020

AWARENESS

Press team 7QC Tools

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1,Check sheet
2,Pareto chart
3,Cause & Effect diagram
4,Stratification
5,Histogram
6,Scatter diagram
7,Control chart
Press team 7QC Tools
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PRESS SHOP - STAMPING PANELS REJECTION & REWORK DATA ANALYSIS

Check sheet
MONTH :April to July
PRODN NATURE OF R/W SCRAP
S.NO SHIFT PART NO PART NAME MDL LINE S INCH CAP OPERATOR FAILURE MODE CAUSE COUNTER MEASURE REMARKS
DATE R/W QTY QTY
1 30.04.05 B 71642 W/HSE INR L/R EMXI HPS C GPK MS SRIDHAR CRACK 8 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
2 30.04.05 A 71232 FRT PLR INR UPR LH EMXI HPS B PR RD PURUSHOTHAMAN CRACK 7 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
3 01.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B MM GR KOKILESWARAN DAMAGE HAMMERING 12 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
4 01.05.05 B 64376 DASH LWR CTR LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 15 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
5 03.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B PR RD PURUSHOTHAMAN NECK BUFFING 27 DIE PROBLEM DIE CORRECTION LINE REJECTION
6 01.06.05 C 64571/81 F/APRON OTR L/R LCI HPS B MM GR KOKILESWARAN SMUDGING 10 DIE PROBLEM DIE CORRECTION LINE REJECTION
7 04.06.05 A 77156/66 RR DR UPR L/R EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 10 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
8 04.06.05 A 65722 SD MBR RH TBI HPS C GPK MS SRIDHAR SCRATCHES BUFFING 10 CHROME WORN OUT DIE CORRECTION LINE REJECTION
9 05.05.05 A 64511 F/APRON INR L/R LCI HPS B GPK KB MANJUNATHAN SMUDGING GRINDING 10 3 DIE PROBLEM DIE CORRECTION LINE REJECTION

Purpose: Data collection

10 05.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
11 05.06.05 A 65782 EXTN RR FLR FRT LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 4 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
12 05.07.05 B 76231 FR DR H/FACE L/R LCI HPS C MM VR SENTHILKUMAR DAMAGE HAMMERING 20 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
13 06.07.05 C 69111 PNL BACK LCI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 6 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
14 13.07.05 B 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 12 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
15 13.05.05 C 71372 ROOF SD INR LH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 25 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
16
17
18
13.04.05
13.06.05
19.06.05
A
B
A
71586
71586
77231
Data should be collected
C/LAMP HSE RH
C/LAMP HSE RH
RR DR H/FACE L/R
TBI
TBI
EMXI
HPS B
HPS B
HPS B
MM
PR
PR
GR KOKILESWARAN CRACK
RD PURUSHOTHAMAN CRACK
RD PURUSHOTHAMAN DAMAGE HAMMERING 22
8
6
DIE PROBLEM
DIE PROBLEM
HANDLING DAMAGE
DIE CORRECTION
DIE CORRECTION
PROPER HANDLING
LINE REJECTION
LINE REJECTION
LINE REJECTION

Accuracy & Adequacy

19 20.07.05 B 69142/52 C/LAMP HSE L/R LCI HPS A GPK MR MAGESH WRINKLES BUFFING 1 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
20 20.04.05 A 77231/41 RR DR H/FACE L/R LCI HPS C PR MS SRIDHAR DAMAGE HAMMERING 4 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
21 22.04.05 B 77118/28 RR DR HORIZANTAL L/R LCI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 20 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
22 22.07.05 B 71632/42 W/HSE INR L/R EMXI HPS C GPK VR SENTHILKUMAR FLANGE CUT GRINDING 4 IMPROPER PROFILE PROPER BLANK LOCATION LINE REJECTION
23 26.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 12 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
24 28.07.05 A 71586 C/LAMP HSE RH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 13 HANDLING DAMAGE PROPER HANDLING LINE REJECTION

