6. SAND DROP PROJECT.pptx in insert of railway
- 2. OUR GOAL,MISSION AND QUALITY POLICY OUR GOAL . . . We are committed to build up the confidence of our customers by adopting the modern manufacturing processes involving support of new innovation with optimal usage of assets available with the organisation at competitive price. OUR MISSION & VISION. . . To be the largest and integrated highest railway insert producer in New India and to make rail travel safer and faster. QUALITY POLICY . . . To satisfy the requirement by continuously improving quality management system. * Providing insistent products quality at right time and price. * Effectively and efficiently utilizing Man, Machine, Material, Method and Measurement. * Involving employees to develop by providing adequate training and motivation for continual improvement of work place and process.
- 3. About Patil Group & KFCPPL RT 6901 RT 381 ACTIVE COMPONENTS AND CUSTOMERS Ribbed Base plate- 4 Hole Ribbed Base plate- 2 Hole Certification: ISO9001:2015
- 4. TEAM MEMBERS:- TEAM FACILATOR:- ABOUT TEAM S.J. SINGH MADHUBAN SINGH RK REDDY AKASH MARTHA BINAY BEHRA N RAKESH KUMAR SUBHASIS MALLICK DIPAK NAHAK AVISHEK ANAND
- 5. QUALITY CIRCLE PROFILE QUALITY CIRCLE STARTS March-2021 PROJECT NO. 7 STARTING DATE 01-03-2021 COMPLETION DATE 30-06-2021 MEETING DAY Daily MEETING TIME 10.00 AM AREA OF WORKING ARPA-450 & ARPA-300 Molding line. DAILY FOLLOW UP AND REIVEIW We are conducting daily meeting at 10 am to review following day rejection.Based on that we will analyse and take preventive actions with the areas assigned person.
- 6. Quality Circle 12 steps Approach
- 7. 1.IDENTIFICATION OF PROBLEM S. No Work Related Problems A B C 1 RT 381 Rejection A 2 Sand drop & mold break A 3 RT 6901 Insert high rejection (JAN-2020) A 4 Grinding and Finishing of RT 6901 Insert C 5 High spillage sand A 6 High manufacturing cost C 7 High Break down rate B 8 Man Power Attrition rate A 9 Space constraints C 10 Mould Box Repair A 11 Insert broken at customer end A 12 Flash Problem A 13 Mould Break Rejection A 14 Reduction in other Melting Cost A 15 Reduction in Hoist Break down A 16 RT 6901 Insert high rejection (JAN-2021) A A : Min Involvement of Other Dept. for solving them B : Involvement of Other Dept. C : Management involvement may be needed in implementing the solution A B C A B C 0 5 10 15 PROBLEMS IN A,B AND C CATAGORY Number of Problems Identified by brainstorming: 16 QC team will work on “A” category problems
- 8. 2.SELECTION OF PROBLEM S. No Work Related Problems SJ SINGH MADHUBAN BINAYA RK REDDY PRASHANTH RAKESH SUBHASIS AKASH Total 1 Sand drop 10 10 10 10 10 10 7 10 77 2 Man Power Attrition rate 9 9 6 6 8 7 8 8 61 3 Reduction in other Melting Cost 9 8 7 6 6 7 7 7 57 4 High spillage sand 7 6 6 8 6 8 6 4 51
- 9. Sand drop Mold break Cold Shrinkage Mis match Short pour -8144 1856 11856 21856 31856 41856 51856 61856 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 80.00% 90.00% 100.00% 27309 23519 4314 4990 1548 176 44.15% 82.17% 89.15% 97.21% 99.72% 100.00% Analysis from January to may FREQUENCY CUM % DEFECTS QUANTITY 3.DEFINING THE PROBLEM Problem Statement:- Higher Sand drop rejection in ARPA -450 & ARPA -300 molding line is 1.42% in March-2021. As shown in above pareto analysis chart from January to May S/D and M/B holds the more than 80% of rejection.
