Quality circle presentation by yusuff
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The document describes the implementation of quality circles at a manufacturing facility. It introduces quality circles as small groups of frontline workers who meet regularly to identify work improvements. Thirteen quality circle teams were formed across different production areas in the coil shop. Each team selected a project to work on related to their work area, such as reducing leak rates, scrap amounts, or increasing productivity. The teams used problem-solving tools and methods like DMAIC to define issues, measure baseline data, analyze causes, improve processes, and ensure sustained results. Several teams achieved improvements like lowering return bend leak rates from 2.1% to 1.1% and brazing leak rates from 3.0% to 1.0%. Overall the quality circles
Quality circle presentation by yusuff
- 1. QUALITY CIRCLE Systematic Approach To Problem Solving Prepared By Mohamed Yusuff Operations U & A together we can Quality Circle!
- 2. Introduction to Quality Circle • It is a small group of frontline operators who continually control and improve the quality of their work, products and services. • They voluntarily meet together on a regular basis to identify improvements in their respective work areas using proven techniques for analyzing and solving work related problems. • QC Circle activities are carried out as part of Total Quality Management(TQM), Operations U & A together we can Quality Circle!
- 3. QUALITY CIRCLE FROM TQM • Continuous Process Improvement – Kaizen, Six Sigma • Employee Empowerment – Quality Circle • Benchmarking – Legally stealing other people’s ideas • Customer-Supplier Partnerships – JIT concept • Management by fact. Operations U & A together we can Quality Circle!
- 4. WHY WE NEED QUALITY CIRCLE • Its provides an opportunity for members to develop their creative thinking • As the members study and learn together, their full potential is realized • To contribute to the improvement and development of an Organisation. Operations U & A together we can Quality Circle!
- 5. OBJECTVES OF QC • Establishment of a pleasant workplace • Establishment of a state of control • Enhancement of morale • Establishment of sound human relations • Better income • Improvement in Quality Assurance Operations U & A together we can Quality Circle!
- 6. POTENTIAL BENIFITS • Increased productivity • Improved quality of work life • Boost employee morale • Enhances creativity • Improved teamwork • Employee involvement Operations U & A together we can Quality Circle!
- 7. ORIGIN OF QC • The first Quality Circle was organized in 1962, by Japan Nippon Telegraph company. • It was supervised by Mr.Deming and Dr.Juran. • Japan Started JUSE (Union of Japan Scientists and Engineers) to spread Quality control circle. Operations U & A together we can Quality Circle!
- 8. Asian Productivity Organization • • • • • • • • • • • • Japan South Korea Taiwan Singapore Malaysia the Philippines Hong Kong India, Indonesia Thailand Sri Lanka Pakistan and Vietnam Operations U & A together we can Quality Circle!
- 9. QUALITY CIRCLE IN COIL SHOP • In Coil shop Quality Circle successfully started on 30th March 2013. • Total 13 team formed on 24th March 2013. • Booklet and training provided 8 th April 2013. • Currently successfully continuing the Improve phase. Operations U & A together we can Quality Circle!
- 10. QC Team Formation-Coil shop Line/Area Assy Brazing CAC-1 1 Team 13 Members 2 Team 26 Members CAC-2 1 Team 6 Members 1 Team 7 Members AHU 1 Team 9 Members 1 Team 10 Members Chiller 1 Team 10 Members 1 Team 9 Members Tubing Coating 2 Team 16 Members 1 Team 9 Members 1 Team 10 Members Resistec Total Team :13 Operations U & A together we can Quality Circle!
- 11. QUALITY CIRCLE IN COIL SHOP • Assigned Leaders and sub leaders for each team. • Team name selected by each team members • Each team took each project from their own area. Total 13 project in progress. Operations U & A together we can Quality Circle!
- 12. Team list with Project Area Team name Team Leader Sub Leader M/C Shop Success Renji Wassil To Reduce Fin & Cu Tube damages in all stages Current Level is 3 NCN/Month Target- 1 NCN/Month Brazing-1 Rose Riders Girish Manoj To Reduce Return Bend Leak rate below 0.5% Current return bend leak rate is 2.1% Target- 0.5 % 3 Brazing-2 Speed Riders Ilyas Mohsin aalam To Reduce Return Bend Leak rate below 0.5% Current return bend leak rate is 2.1 % Target- 0.5 % 4 M/C Shop Fire Crackers Raj kamal Emilio To Eliminate wrong Coil assembly Current Level is 3 NCN/Month Target- 1 NCN/Month 5 Brazing Seven Star Brazers Varghese Ansar To Reduce Brazing Leak rate Below 1% Current leak rate is 3 % Target - 1 % 6 Parts Perfect Jahangir Mahroof To Reduce InProcess scraps of copper tubes Current scrap is 12 Lbs Target to below 4 Lbs Assy Brazing Bullets Monir Akbar, Sabbir To Reduce InProcess scraps of copper tubes Current scrap is 12 Lbs Target to below 4 Lbs M/C Shop YIPS Express Azziz Blitz ,Iliyas To Increase Per day production by 30% Avg daily production is 11 Target to 14 9 Brazing Courage Abdul Khader Fakrudeen To Reduce Brazing Leak rate Below 1% Current leak rate is 4.6 % Target- 1 % 10 M/C Shop S.N Line 1 2 CAC-1 CAC-2 7 CAC Tube shop 8 AHU Chiller 11 12 13 PSDOS (P ro blem so lving, Develop in g o f skill) Resistec Target description Krishna Current scrap is 1.8 Lbs Erwin,Malick To Reduce In Process scraps of Copper tubes Kumar Jha Target to below 0.5 Lbs Royal Challengers Anas Professional Aquil Hassan To Reduce In Process scraps of Copper tubes Current scrap is 7 Lbs Target to below 4 Lbs Resistec X1 Thaisen Jackson To Improve Efficiency of coating line Current Level is 2 NCN/Month Target- 0 NCN/Month Brazing Chiller Parts&Assy Tube shop Project description Coating Operations U & A Ashraful To Reduce Brazing Leak rate Below 1% ,Ajay Kumar together we can Current leak rate is 3.1 % Target- 1 % Quality Circle!