Press team 7QC Tools

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Press shop rejection (Rework) data - April to July

Sample format
PRESS SHOP - STAMPING PANELS REJECTION & REWORK DATA ANALYSIS
MONTH :April to July
PRODN NATURE OF R/W SCRAP
S.NO SHIFT PART NO PART NAME MDL LINE S INCH CAP OPERATOR FAILURE MODE CAUSE REMARKS
DATE R/W QTY QTY
1 30.04.05 B 71642 W/HSE INR L/R EMXI HPS C GPK MS SRIDHAR CRACK 8 D/C PERSSURE VARIATION LINE REJECTION
2 30.04.05 A 71232 FRT PLR INR UPR LH EMXI HPS B PR RD PURUSHOTHAMAN CRACK 7 D/C PERSSURE VARIATION LINE REJECTION
3 01.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B MM GR KOKILESWARAN DAMAGE HAMMERING 12 HANDLING DAMAGE LINE REJECTION
4 01.05.05 B 64376 DASH LWR CTR LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 15 HANDLING DAMAGE LINE REJECTION

5 03.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B PR RD PURUSHOTHAMAN NECK BUFFING 27 DIE PROBLEM LINE REJECTION
6 01.06.05 C 64571/81 F/APRON OTR L/R LCI HPS B MM GR KOKILESWARAN SMUDGING 10 DIE PROBLEM LINE REJECTION
7 04.06.05 A 77156/66 RR DR UPR L/R EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 10 SCRAP STICK WITH DIE LINE REJECTION
8 04.06.05 A 65722 SD MBR RH TBI HPS C GPK MS SRIDHAR SCRATCHES BUFFING 10 CHROME WORN OUT LINE REJECTION
9 05.05.05 A 64511 F/APRON INR L/R LCI HPS B GPK KB MANJUNATHAN SMUDGING GRINDING 10 3 DIE PROBLEM LINE REJECTION

10 05.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE LINE REJECTION
11 05.06.05 A 65782 EXTN RR FLR FRT LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 4 HANDLING DAMAGE LINE REJECTION
12 05.07.05 B 76231 FR DR H/FACE L/R LCI HPS C MM VR SENTHILKUMAR DAMAGE HAMMERING 20 HANDLING DAMAGE LINE REJECTION
13 06.07.05 C 69111 PNL BACK LCI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 6 HANDLING DAMAGE LINE REJECTION
14 13.07.05 B 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 12 HANDLING DAMAGE LINE REJECTION
15 13.05.05 C 71372 ROOF SD INR LH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 25 HANDLING DAMAGE LINE REJECTION

16 13.04.05 A 71586 C/LAMP HSE RH TBI HPS B MM GR KOKILESWARAN CRACK 8 DIE PROBLEM LINE REJECTION
17 13.06.05 B 71586 C/LAMP HSE RH TBI HPS B PR RD PURUSHOTHAMAN CRACK 6 DIE PROBLEM LINE REJECTION
18 19.06.05 A 77231 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE LINE REJECTION
19 20.07.05 B 69142/52 C/LAMP HSE L/R LCI HPS A GPK MR MAGESH WRINKLES BUFFING 1 D/C PERSSURE VARIATION LINE REJECTION
20 20.04.05 A 77231/41 RR DR H/FACE L/R LCI HPS C PR MS SRIDHAR DAMAGE HAMMERING 4 HANDLING DAMAGE LINE REJECTION
21 22.04.05 B 77118/28 RR DR HORIZANTAL L/R LCI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 20 SCRAP STICK WITH DIE LINE REJECTION
22 22.07.05 B 71632/42 W/HSE INR L/R EMXI HPS C GPK VR SENTHILKUMAR FLANGE CUT GRINDING 4 IMPROPER PROFILE LINE REJECTION