- 10. 3.DEFINING THE PROBLEM A Sand Drop is a casting defect due to the loss of a portion of sand from the core or other overhanging section.
- 11. Impact of Problem Objective Setting To Reduce 3.DEFINING THE PROBLEM The loose sand that falls into the cavity will also cause a dirty casting surface, either on the top or bottom surface of the casting, depending upon the relative densities of the sand and the liquid. Due to this the casting get rejected and customer satisfaction decreased. Rejection due to sand drop. To Increase To produce good quality casting with increase productivity.
- 12. Process flow diagram:- Well prepared green sand Bottom box mold prepare Top box mold prepare Setting of core into mold cavity Making pouring cup and venting the mold Place top box parallel & put two guide pin Prepared box send to pouring line Clamp the top & bottom box in cross Clean slag from the passage of ladle during pouring Pouring De-gassing Open clamp and send to shake out Bunch shift to De- gate area Empty box send to line again The bunch hammered and send for shot- blasting After shot blast inserts are sent for 1’st stage check End Detection of Problem during 1ST stage rejection check 3.DEFINING THE PROBLEM Problem generated area
- 13. 4.ANALYSIS OF THE PROBLEM Understanding the current situation:- As shown in above graph from January to March sand drop rejection increases from 0.98% to 1.42%. Jan/21 Feb/21 Mar/21 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 6326 7251 8316 0.98% 1.16% 1.42% QC PRJT SD &MB SAND DROP SD% MONTH QUANTITY
- 14. S.NO POSSIBLE CAUSES CATAGORY 1 Loose mounting of cavity METHOD 2 Improper Cavity parting line radius METHOD 3 Improper Pattern alignment on table METHOD 4 Misalignment of cope and drag MAN/MACHINE 5 Dry sand MACHINE 6 Low mould hardness MAN 7 Low GCS MACHINE 8 Mold release MAN 9 Improper Core Dimensions MAN 10 Smooth Box transfer MACHINE 11 Improper box clamping MAN 12 Improper Core Placing MAN 13 Traceability of Heat code MAN 14 Improper leveling of Lifting pins MAN/MACHINE 15 Improper De- slagging MAN/MATERIAL 16 Empty mold box not cleaning MAN 17 Pallet not cleaning MAN 18 Sand fusion METHOD B R A I N S T O R M I N G 5. IDENTIFICATION OF CAUSES
- 15. Machine Man Material Method Ishikawa Diagram 5. IDENTIFICATION OF CAUSES Improper leveling of Lifting pins SAND DROP Loose mounting of cavity Improper Pattern alignment on table Low GCS Improper Core Dimensions Mold release Low mould hardness Improper Cavity parting line radius Improper box clamping Traceability of Heat code Improper Core Placing Dry sand pallet not cleaning Empty mold box not cleaning Sand fusion Misalignment of cope and drag Improper leveling of Lifting pins Improper De- slagging Smooth Box transfer Misalignment of cope and drag Measurement
- 16. CAUSE NO Possible causes Standard Actual Validation 1 Loose mounting of pattern cavity Pattern cavity should be always tight and looseness not allowed. Verified and observed ok Invalid 2 Improper Cavity parting line radius Proper parting line radius should be maintained. Minimum radius is R2. Verified and observed that sometimes the radius found broken. Valid cause 3 Improper Pattern alignment on table Pattern plate should be fitted parallelly on table Observed and found ok Invalid 4 Misalignment cope and drag Basic clearance i.e. 0.2mm should be maintained between closing pin and mould box bushes. Observed and found ok Invalid 5 Dry sand Proper cleaning of pattern and the mold should be done to avoid dry sand of every box. Observed and found ok Invalid 6 Low mould hardness Mould hardness should be maintained 85MHN and above. Verified and observed ok Invalid 7 Low GCS GCS should be maintained 1360gm/cm ² to 1500gm/cm ² . Verified and observed ok Invalid 8 Improper Core Dimensions 0.3 MM clearance between pattern print dia and core print dia and 0.6 MM clearance between core length and cavity print length. Verified and observed that sometimes variation found in the dimension. Valid cause 9 Smooth Box transfer After the closing of mould box, the boxes should smoothly transfer to pouring line and don’t touch each other during transfer. Verified and observed ok Invalid Validation Chart 5. Identification of Causes
