Sample Project which help you to understand the concept

1. QUALITY CIRCLECOIL SHOP
E
L
P
M
Aleak from….. To ……
S
PROJECT TITLE: To reduce
Operations U & A
together we can
Quality Circle!

2. INTRODUCTION
TEAM NAME
:…XXXXX………………..
LEADER NAME
:………ABCD……………..
PROJECT TITLE
:To reduce the leak from .. To ..
AREA
DATE
Operations U & A
E
L
P
M:…Coil Shop –Brazing Area
A
S
:………starting date……..
together we can
Quality Circle!

3. TEAM STRUCTURE
Team leader
HOD/Supervisor
Sub leader
M
A
S
E
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Quality coordinator
Operations U & A
together we can
Maintenance coordinator
Quality Circle!

4. Team Attendance
Name
S.
NO
Position in
Team
WK-
WK-
WK-
1
Koshik
Leader
P
P
XXXX
Sub Leader P
P
YYYY
Coordinator P
P
ZZZZ
Recorder
P
P
5
GGGG
Data collector
P
P
WK-
WK-
WK-
WK-
P
4
WK-
P
3
WK-
P
2
WK-
M
A
S
Operations U & A
E
L
P
P
A
together we can
Quality Circle!

5. GANT CHART
Phase
WK-14
WK-16
WK-18
WK-20
WK-22
WK-24
WK-26
WK-28
WK-30
WK-32
Define
Measure
Analyze
Improve
Control
Operations U & A
M
A
S
E
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P
together we can
Quality Circle!

6. DEFINE PHASE
E
L
M
A
S
Operations U & A
P
together we can
Quality 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 lines
E
L
P
How much is the Problem : Daily avg Yield rate of CAC1 is 94%
M
A
S
Boundaries of the Problem:CAC-1 brazing area to leak
testing area.
Define
Operations U & A
together we can
Quality Circle!

8. SIPOC
• SIPOC(Supplier, Input , Process , Output & Customer)
Specific Process flow chart with SIPOC.
Inputs
Foil,Power,Man
power
Fin press
Collar
crack,Gathering
Coil assy with
end plate
Cu tube,fins
Lacing
Cu bend,coil
bend,damage
VE
M
A
S
E
Lbend
PU
Flare crack,coil
damage….
Cu tube with
ring
Cross
insert,dust,oil
Oxy,LPG,Torch
Brazing
Defect,burn
mark,leak
Coil,power,coupl
er
Leak
test
Leak,damage…
Outputs
Define
Operations U & A
together we can
Quality Circle!

9. DRILL DOWN TREE
……To reduce Leak……
Our Project
From.. To ..
E
L
P
Our target
M
A
S
Yield rate will improve
What improve
Production target of 750 MSAR
achieve
Company target
Define
Operations U & A
together we can
Quality Circle!

10. Review-Define Phase
Phase
Plan/
Actual
WK-14
WK-15
WK-16
WK-17
WK-
WK-
WK-
WK-
WK-
Plan
Define
Actual
M
A
S
Operations U & A
E
L
P
together we can
Quality Circle!

11. MEASURE
E
L
P
PHASE
M
A
S
Operations U & A
together we can
Quality Circle!

12. MEASURE PHASE
Line:CAC-1
Problem : High leak rate in CAC-1
E
L
P
M
A
Where/Area:In CAC-1/Brazing area
S
Current Level:Avg 94% yield/day
Measure
Operations U & A
together we can
Quality Circle!

13. Data Collection
Last One year or minimum 6 month data need to
collect.
Data collected for……6…………Months
E
Data Type : Continuous /PL
Discrete
Data format: Excel AM
S ..Daily leak testing report
Reference Document
Measure
Operations U & A
together we can
Quality 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=15789
Operations U & A
(Total defect/total Production)*1000000:…
3/381*1000000=7874
M
A
S
Sigma Level: Calculate from sigma
table
E
L
P
Sigma Level:Calculate from sigma
table
Measure
Completion time:……Aug’13..
together we can
Quality Circle!