23 26.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 12 SCRAP STICK WITH DIE LINE REJECTION
24 28.07.05 A 71586 C/LAMP HSE RH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 13 HANDLING DAMAGE LINE REJECTION

Press team 7QC Tools

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Press shop rejection (Rework) data - April to July

Sample format

Rejection at April May June July Total

LINE REJECTION 522 669 1078 215 2484
INHOUSE REJ 12 15 18 8 53
CUSTOMER REJ 2 0 0 0 2
TOTAL 522 669 1078 215 2269

Press team 7QC Tools

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Press shop rejection (Rework) data - April to July

Sample format
Failure mode April M ay June July Total
CRACK 20 12 16 4 52

DAMAGE 161 466 810 137 1574

FLANGE CUT 10 5 28 2 45
FLANGE VARIATION 3 0 0 0 3
HOLE BURR 113 0 0 0 113
HOLE DENT 24 12 41 0 77
LINE MARK 5 0 0 0 5
NECK 10 15 3 15 43
SCRAP MARK 69 101 125 48 343
SCRATCHES 6 14 18 7 45
SMUDGING 15 7 0 2 24
TRIM BURR 46 25 7 0 78
TRIM DENT 0 0 11 0 11
WRINKLES 40 12 3 0 55
FLANGE CRACK 0 0 16 0 16
TOTAL 522 669 1078 215 2484

Press team 7QC Tools

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PARETO CHART
REJECTION- April to July
1600 100 100 100
95
92 92
90
1400

Pareto diagram
86
82 80
1200 77
70
1000 63
60

% OF RISK
800 50
QTY

40
600
30
400
20

Purpose: To under stand vital few

200
10

0 0

issue of the problem to decide

Neck

Flangecut/ Flange
Trim burr/ Trim

crack// Flange

No scratches
No wrinkle /
Scrap mark

Smudging

Line mark
Hole burr

Hole dent

variation
Damage

priority of the issue.

TOTAL
PRODUCT
dent
No Crack /

CHARACTERISTICS
QTY

1574 343 113 95 89 79 77 64 45 5 2,484

Press team 7QC Tools

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Tool no: 2- Pareto diagram
Sample format
PARETO CHART
REJECTION (Rework)- April to July
1600 100 100 100
95
92 92
90
1400 86
82 80
1200 77
70
1000 63
60

% OF RISK
800 50
QTY

40
600
30
400
20
200
10

0 0
Neck

Flangecut/ Flange
Trim burr/ Trim

crack// Flange

No scratches
No wrinkle /
Scrap mark

Smudging

Line mark
Hole dent
Hole burr

variation
Damage

TOTAL
PRODUCT
dent
No Crack /

CHARACTERISTICS
QTY

1574 343 113 95 89 79 77 64 45 5 2,484

Press team 7QC Tools

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3. Cause & Effect diagram

or
Fish bone diagram or
ISHIKAWA diagram or
Diagnostic tool

Purpose: To identify root cause

Press team 7QC Tools
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Cause & Effect diagram

Causes Brain storming should be done
before, cause & effect diagram.

Level:1- All possible causes.

Level:2- Identified major causes.
Level:3- Validated root cause.

Press team 7QC Tools

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Tool no: 3- Cause & Effect diagram

MACHINE Pnl Damage
MAN
*Ejector hitting

Lack of Skill *Die profile hitting

*Die surface damage
*Less shut height
*Operator fatigue *No quality mind
*Shearing plunger mark
Die plunger mark

*Rm damage
*Improper loading
*Pnl big size
*Over stacking
*Damage in previous
operation *Improper stacking
*Pnl falling down

MATERIAL

METHOD
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Tool no: 3- Cause & Effect diagram

Example:1
Panel damage
Why ?
Improper pnl location
Why ?
Difficult to locate the panel
Why ?
More distance between die
and operator
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Tool no: 3- Cause & Effect diagram

