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together we can Quality Circle!Operations U & A
QUALITY CIRCLE
Systematic Approach To Problem Solving
Prepared By Mohamed Yusuff
together we can Quality Circle!Operations U & A
Introduction to Quality Circle
• It is a small group of frontline operators who
continually control and improve the quality of
their work, products and services.
• They voluntarily meet together on a regular
basis to identify improvements in their
respective work areas using proven techniques
for analyzing and solving work related problems.• QC Circle activities are carried out as part of
Total Quality Management(TQM),
together we can Quality Circle!Operations U & A
QUALITY CIRCLE FROM TQM
• Continuous Process Improvement – Kaizen, Six
Sigma
• Employee Empowerment – Quality Circle
• Benchmarking – Legally stealing other people’s
ideas
• Customer-Supplier Partnerships – JIT concept
• Management by fact.
together we can Quality Circle!Operations U & A
WHY WE NEED QUALITY CIRCLE
• Its provides an opportunity for members
to develop their creative thinking
• As the members study and learn
together, their full potential is realized
• To contribute to the improvement and
development of an Organisation.
together we can Quality Circle!Operations U & A
OBJECTVES OF QC
• Establishment of a pleasant workplace
• Establishment of a state of control
• Enhancement of morale
• Establishment of sound human relations
• Better income
• Improvement in Quality Assurance
together we can Quality Circle!Operations U & A
• Increased productivity
• Improved quality of work life
• Boost employee morale
• Enhances creativity
• Improved teamwork
• Employee involvement
POTENTIAL BENIFITS
together we can Quality Circle!Operations U & A
ORIGIN OF QC
• The first Quality Circle was organized in 1962, by Japan Nippon Telegraph company.
• It was supervised by Mr.Deming and Dr.Juran.
• Japan Started JUSE (Union of Japan Scientists and Engineers) to spread Quality control circle.
together we can Quality Circle!Operations U & A
Asian Productivity Organization
• Japan• South Korea • Taiwan• Singapore• Malaysia • the Philippines• Hong Kong• India, • Indonesia• Thailand• Sri Lanka • Pakistan and Vietnam
together we can Quality Circle!Operations U & A
QUALITY CIRCLE IN COIL SHOP
• In Coil shop Quality Circle successfully started on 30th March 2013.
• Total 13 team formed on 24th March 2013.
• Booklet and training provided 8th April 2013.
• Currently successfully continuing the Improve phase.
together we can Quality Circle!Operations U & A
QC Team Formation-Coil shop
Line/Area Assy Brazing Tubing Coating
CAC-11 Team
13 Members2 Team
26 Members 2 Team16
MembersCAC-21 Team
6 Members1 Team
7 Members
AHU1 Team
9 Members1 Team
10 Members 1 Team9 Members
Chiller1 Team
10 Members1 Team
9 Members
Resistec1 Team
10 Members
Total Team :13
together we can Quality Circle!Operations U & A
QUALITY CIRCLE IN COIL SHOP
• Assigned Leaders and sub leaders for each team.
• Team name selected by each team members
• Each team took each project from their own area. Total 13 project in progress.
together we can Quality Circle!Operations U & A
Team list with Project
S.N Line Area Team nameTeam
LeaderSub Leader Project description Target description
1
CAC-1
M/C Shop Success Renji WassilTo Reduce Fin & Cu Tube damages in all stages
Current Level is 3 NCN/Month Target- 1 NCN/Month
2 Brazing-1 Rose Riders Girish ManojTo Reduce Return Bend Leak rate below 0.5%
Current return bend leak rate is 2.1%Target- 0.5 %
3 Brazing-2 Speed Riders IlyasMohsin aalam
To Reduce Return Bend Leak rate below 0.5%
Current return bend leak rate is 2.1 %Target- 0.5 %
4CAC-2
M/C Shop Fire Crackers Raj kamal Emilio To Eliminate wrong Coil assemblyCurrent Level is 3 NCN/Month Target- 1 NCN/Month
5 BrazingSeven Star
BrazersVarghese Ansar To Reduce Brazing Leak rate Below 1%
Current leak rate is 3 %Target - 1 %
6 CACTube shop
Parts Perfect Jahangir MahroofTo Reduce InProcess scraps of copper tubes
Current scrap is 12 LbsTarget to below 4 Lbs
7 Assy Brazing Bullets MonirAkbar,Sabbir
To Reduce InProcess scraps of copper tubes
Current scrap is 12 LbsTarget to below 4 Lbs
8AHU
M/C Shop YIPS Express AzzizBlitz
,IliyasTo Increase Per day production by 30%
Avg daily production is 11 Target to 14
9 Brazing CourageAbdul
KhaderFakrudeen To Reduce Brazing Leak rate Below 1%
Current leak rate is 4.6 %Target- 1 %
10Chiller
M/C ShopPSDOS
(Problem solving,Developing of skill)
Krishna Kumar Jha
Erwin,MalickTo Reduce In Process scraps of Copper tubes
Current scrap is 1.8 LbsTarget to below 0.5 Lbs
11 BrazingRoyal
ChallengersAnas
Ashraful,Ajay Kumar
To Reduce Brazing Leak rate Below 1%Current leak rate is 3.1 %Target- 1 %
12Chiller Tube shop
Parts&Assy Professional Aquil HassanTo Reduce In Process scraps of Copper tubes
Current scrap is 7 LbsTarget to below 4 Lbs
13 Resistec Coating Resistec X1 Thaisen Jackson To Improve Efficiency of coating lineCurrent Level is 2 NCN/Month Target- 0 NCN/Month
together we can Quality Circle!Operations U & A
GANT CHART-Full Program
Description Plan/ Actual
WK-12WK-
13,14
WK-15,16,1
7
WK-18,19,
WK20-48
WK-48-52
WK-52
Intro+ education+ team formation
PLAN
ACTUAL
Define phase Training + project assign
PLAN
ACTUAL
Measure phase training + data collection+ Brainstorming
PLAN
ACTUAL
Analyze(Training+Pareto chart)
PLAN
ACTUAL
Improve Phase(Implementation)
PLAN
ACTUAL
Control Phase training+ implement
PLAN
ACTUAL
-Planned -Completed
together we can Quality Circle!Operations U & A
ABOUT PROJECTS
• Format used – DMAIC
Define, Measure, Analyze, Improve &
Control
• Periodical training & meeting conducted.