- 17. Validation Chart 5. Identification of Causes CAUSE NO Possible causes Standard Actual Validation 10 Improper box clamping Clamping should be done diagonally and with equal force at both end and only cotton waste will be used for clamping. Observed and found that some times due to un-available of cotton waste clamping done with rejected hand-gloves. Valid cause 11 Improper Core Placing During the placing of core in core print ,the pattern print lock and core print lock should match properly. Observed and found that some times, the core print lock and pattern pin lock does not match. Valid cause 12 Traceability of Heat code Required amount of fevi quik should be used to paste the plastic numbers. Verified and observed ok Invalid 13 Improper leveling of Lifting pins 4-lifting pin should always be levelled . Verified and observed ok Invalid 14 Maintain proper sand hopper level for better sand quality purpose. Hopper level should be maintained minimum 80%- 85% Observed and found below 40% of sand hopper level due to unavailable of silica sand. Valid cause 15 Improper De-slagging After treatment of liquid metal slag should be properly clean by using slag powder with the spoon Verified and observed ok Invalid 16 Empty mold box not cleaning After knock-out all cope and drag boxes should be clean properly. Verified and observed ok Invalid 17 pallet not cleaning Pallet trolley cleaned properly before placing prepared mould box. Verified and observed ok Invalid 18 Sand fusion Pouring temperature should be maintain 1380ºC to 1410ºC . Verified and observed ok Invalid
- 18. 6. ROOT CAUSE ANALYSIS Cause 1 Cause 2 Cause 3 Cause 4 Cause 5 Improper Cavity parting line radius Improper Core Dimensions Improper Core Placing Not Maintaining proper sand hopper level Improper box clamping 1st WHY? M-seal used for radius making removed Core box not cleaning and sand not ramming properly. Due to core print not match with pattern print Not adding new sand in time Box over clamped 2nd WHY? Due to repeated jolting vibration. Lack of awareness Operator not placed core properly Required amount of new sand not available Packing provide between box and clamp not maintained properly 3rd WHY? ---- ---- Lack of awareness about the process. ----- Lack of awareness about the process.
- 19. 7.DATA ANALYSIS With the Help of :- Team member ,Team Leader, Supervisors. S.NO Root cause Effect Suitable Suggestion For Counter Action 1 Due to repeated jolting vibration. Mold parting line edge breakage M-seal checking frequency defined and updated in daily check list 2 Lack of awareness Core print area sand will fall on cavity profile. Proper training given about the process Brainstorming
- 20. S.NO Root cause Effect Suitable Suggestion For Counter Action 3 Lack of awareness about the process core print area mold breakage fixed and trained specific person for core placing & alternative person get trained at the time of absent of the existing core setter. 4 Required amount of new sand not available Sand cooling not done properly and sand become dry due to high temperature ------ 5 Lack of awareness about the process. box side walls stacked sand falls on mold cavity Diagonally clamping should be done. 7.DATA ANALYSIS Suitable Suggestion For Counter Action :- 5
