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together we can Quality Circle!Operations U & A

QUALITY CIRCLE-COIL SHOP

PROJECT TITLE: To reduce leak from….. To ……SAMPLE


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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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


DEFINE PHASE

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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


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

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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:


(Total defect/total Production)*1000000:…3/381*1000000=7874

Sigma Level:Calculate from sigma table

Completion time:……Aug’13..

Measure

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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

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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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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

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We can use pareto or other seven QC tools to analyze.


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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PARETO CHART –x6

Problem(x6):…………………………………………………………….………………………………………………………………………………

Analyze

X’s Variables

Data

Conclusion:……………………………………………………………………………………………………………………………………

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PARETO CHART –x7

Problem(x7):…………………………………………………………….………………………………………………………………………………

Analyze

X’s Variables

Data

Conclusion:……………………………………………………………………………………………………………………………………

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PARETO CHART –x8

Problem(x8):…………………………………………………………….………………………………………………………………………………

Analyze

X’s Variables

Data

Conclusion:……………………………………………………………………………………………………………………………………

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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


Review-Analyze Phase

Phase Plan/ Actual


Analyze

Plan

Actual

Analyze

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together we can Quality Circle!Operations U & AImprove

IMPROVEPHASE

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together we can Quality Circle!Operations U & AControl

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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Location:

Implemented Method:


IMPROVEMENT-Y2

Improve

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Location:

Implemented Method:


IMPROVEMENT-Y3

Improve

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Location:

Implemented Method:


IMPROVEMENT-Y4

Improve

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Location:

Implemented Method:


IMPROVEMENT-Y5

Improve

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Review-Improve Phase

Phase Plan/ Actual


Improve

Plan

Actual

Improve

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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


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CONTROL CHART-Y3

Control


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CONTROL CHART-Y4

Control


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CONTROL CHART-Y5

Control


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Current Level and Target Level

Target Level Measurement:


(Total defect/total Production)*1000000:…3/381*1000000=7874

Sigma Level : Calculate from sigma table

Project Acheived Level:

Control

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Review-Control Phase

Phase Plan/ Actual


Control

Plan

Actual

Control

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Summary of the Project

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