• Internal meeting conducted by team
leaders in work place every month to
define their own stage problems.
together we can Quality Circle!Operations U & A
ABOUT PROJECTS
• Tools used
- Pareto chart
- Cause and Effect diagram
- FDM(Function Deployment Matrix)
- Brainstorming
- Check sheets
together we can Quality Circle!Operations U & A
• Each Project working on minimum 2
problems which is to improve on their
stage.
• Total 32 improvements related to their
own stage is in progress.
Improvements observed
together we can Quality Circle!Operations U & A
Major improvements
Return Bend Leak rate reduction in CAC-1 (Team-Rose riders & speed riders)
Action Taken:1.Check sheet displayed to monitor the leak from every stage.
2.Input Butane pressure regularized by placing adjustable pressure gauge.
3.Practicing Pre heat to reduce oil level in flare.(if found more oil on flares)
4.Continual feed back system by internal operator itself.
Brazing Leak reduction in AHU & Applied Coil shop(Team-Seven star brazers, Courage& Royal challengers)
Leak rate-1.1%Leak rate-2.1%
Leak rate-1.0%Leak rate-3.0%
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location:CAC-1 Brazing Area Team-Rose riders
Type: Quality Improvement (Leak rate reduction)
Effect on implementation: Return bend leak rate will be reduce
Dust and moisture accumulate on return bend which is stored in box can creates corrosion and cause leak
Return bend stored box will arrange and N2 gas will insert in serial to all box, so that external moisture will not enter.
IMPROVEMENTS
Improve18
N2 IN N2 OUT
Return bend storage box
Return bend storage box
Return bend storage box
In progress
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location: CAC2 Machine shop Team- Fire Crackers
Type: Productivity Improvement
Effect on implementation: Wrong coil assembly will reduce
After Process sheet obtain from scheduling, in coil shop there exist manual editing for coil size and hair pin Qty which creates wrong coil due to wrong entry.
With the help of Scheduling process sheet changed with required data to produce coil without manual editing
IMPROVEMENTS
Improve19
Photos attached on next slide
Photos attached on next slide
Process In progress
together we can Quality Circle!Operations U & A
Process sheet-Current
together we can Quality Circle!Operations U & A
Modified Process sheet
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location: AHU Brazing Area Team-Royal Challengers
Type: Quality Improvement (Leak rate reduction)
Effect on implementation: Constant gas pressure obtain thus leak rate will reduce
Gas pressure was not proper due to flux blockage ,lengthy hose and hose frequent damage.
Brazing hose arranged and standardized by extending steel pipe up to brazing stage to make hose length short and constant gas pressure.
IMPROVEMENTS
Improve22
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location: Resistec Team-Resistec 11
Type: Productivity Improvement
Effect on implementation: Process time reduction with improved Quality
Coils were coated by keeping on drums. Coating done on one face and hold it for drying about 6 hrs and then coating on the opposite side..
Moving trolley made with hanging system, Now coils will coat/spray and directly move to the oven without lifting the coils
IMPROVEMENTS
Improve23
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location: Chiller Team-Courage
Type: Productivity and Quality Improvement
Effect on implementation: Process time reduction with improved Quality
During Crimping for valve insertion in Evap coil, there no flare exist, which cause difficulties in brazing tends to leak occur
Design of crimping tool need to alter by cutting a slot in tool of flare rest area.
IMPROVEMENTS
Improve24
In Progress
together we can Quality Circle!Operations U & A
Before Improvement After Improvement
Location: CAC Tube Shop Team-Perfect Type
Productivity and scrap reduction Improvement
Effect on implementation: Cu tube Scrap due to roll end will totally eliminate.
In straight tube cutting machine roll end tube not able to cut due to machine limitation
Manual cutting machine ordered so as to cut roll end tube at instant, by this minimum length can be cut according to our process requirement.
IMPROVEMENTS
Improve25
together we can Quality Circle!Operations U & A
Various improvements
• CU Scrap reduction by introducing
– Tube clamping system to standardize the cutting angle.
• Process improvement
– AHU brazing carried out in sequence table to increase
productivity
together we can Quality Circle!Operations U & A