Sample project-Quality Circle
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The quality circle aims to reduce leaks from the coil assembly process in the brazing area. They identified work distribution as a major cause of leaks and improved it by distributing work according to coil model and brazing type. Data was collected before and after the improvement, which showed reduced leak rates and improved production yields, meeting the quality circle's goals.
Sample project-Quality Circle
- 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 L P 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 L 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 S E L P ,, ,, ,, ,, 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 L 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 L P Measure Operations U & A together we can Quality Circle!
- 20. ANALYZE E L P PHASE M A S 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 L 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 L P 14 M A S 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 L 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 L 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 L 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 L 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 L 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 L 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 L 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 L 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 L P 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 A S E L P 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 L P 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 L P 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 L P 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 L 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 L P 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 L P together we can Quality Circle!