Brainstorming- Foundry Unit to achieve the quality
- 1. BRAINSTORMING Recurring Process Failure- Foundry Unit
- 2. Problem Statement Our manufacturing process is experiencing recurring failures like Dimension failure of the product , Increase downtime that are impacting productivity, quality, and overall efficiency. the problems persist, leading to increased WIP, higher production costs, and compromised product quality.
- 3. Brainstorming MAN MACHINE MATERIAL 1. Lack of training - Operators may not be adequately trained. 2. Negligence - Carelessness or inattentiveness during operations. 3. Fatigue - Workers may be tired, leading to errors. 4. Miscommunication - Poor communication among team members. 5. Non-compliance - Workers not following standard operating procedures. 6. Inadequate supervision - Insufficient oversight of processes. 7. Lack of motivation - Low employee morale affecting performance. 8. Human error - Mistakes made unintentionally by workers. 9. Resistance to change - Employees not adapting to new processes or technology. 1. Equipment wear and tear - Machines deteriorate over time, affecting performance. 2. Insufficient preventive maintenance - Lack of regular maintenance leading to breakdowns. 3. Obsolete technology - Using outdated machines that are less efficient. 4. Calibration errors - Machines not properly calibrated, leading to inaccurate output. 5. Overloading equipment - Machines being used beyond their capacity. 6. Frequent breakdowns - Repeated equipment failures disrupting processes. 7. Poor machine setup - Incorrect setup of machines leading to process errors. 8. Inconsistent power supply - Fluctuations in power affecting machine performance. 9. Inadequate spare parts - Lack of necessary spare parts causing delays. 10. Improper machine operation - Machines not being used as intended. 1. Low-quality raw materials - Using substandard materials affecting output quality. 2. Material shortages - Interruptions in material supply causing delays. 3. Material contamination - Contaminants in materials causing defects. 4. Inconsistent material properties - Variations in material properties leading to inconsistency. 5. Improper storage of materials - Materials not stored correctly, leading to degradation. 6. Supply chain disruptions - Issues with suppliers causing delays or quality issues. 7. Uncontrolled inventory - Poor inventory management leading to material shortages or surpluses. 8. Mixing incompatible materials - Using materials that should not be combined. 9. Incorrect material specifications - Using materials that do not meet process requirements.
- 4. Brainstorming METHOD MOTHER NATURE MEASUREMENTS 1. Lack of standardization - Inconsistent processes due to lack of standard procedures. 2. Improper process design - Processes not optimized for efficiency. 3. Inadequate process controls - Insufficient monitoring and control of processes. 4. Complex procedures - Overly complicated methods leading to errors. 5. Lack of documentation - Poorly documented processes leading to inconsistency. 6. Inefficient workflow - Processes not organized in a logical sequence. 7. Outdated methods - Using old methods that are no longer effective. 8. Failure to update processes - Not revising processes in light of new information or technology. 9. Improper sequencing of tasks - Tasks not performed in the correct order. 10. Poor change management - Ineffective implementation of new processes or changes. 1. Temperature fluctuations - Variations in temperature affecting processes or material properties. 2. Humidity levels - High or low humidity impacting material handling or processing. 3. Seasonal variations - Changes in seasons affecting supply chains or process conditions. 4. Environmental contamination - External contaminants affecting process or product quality. 1. Inaccurate instruments - Measurement tools not providing accurate readings. 2. Lack of calibration - Measuring instruments not regularly calibrated. Inconsistent measurement methods - Different methods leading to varying results. 3. Human error in measurement - Mistakes made while taking measurements. 4. Measurement tool wear - Deterioration of tools leading to inaccurate readings. 5. Inadequate measurement frequency - Measurements not taken often enough to ensure process control. 6. Improper measurement conditions - Environment affecting the accuracy of measurements. 7. Poor data recording - Inaccurate or inconsistent recording of measurements. 8. Lack of precision - Measurement tools or methods not precise enough for the required accuracy.
- 5. Cause and Effect Diagram
- 6. Data Validation Sl. No Possible cause Validation 1 Lack of training ✖ 2 Negligence ✖ 3 Fatigue ✔ 4 Miscommunication ✖ 5 Non-compliance ✖ 6 Inadequate supervision ✖ 7 Lack of motivation ✖ 8 Human error ✖ 9 Resistance to change ✖ 10 Equipment wear and tear ✖ 11 Insufficient preventive maintenance ✖ 12 Obsolete technology ✔ 13 Calibration errors ✖ 14 Overloading equipment ✖ 15 Frequent breakdowns ✖ 16 Poor machine setup ✖ 17 Inconsistent power supply ✖ 18 Inadequate spare parts ✖ 19 Improper machine operation ✖ 20 Low-quality raw materials ✔ 21 Material shortages ✖ 22 Material contamination ✖ 23 Inconsistent material properties ✖ 24 Improper storage of materials ✖ 25 Supply chain disruptions ✖ Sl. No Possible cause Validation 26 Uncontrolled inventory ✖ 27 Mixing incompatible materials ✖ 28 Incorrect material specifications ✖ 29 Temperature fluctuations ✔ 30 Humidity levels ✖ 31 Seasonal variations ✖ 32 Environmental contamination ✖ 33 Lack of standardization ✖ 34 Improper process design ✖ 35 Inadequate process controls ✔ 36 Complex procedures ✖ 37 Lack of documentation ✔ 38 Inefficient workflow ✖ 39 Outdated methods ✖ 40 Failure to update processes ✖ 41 Improper sequencing of tasks ✖ 42 Poor change management ✖ 43 Inaccurate instruments. ✖ 44 Lack of calibration ✖ 45 Human error in measurement ✖ 46 Measurement tool wear ✖ 47 Inadequate measurement frequency ✖ 48 Improper measurement conditions ✖ 49 Poor data recording ✔ 50 Lack of precision ✔
- 7. Root cause Analysis and Action Plan Manpower Fatigue Process variation Temperature fluctuations Low-quality raw materials Inadequate process controls Lack of documentation & data recording Lack of precision Difficult to work Obsolete technology Single source vendor Unskilled process owner Unavailability of skill manpower Unavaility of latest testing meter Root cause Hot zone- Furnace, knockout, Degating High worker attrition rate Action Plan 1. Incentive & Motivation to be given 2. less working hour 3. Refreshment drink 1. Technology to be updated such as Sand Plant, Testing equipments. 2. Maintenance trainings to be given all the machine owners 1. Provide digital online display temperature meter to maintain the parameters accordingly 1. Safety stock to be maintain at least 15days. 2. Vendor audit before procurement 1. Training , Motivation & Counseling to be done 1. Recruitment or training to be given 2. QMS training required 1. Required latest digital temperature measurement equipment, Sand testing equipment, metal testing equipment.