 11

SEP. 11 OCT. 11 NOV. 11

0

50

100

150

200

250

300

Required

Provided

MONTHS & YEARS

LABO

UR

PRODUCTION VS DESPATCHMonths Opening

StockProd. Desp. Stock Level

JAN. 11312 905 851

350

FEB. 11364 850 840

350

MAR. 11375 892 831

350

APR. 11435 760 636

350

MAY. 11560 744 810

350

JUN. 11494 712 637

350

JUL. 11567 1020 1088

350

AUG. 11502 990 1069

350

SEP. 11 423 937 1130 350

OCT. 11 231 945 645 350

NOV. 11 531 960 822 350

PRODUCTION VS DESPATCH

JAN. 11 FEB. 11 MAR. 11

APR. 11

MAY. 11

JUN. 11 JUL. 11 AUG. 11

SEP. 11 OCT. 11

NOV. 11

0

200

400

600

800

1000

1200

Opening Stock

Prod.

Desp.

Space Capacity

Qty.

in M

T.

Months & Years

CAUSES EFFECT DELAY SHIFTING & LOADING FG.

Months Wrong

loading

Canter breakdown Pilot M/C

Faulty

Vehicle not

AvailableJAN. 11

0 5 0 2FEB. 11

0 3 1 1MAR. 11

1 1 2 2APR. 11

0 2 0 0MAY. 11

0 3 0 1JUN. 11

0 6 2 2JUL. 11

2 2 1 3ADG. 11

1 4 2 3SEP. 11 0 4 0 0

OCT.11 0 2 0 0

NOV. 11 0 2 0 1

CAUSES EFFECT DELAY SHIFTING & LOADING FGS.

JAN. 11 FEB. 11 MAR. 11

APR. 11 MAY. 11

JUN. 11 JUL. 11 ADG. 11

SEP. 11 OCT.11 NOV. 11

0

2

4

6

8

10

12

Vehicle not Available

Pilot M/C Faulty

Canter breakedown

Wrong loading

NO. O

F TI

ME

MONTH & YEAR

REMEDY OF CAUSES

1. Fix inventory levels of finished goods according to production level.

2. Install a lift to facilitate handling of excess stock.3. Revise wages of contract labour annually.4. Old canter should be replaced in order to avoid breakdowns.5. Pallet machine should be serviced as per maintenance

schedule in order to avoid breakdowns.6. Store finished goods inventory according to lot, shade and

counts. 7. Marketing should provide dispatch advice one day in advance.8. One vehicle, dedicated for shifting goods is required at all

times.

IMPLIMENTATION

Lift under construction, would come in operation till 15th Jan 2012.

Storage of finished goods in lot wise. Contractor labour rates revised.Pallet machine maintenance scheduled for

prevention of faults.

VALIDATION OF GAINS

Project is under progress…………..

HOLD THE GAINSCheck to see that elevator is serviced

regularly and maintained according to schedule

Monthly check to ensure that pallet machine is being serviced according to schedule

Check daily that F.G. inventory is stored systematically