15. Cause & Effect(Leak reduction)
Man
Material
Communication
Return bend dust
Oil presence in flare
Dust/gloves burr in flares
Return Bend dimension
Hair pin length mismatch
End Plate disturbance
E
L
P
Corroded/Dust
lead
M
A
S
View of operator
Torch handling
method
Manual Flaring
Work Distribution
Awareness
Pinching tool
Gas mixing proportion
Flare punch dimension
Header feeder to coil
mismatch
Method
Gas flow low
Pressure Gauge not visible
Flare Crack
Lead Rod Storage
Brazing Skill
Conveyor angle slide
Lacing Jig
Machine
Measure
Operations U & A
together we can
Quality Circle!

16. KPIV/KPOV
List Down the Cause Variables from C&E diagram
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
E
L
12.
P
M13.
A
S 14.
15.
16.
Measure
Operations U & A
together we can
Quality Circle!

17. FDM(Function Deployment Matrix)
Variables(x’s)
Productivity
Low:3 Mid:5 Max:9
Cost
Low:3 Mid:5 Max:9
Quality
Low:3 Mid:5 Max:9
Total 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
,,
,,
,,
,,
,,
,,
,,
M
A
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E
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,,
,,
,,
,,
Operations U & A
Measure
together we can
Quality Circle!

18. SELECTED CAUSE LIST-x’s
ListDown the Cause Variables from C&E from diagram diagram
List Down the Variables(x) & FDM C&E
x1.Work distribution
x2.Skill
x3.Hair pin length
x4.XXXXX
x5.YYYY
x6.ZZZZ
x7.GGGG
x8FFF
M
A
S
E
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P
Measure
Operations U & A
together we can
Quality Circle!

19. Review-Measure Phase
Phase
Plan/
Actual
WK-14
WK-15
WK-16
WK-17
WK-18
WK-19
WK-20
WK-22
WK-24
Plan
Measure
Actual
M
A
S
E
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P
Measure
Operations U & A
together we can
Quality Circle!

20. ANALYZE
E
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PHASE
M
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Analyze
Operations U & A
together we can
Quality Circle!

21. Data collection for small variables(x’s)
S.No
x’s
Variables
Data type
1
x1
Work distribution
Continous
2
x2
Skill
,,
3
x3
Hair pin length
,,
4
x4
XXXXX
,,
5
x5
6
x6
7
x7
8
x8
M
A
S
YYYY
E
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P
Remarks
,,
ZZZZ
,,
GGGG
,,
FFF
,,
We can use pareto or other seven QC tools to
analyze.
Operations U & A
together we can
Analyze
Quality Circle!

22. PARETO CHART –x1
Problem(x1):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
15
………………
x1
x1.Work distribution
x2
Skill
x3
Hair pin length
x4
x4.XXXXX
x5
x5.YYYY
x6
x6.ZZZZ
x7
x7.GGGG
x8
x8FFF
14
15
15
8
13
14
7
4
1
E
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14
M
A
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10
14
13
8
7
5
4
1
5
X1
X2
X3
X4
X5
X6
X7
X8
96
90
84
81
79
X6
X7
X8
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

23. PARETO CHART –x2
Problem(x2):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

24. PARETO CHART –x3
Problem(x3):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

25. PARETO CHART –x4
Problem(x4):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

26. PARETO CHART –x5
Problem(x5):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

27. PARETO CHART –x6
Problem(x6):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

28. PARETO CHART –x7
Problem(x7):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

29. PARETO CHART –x8
Problem(x8):
…………………………………………………………….
………………………………………………………………
X’s Variables Data
………………
M
A
S
E
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P
Conclusion:
………………………………………………………………
Analyze
Operations U & A
together we can
Quality Circle!

30. MAJOR CAUSE LIST-Y’s
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. XXXXX
M
A
S
E
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P
Analyze
Operations U & A
together we can
Quality Circle!