- 21. 8.DEVELOPING SOLUTIONS ACTIONS AGAINST ROOT CAUSE Sr.no Valid cause Root cause Action Responsible Target date Status 1 Improper Cavity parting line radius Due to repeated jolting vibration. M-seal checking frequency defined and updated in daily check list. DIWAKAR & BINAY BHUSAN -- DONE Parting line radius
- 22. ACTIONS AGAINST ROOT CAUSE Sr.no Valid cause Root cause Action Responsible Target date Status 2 Improper Core Dimensions Lack of awareness Proper training given about the process Diwakar sethi & Avay pradhan NA Regular monitoring Going on 8.DEVELOPING SOLUTIONS Core box length Core box Flat dia Core box round dia Core round diameter Core flat diameter Core length
- 23. ACTIONS AGAINST ROOT CAUSE Sr.no Valid cause Root cause Action Responsible Target date Status 3 Improper Core Placing Lack of awareness about the process. We fixed and trained specific person for core placing & alternative person get trained at the time of absent of the existing core setter. Deepak Nahak & Avisek anand -- Regular monitoring Going on 8.DEVELOPING SOLUTIONS Core placing video
- 24. ACTIONS AGAINST ROOT CAUSE Sr.no Valid cause Root cause Action Responsible Target date Status 4 Maintain proper sand hopper level Required amount of new sand not available We requested management to provide new sand in time. Ram Singh -- Regular monitoring Going on 8.DEVELOPING SOLUTIONS
- 25. ACTIONS AGAINST ROOT CAUSE Sr.no Valid cause Root cause Action Responsible Target date Status 5 Improper box clamping Lack of awareness about the process. Diagonally clamping should be done. Deepak Nahak & Avisek anand -- Regular monitoring & training going on. 8.DEVELOPING SOLUTIONS Clamping video
- 26. 9. FORESEEING PROBABLE RESISTANCE FORSEEING THE PROBLEM SR NO Valid cause Root Cause ACTION RESISTANCE PROPOSED SOLUTION Man Quality Tooling Safety 1 Improper Cavity parting line radius Due to repeated jolting vibration. M-seal checking frequency defined and updated in daily check list. Not found Not found Not found Not found - 2 Improper Core Dimensions Lack of awareness Proper training given about the process Not found Not found Not found Not found - 3 Improper Core Placing Lack of awareness about the process. We fixed and trained specific person for core placing. If any of them are absent then we will train the new person and replaced that person. Continuous follow up taken by molding supervisor. Not found Not found Not found Not found - 4 Maintain proper sand hopper level Required amount of new sand not available We requested management to provide new sand in time. Not found Not found Not found Not found - 5 Improper box clamping Lack of awareness about the process. Proper training given and regular monitoring going on. Not found Not found Not found Not found -
- 27. 10. TRIAL IMPLEMENTATION & CHECK PERFORMANCE Sr. No VALID CAUSE ROOT CAUSE ACTION Trail 1 Trail 2 Trail 3 Trail 4 Trail 5 A Shift B Shift A Shift B Shift A Shift B Shift A Shift B Shift A Shift B Shift 1 Improper Cavity parting line radius Due to repeated jolting vibration. M-seal checking frequency defined and updated in daily check list. Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced 2 Improper Core Dimensions Lack of awareness Proper training given about the process Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced 3 Improper Core Placing Lack of awareness about the process. We fixed and trained specific person for core placing. If any of them are absent then we will train the new person and replaced that person. Continuous follow up taken by molding supervisor. Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced 4 Maintain proper sand hopper level Required amount of new sand not available We requested management to provide new sand in time. Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced 5 Improper box clamping Lack of awareness about the process. Proper training given and regular monitoring going on. Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced Defect reduced
