Sample project-Quality Circle

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    10-Jun-2015

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Sample Project which help you to understand the concept

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<ul><li> 1. QUALITY CIRCLECOIL SHOPE L PM Aleak from.. To S PROJECT TITLE: To reduceOperations U &amp; Atogether we canQuality Circle!</li></ul> <p> 2. INTRODUCTION TEAM NAME:XXXXX..LEADER NAME:ABCD..PROJECT TITLE:To reduce the leak from .. To ..AREA DATEOperations U &amp; AE L PM:Coil Shop Brazing Area A S :starting date..together we canQuality Circle! 3. TEAM STRUCTURE Team leader HOD/SupervisorSub leaderM A SE L PQuality coordinatorOperations U &amp; Atogether we canMaintenance coordinatorQuality Circle! 4. Team Attendance NameS. NOPosition in TeamWK-WK-WK-1KoshikLeaderPPXXXXSub Leader PPYYYYCoordinator PPZZZZRecorderPP5GGGGData collectorPPWK-WK-WK-WK-P4WK-P3WK-P2WK-M A SOperations U &amp; AE L P P Atogether we canQuality Circle! 5. GANT CHART PhaseWK-14WK-16WK-18WK-20WK-22WK-24WK-26WK-28WK-30WK-32Define Measure Analyze Improve ControlOperations U &amp; AM A SE L Ptogether we canQuality Circle! 6. DEFINE PHASE E L M A SOperations U &amp; APtogether we canQuality Circle! 7. 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 linesE L PHow much is the Problem : Daily avg Yield rate of CAC1 is 94%M A SBoundaries of the Problem:CAC-1 brazing area to leak testing area. Define Operations U &amp; Atogether we canQuality Circle! 8. SIPOC SIPOC(Supplier, Input , Process , Output &amp; Customer) Specific Process flow chart with SIPOC. Inputs Foil,Power,Man powerFin press Collar crack,GatheringCoil assy with end plateCu tube,finsLacing Cu bend,coil bend,damageVEM A SE Lbend PUFlare crack,coil damage.Cu tube with ringCross insert,dust,oilOxy,LPG,TorchBrazing Defect,burn mark,leakCoil,power,coupl erLeak test Leak,damageOutputsDefine Operations U &amp; Atogether we canQuality Circle! 9. DRILL DOWN TREE To reduce LeakOur ProjectFrom.. To ..E L POur targetM A SYield rate will improveWhat improveProduction target of 750 MSAR achieveCompany targetDefine Operations U &amp; Atogether we canQuality Circle! 10. Review-Define Phase PhasePlan/ ActualWK-14WK-15WK-16WK-17WK-WK-WK-WK-WK-Plan DefineActualM A SOperations U &amp; AE L Ptogether we canQuality Circle! 11. MEASURE E L P PHASE M A SOperations U &amp; Atogether we canQuality Circle! 12. MEASURE PHASELine:CAC-1 Problem : High leak rate in CAC-1 EL PM A Where/Area:In CAC-1/Brazing area S Current Level:Avg 94% yield/day Measure Operations U &amp; Atogether we canQuality Circle! 13. Data Collection Last One year or minimum 6 month data need to collect. Data collected for6Months E Data Type : Continuous /PL Discrete Data format: Excel AM S ..Daily leak testing report Reference DocumentMeasure Operations U &amp; Atogether we canQuality Circle! 14. Current Level and Target Level Current Level Measurement:Target Level Measurement:DPMO(Defects per Million Opportunities)DPMO(Defects per Million Opportunities)(Total defect/total Production)*1000000: (6/381)*1000000=15789Operations U &amp; A(Total defect/total Production)*1000000: 3/381*1000000=7874M A SSigma Level: Calculate from sigma tableE L PSigma Level:Calculate from sigma tableMeasure Completion time:Aug13.. together we can Quality Circle! 15. Cause &amp; Effect(Leak reduction) ManMaterialCommunicationReturn bend dust Oil presence in flare Dust/gloves burr in flaresReturn Bend dimensionHair pin length mismatchEnd Plate disturbanceE L PCorroded/Dust leadM A SView of operator Torch handling methodManual FlaringWork DistributionAwarenessPinching toolGas mixing proportionFlare punch dimensionHeader feeder to coil mismatchMethodGas flow low Pressure Gauge not visibleFlare CrackLead Rod StorageBrazing SkillConveyor angle slide Lacing JigMachineMeasure Operations U &amp; Atogether we canQuality Circle! 16. KPIV/KPOV List Down the Cause Variables from C&amp;E diagram1. 2. 3. 4. 5. 6. 7. 8.9. 10. 11. E L 12. P M13. A S 14. 15. 16. MeasureOperations U &amp; Atogether we canQuality Circle! 17. FDM(Function Deployment Matrix) Variables(xs)Productivity Low:3 Mid:5 Max:9Cost Low:3 Mid:5 Max:9Quality Low:3 Mid:5 Max:9Total WeightageWork Distribution6466*5+4*5+6*5=80Brazing Skill8688*9+6*5+8*9=174Pressure Gauge not visible,, ,, ,, ,, ,, ,, ,,M A SE L P,, ,, ,, ,,Operations U &amp; AMeasure together we canQuality Circle! 18. SELECTED CAUSE LIST-xs ListDown the Cause Variables from C&amp;E from diagram diagram List Down the Variables(x) &amp; FDM C&amp;E x1.Work distribution x2.Skill x3.Hair pin length x4.XXXXX x5.YYYY x6.ZZZZ x7.GGGG x8FFFM A SE L PMeasure Operations U &amp; Atogether we canQuality Circle! 19. Review-Measure Phase PhasePlan/ ActualWK-14WK-15WK-16WK-17WK-18WK-19WK-20WK-22WK-24Plan MeasureActualM A SE L PMeasure Operations U &amp; Atogether we canQuality Circle! 