- 13. GANT CHART-Full Program -Planned Description Intro+ education+ team formation Define phase Training + project assign Measure phase training + data collection+ Brainstorming Analyze(Training+ Pareto chart) Improve Phase(Implementation) Control Phase training+ implement Operations U & A -Completed Plan/ Actual WK-12 WK13,14 WK15,16,17 WK18,19, WK 20-48 WK48-52 WK-52 PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL PLAN ACTUAL together we can Quality Circle!
- 14. ABOUT PROJECTS • Format used – DMAIC Define, Measure, Analyze, Improve & Control • Periodical training & meeting conducted. • Internal meeting conducted by team leaders in work place every month to define their own stage problems. Operations U & A together we can Quality Circle!
- 15. ABOUT PROJECTS • Tools used - Pareto chart - Cause and Effect diagram - FDM(Function Deployment Matrix) - Brainstorming - Check sheets Operations U & A together we can Quality Circle!
- 16. Improvements observed • Each Project working on minimum 2 problems which is to improve on their stage. • Total 32 improvements related to their own stage is in progress. Operations U & A together we can Quality Circle!
- 17. Major improvements Return Bend Leak rate reduction in CAC-1 (Team-Rose riders & speed riders) Brazing Leak reduction in AHU & Applied Coil shop (Team-Seven star brazers, Courage& Royal challengers) Leak rate-2.1% Leak rate-1.1% Action Taken: 1.Check sheet displayed to monitor the leak from every stage. 2.Input Butane pressure regularized by placing adjustable pressure gauge. 3.Practicing Pre heat to reduce oil level in flare.(if found more oil on flares) 4.Continual feed back system by internal operator itself. Leak rate-3.0% Operations U & A Leak rate-1.0% together we can Quality Circle!
- 18. IMPROVEMENTS Location:CAC-1 Brazing Area Team-Rose riders Type: Quality Improvement (Leak rate reduction) Before Improvement N2 IN After Improvement Return bend storage box Return bend storage box Return bend storage box N2 OUT In progress Dust and moisture accumulate on return bend which is stored in box can creates corrosion and cause leak Return bend stored box will arrange and N2 gas will insert in serial to all box, so that external moisture will not enter. Effect on implementation: Return bend leak rate will be reduce 18 Improve Operations U & A together we can Quality Circle!
- 19. IMPROVEMENTS Location: CAC2 Machine shop Team- Fire Crackers Type: Productivity Improvement Before Improvement After Improvement Photos attached on next slide Photos attached on next slide Process In progress After Process sheet obtain from scheduling, in coil shop there exist manual editing for coil size and hair pin Qty which creates wrong coil due to wrong entry. With the help of Scheduling process sheet changed with required data to produce coil without manual editing Effect on implementation: Wrong coil assembly will reduce 19 Improve Operations U & A together we can Quality Circle!
- 20. Process sheet-Current Operations U & A together we can Quality Circle!
- 21. Modified Process sheet Operations U & A together we can Quality Circle!
- 22. IMPROVEMENTS Location: AHU Brazing Area Team-Royal Challengers Type: Quality Improvement (Leak rate reduction) Before Improvement Gas pressure was not proper due to flux blockage ,lengthy hose and hose frequent damage. After Improvement Brazing hose arranged and standardized by extending steel pipe up to brazing stage to make hose length short and constant gas pressure. Effect on implementation: Constant gas pressure obtain thus leak rate will reduce 22 Improve Operations U & A together we can Quality Circle!
- 23. IMPROVEMENTS Location: Resistec Team-Resistec 11 Type: Productivity Improvement Before Improvement Coils were coated by keeping on drums. Coating done on one face and hold it for drying about 6 hrs and then coating on the opposite side.. After Improvement Moving trolley made with hanging system, Now coils will coat/spray and directly move to the oven without lifting the coils Effect on implementation: Process time reduction with improved Quality 23 Improve Operations U & A together we can Quality Circle!
- 24. IMPROVEMENTS Location: Chiller Team-Courage Type: Productivity and Quality Improvement Before Improvement After Improvement In Progress During Crimping for valve insertion in Evap coil, there no flare exist, which cause difficulties in brazing tends to leak occur Design of crimping tool need to alter by cutting a slot in tool of flare rest area. Effect on implementation: Process time reduction with improved Quality 24 Improve Operations U & A together we can Quality Circle!
- 25. IMPROVEMENTS Location: CAC Tube Shop Team-Perfect Type Productivity and scrap reduction Improvement Before Improvement In straight tube cutting machine roll end tube not able to cut due to machine limitation After Improvement Manual cutting machine ordered so as to cut roll end tube at instant, by this minimum length can be cut according to our process requirement. Effect on implementation: Cu tube Scrap due to roll end will totally eliminate. 25 Improve Operations U & A together we can Quality Circle!
- 26. Various improvements • CU Scrap reduction by introducing – Tube clamping system to standardize the cutting angle. • Process improvement – AHU brazing carried out in sequence table to increase productivity Operations U & A together we can Quality Circle!
- 27. Operations U & A together we can Quality Circle!