- 28. Jan-21 Feb -21 Mar-21 Ap r-21 May -21 Ju n-21 Jul-21 Aug-21 Sep -21 2.62% 1.99% 2.30% 2.28% 2.23% 1.88% 1.71% 1.87% 1.73% 1.07% 1.16% 1.51% 0.78% 0.63% 0.90% 0.81% 0.87% 0.72% Jan-21 Feb-21 Mar-21 Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 3.00% 2.33% 2.40% 2.44% 2.73% 2.57% 2.10% 2.68% 2.05% 0.88% 1.11% 1.29% 0.94% 0.89% 1.00% 0.84% 1.08% 0.83% As shown in above two charts the details comparison between ARPA-450 and ARPA-300 LINE Here we compared sand drop against the total rejection from the month JANUARY to SEPTEMBER. ARPA 450 ARPA 300 10. TRIAL IMPLEMENTATION & CHECK PERFORMANCE
- 29. Jan-21 Feb-21 Mar-21 Apr-21 May-21 Jun-21 Jul-21 Aug-21 Sep-21 3.00% 2.33% 2.40% 2.44% 2.73% 2.57% 2.10% 2.68% 2.05% 0.88% 1.11% 1.29% 0.94% 0.89% 1.00% 0.84% 1.08% 0.83% In ARPA-300 Machine condition is not good and in July we had not considered the rejection quantity as we run the 14-cavity pattern as trial basis. In August 14-cavity pattern full production in ARPA-300 line so, the rejection quantity is high. ARPA 300 10. TRIAL IMPLEMENTATION & CHECK PERFORMANCE
- 30. 0 1000 2000 3000 4000 5000 6000 7000 8000 9000 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 6326 7251 8316 3407 2009 4340 4220 5581 5022 0.98 1.16 1.42 0.83 0.71 0.93 0.82 0.95 0.77 In may one shift running because of man power not available due to covid-19. Project start OVERALL SAND DROP REJECTION OF BOTH ARPA-450 AND ARPA-300 LINE FRON JANUARY TO SEPTEMBER 2021 10. TRIAL IMPLEMENTATION & CHECK PERFORMANCE Continuous Monitoring is going on…………. JAN MAR APRIL MAY JUNE JULY AUG SEPT FEB
- 31. 11.REGULAR IMPLEMENTAION Sr. No. Valid cause Actions Control points Updated Document 1 Improper Cavity parting line radius M-seal checking frequency defined and updated in daily check list. 1.Cope and drag plate pattern parting line radius and stem parting line radius should be observed carefully. 2 Improper Core Dimensions Proper training given about the process 1.Core print diameter and length not overcome below specification 2.Round dia-29 MM MAX 3.Flat side dia-30.8 MM MAX 4.Total length-102 MM MAX 3 Improper Core Placing We fixed and trained specific person for core placing. If any of them are absent then we will train the new person and replaced that person. Continuous follow up taken by molding supervisor. 1.Core print and pattern print lock will match during placing of core & avoid over length core. ----------------------- 4 Maintain proper sand hopper level We requested management to provide new sand in time. 1.Minimum 50-60 Tons of sand should be available to avoid dry sand. ----------------------- 5 Improper box clamping Proper training given and regular monitoring going on. 1.Uniform clamping should be done in diagonally 2.Always use cotton for tighten the clamp. 3. Packing provide between box and clamp maintained properly.
- 32. 12. Follow up & Review Presentation skill improved Self confidence increased Team spirit developed Communicatio n skill improved Computer knowledge improved INTANGIBLE BENEFITS TANGIBLE BENEFITS 5Why Analysis PDCA Cycle Ishikawa Diagram Sand drop rejection reduced from 1.42% to 0.82%. As rejection reduced productivity increased.
- 33. 12. FOLLOW UP & RE-VIEW Continuous Monitoring is going on………. PLAN ACTUAL STEPS MARCH APRIL MAY JUNE JULY WEEK-1 WEEK-2 WEEK-3 WEEK-4 WEEK-1 WEEK-2 WEEK-3 WEEK-4 WEEK-1 WEEK-2 WEEK-3 WEEK-4 WEEK-1 WEEK-2 WEEK-3 WEEK-4 WEEK-1 WEEK-2 WEEK-3 WEEK-4 1.Identification of work related Problem 2.Selection of Problem 3.Define the Problem 4.Analyse the Problem 5.Identification of causes 6. Find out the root cause 7.Data Analysis 8.Devloping solution 9.Foreseeing Probable Resistance 10.Trial Implementations & Check Performance 11.Regular Implementation 12.Follow-up & Review
- 34. Thank You Any Questions Please......