20. ANALYZE E L P PHASE M A SAnalyze Operations U &amp; Atogether we canQuality Circle! 21. Data collection for small variables(xs)S.NoxsVariablesData type1x1Work distributionContinous2x2Skill,,3x3Hair pin length,,4x4XXXXX,,5x56x67x78x8M A S YYYYE L PRemarks,,ZZZZ,,GGGG,,FFF,,We can use pareto or other seven QC tools to analyze. Operations U &amp; Atogether we canAnalyzeQuality Circle! 22. PARETO CHART x1 Problem(x1): . Xs Variables Data 15 x1x1.Work distributionx2Skillx3Hair pin lengthx4x4.XXXXXx5x5.YYYYx6x6.ZZZZx7x7.GGGGx8x8FFF1415158 13 14 7 4 1E L P 14M A S 1014 138754 15X1X2X3X4X5X6X7X89690848179X6X7X8Conclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 23. PARETO CHART x2 Problem(x2): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 24. PARETO CHART x3 Problem(x3): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 25. PARETO CHART x4 Problem(x4): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 26. PARETO CHART x5 Problem(x5): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 27. PARETO CHART x6 Problem(x6): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 28. PARETO CHART x7 Problem(x7): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 29. PARETO CHART x8 Problem(x8): . Xs Variables Data M A SE L PConclusion: Analyze Operations U &amp; Atogether we canQuality Circle! 30. MAJOR CAUSE LIST-Ys 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. XXXXXM A SE L PAnalyze Operations U &amp; Atogether we canQuality Circle! 31. Review-Analyze Phase PhasePlan/ ActualWK-14WK-15WK-16WK-17WK-18WK-20WK-22WK-24WK-26Plan AnalyzeActualM A SE L PAnalyze Operations U &amp; Atogether we canQuality Circle! 32. IMPROVE E L P PHASE M A SImprove Operations U &amp; Atogether we canQuality Circle! 33. Data collection for Main variables(Ys)S.NoYsVariables1Y12Y23Y3Hair pin length4Y4XXXXX5Y5Work distribution for brazingSkillM A SImprovement Action Distribution of work accor to model and type of brazingE L PRemarks Finish date: W-22;;Control Operations U &amp; Atogether we canQuality Circle! 34. IMPROVEMENT-Y1 Location:After ImprovementBefore ImprovementPhoto attachmentBefore Problem descriptionM A SE L PPhoto attachmentSolution to that Problem and advantage descriptionImplemented Method: Effect on implementation:Improve Operations U &amp; Atogether we canQuality Circle! 35. IMPROVEMENT-Y2 Location:After ImprovementBefore ImprovementM A SE L PImplemented Method: Effect on implementation:Improve Operations U &amp; Atogether we canQuality Circle! 36. IMPROVEMENT-Y3 Location:After ImprovementBefore ImprovementM A SE L PImplemented Method: Effect on implementation:Improve Operations U &amp; Atogether we canQuality Circle! 37. IMPROVEMENT-Y4 Location:After ImprovementBefore ImprovementM A SE L PImplemented Method: Effect on implementation:Improve Operations U &amp; Atogether we canQuality Circle! 38. IMPROVEMENT-Y5 Location:After ImprovementBefore ImprovementM A SE L PImplemented Method: Effect on implementation:Improve Operations U &amp; Atogether we canQuality Circle! 39. Review-Improve Phase PhasePlan/ ActualWK-14WK-15WK-16WK-17WK-18WK-20WK-22WK-24WK-26Plan ImproveActualM A SE L PImprove Operations U &amp; Atogether we canQuality Circle! 40. CONTROL E L P PHASE M A SControl Operations U &amp; Atogether we canQuality Circle! 41. Data collection for Main variables(Ys)S.NoYsVariablesData type1Y12Y2Skill3Y3Hair pin length4Y4XXXXX5Y5RemarksY1. Work distributionM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 42. CONTROL CHART-Y1 Use Check sheet or other monitoring tool to standardize the processM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 43. CONTROL CHART-Y2 Use Check sheet or other monitoring tool to standardize the processM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 44. CONTROL CHART-Y3 Use Check sheet or other monitoring tool to standardize the processM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 45. CONTROL CHART-Y4 Use Check sheet or other monitoring tool to standardize the processM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 46. CONTROL CHART-Y5 Use Check sheet or other monitoring tool to standardize the processM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 47. Current Level and Target Level Target Level Measurement:DPMO(Defects per Million Opportunities)E L P(Total defect/total Production)*1000000:3/381*1000000=7874M A SSigma Level : Calculate from sigma tableProject Acheived Level: Control Operations U &amp; Atogether we canQuality Circle! 48. Review-Control Phase PhasePlan/ ActualWK-14WK-5WK-16WK-17WK-18WK-20WK-22WK-24WK-26Plan ControlActualM A SE L PControl Operations U &amp; Atogether we canQuality Circle! 49. Summary of the ProjectM A SOperations U &amp; AE L Ptogether we canQuality Circle!</p>