31. Review-Analyze Phase
Phase
Plan/
Actual
WK-14
WK-15
WK-16
WK-17
WK-18
WK-20
WK-22
WK-24
WK-26
Plan
Analyze
Actual
M
A
S
E
L
P
Analyze
Operations U & A
together we can
Quality Circle!

32. IMPROVE
E
L
P
PHASE
M
A
S
Improve
Operations U & A
together we can
Quality Circle!

33. Data collection for Main variables(Y’s)
S.No
Y’s
Variables
1
Y1
2
Y2
3
Y3
Hair pin length
4
Y4
XXXXX
5
Y5
Work distribution
for brazing
Skill
M
A
S
Improvement
Action
Distribution of
work accor to
model and type
of brazing
E
L
P
Remarks
Finish date:
W-22
;;
………
Control
Operations U & A
together we can
Quality Circle!

34. IMPROVEMENT-Y1
Location:
After Improvement
Before Improvement
Photo attachment
Before Problem description
M
A
S
E
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Photo attachment
Solution to that Problem and
advantage description
Implemented Method:
Effect on implementation:
Improve
Operations U & A
together we can
Quality Circle!

35. IMPROVEMENT-Y2
Location:
After Improvement
Before Improvement
M
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S
E
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Implemented Method:
Effect on implementation:
Improve
Operations U & A
together we can
Quality Circle!

36. IMPROVEMENT-Y3
Location:
After Improvement
Before Improvement
M
A
S
E
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Implemented Method:
Effect on implementation:
Improve
Operations U & A
together we can
Quality Circle!

37. IMPROVEMENT-Y4
Location:
After Improvement
Before Improvement
M
A
S
E
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Implemented Method:
Effect on implementation:
Improve
Operations U & A
together we can
Quality Circle!

38. IMPROVEMENT-Y5
Location:
After Improvement
Before Improvement
M
A
S
E
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Implemented Method:
Effect on implementation:
Improve
Operations U & A
together we can
Quality Circle!

39. Review-Improve Phase
Phase
Plan/
Actual
WK-14
WK-15
WK-16
WK-17
WK-18
WK-20
WK-22
WK-24
WK-26
Plan
Improve
Actual
M
A
S
E
L
P
Improve
Operations U & A
together we can
Quality Circle!

40. CONTROL
E
L
P
PHASE
M
A
S
Control
Operations U & A
together we can
Quality Circle!

41. Data collection for Main variables(Y’s)
S.No
Y’s
Variables
Data type
1
Y1
2
Y2
Skill
3
Y3
Hair pin length
4
Y4
XXXXX
5
Y5
Remarks
Y1. Work distribution
M
A
S
E
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P
………
Control
Operations U & A
together we can
Quality Circle!

42. CONTROL CHART-Y1
• Use Check sheet or other monitoring tool to standardize the
process
M
A
S
E
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Control
Operations U & A
together we can
Quality Circle!

43. CONTROL CHART-Y2
• Use Check sheet or other monitoring tool to standardize the
process
M
A
S
E
L
P
Control
Operations U & A
together we can
Quality Circle!

44. CONTROL CHART-Y3
• Use Check sheet or other monitoring tool to standardize the
process
M
A
S
E
L
P
Control
Operations U & A
together we can
Quality Circle!

45. CONTROL CHART-Y4
• Use Check sheet or other monitoring tool to standardize the
process
M
A
S
E
L
P
Control
Operations U & A
together we can
Quality Circle!

46. CONTROL CHART-Y5
• Use Check sheet or other monitoring tool to standardize the
process
M
A
S
E
L
P
Control
Operations U & A
together we can
Quality 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=7874
M
A
S
Sigma Level : Calculate from sigma table
Project Acheived Level:
Control
Operations U & A
together we can
Quality Circle!

48. Review-Control Phase
Phase
Plan/
Actual
WK-14
WK-5
WK-16
WK-17
WK-18
WK-20
WK-22
WK-24
WK-26
Plan
Control
Actual
M
A
S
E
L
P
Control
Operations U & A
together we can
Quality Circle!

49. Summary of the Project
M
A
S
Operations U & A
E
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P
together we can
Quality Circle!