Example:2
Panel damage
Why ?
Damage in previous
operation
Why ?
Die surface damage
Why ?
Damaged Raw material
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Tool no: 3- Cause & Effect diagram

Example:4
Panel damage
Why ?
Improper pnl location
Why ?
Difficult Pnl location
Why ?
M/C shut height less
Why ?
M/C design
Press team 7QC Tools
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Tool no: 3- Cause & Effect diagram

Example:3
Panel damage
Why ?
Improper pnl handling
Why ?
Operator fatigue
Why ?
Large size panel loading
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Tool no: 3- Cause & Effect diagram

Example:5
Panel damage
Why ?
Ejector hitting
Why ?
Polyolefin bush worn out
Why ?
Soft material
Press team 7QC Tools
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Stratification
Purpose: To group related factors
compare & under stand depth of
problem

Support tool for cause analysis

Press team 7QC Tools
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Tool no: 4- Stratification

Sample format
JSL
PRESS SHOP - REWORK CONTROL DATA
DAMAGE ITEMS

DAMAGE ANALYSIS - APRIL TO JULY

780

900

800

700

600

500
313

400

300
120

80

200
59

56

50

52

34

30
100

PART NO 71576/86 EMXI 77231/41 LCI 71154/64 LCI 71564 EMXI 64111/21 LCI 64571/81 LCI 71632/42 EMXI 65782 LCI 65538/48 EMXI 69142/52 LCI TOTAL
QTY 780 313 120 80 59 56 50 52 34 30 1574

Press team 7QC Tools

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Tool no: 4- Stratification

Sample format
PRESS SHOP - REWORK CONTROL DATA

CAUSEWISE DAMAGE ANALYSIS - APRIL TO JULY

780

900

800

700

600

500
313

400

300
120

80

59

200

56

50
100

IMPROPER PNL EJECTOR DIE PROFILE IMPROPER P NL DIIIFFICALT

RM DAMAGE OTHERS TOTAL
LOADING HITTING HITTING HANDLING PNL LOCATION
780 313 120 80 59 56 50 1458

Press team 7QC Tools

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Histogram
Purpose: To under stand
frequency distribution
To assess process capability &
to under stand variation
Press team 7QC Tools
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Tool no: 5- Histogram

Sample format
PRESS SHOP MONTHWISE FAILURE CONTROL GRAPH - APRIL TO JULY
MONTH APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR TOTAL

EMXI 200 250 200 170 820

LCI 130 150 158 130 568

TBI 60 79 30 17 186
594

MODELWISE - GRAPH
300

EMXI
250
250
LCI

200 200 TBI

200
NO OF PNLS

170
158
150
150
130 130

100
79
60
50
30
17

MONTH

S HE A RIN G M/ C U P H GRA P H
#REF !

#REF !
1 000
9 00

Press team
U PH

8 00 #REF !
7 00
6 00

7QC Tools
5 00 #REF !
4 00
3 00

1
MO N T H
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Scatter diagram
Purpose: To establish relation ship
between cause or cause and effect

To support cause validation to

establish process parameters
Press team 7QC Tools
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Tool no: 6- Scatter diagram

Sample format
JSL
PRESS SHOP - REWORK CONTROL DATA

CAUSEWISE ANALYSIS - APRIL TO JULY

500

45 0
400
31 3

300
28 0
2 14

200
14 7

100

IMP ROP ER P NL EJECTOR DIE P R OFILE IMP ROP ER P NL DIIIFFICALT

CAUSE RM DAMAGE OTHERS TOTAL
L OADING HITTING HITTING HANDLING P NL LOCATION
QTY 450 313 280 214 147 90 80 1574

P RODN QTY 9856 9645 8951 7542 7214 6583 5462 55253

Press team 7QC Tools

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Tool no: 6- Scatter diagram

71232/42 05000 - Neck
Panel getting neck

Panel scratches

Die surface damage

Burr in Raw material

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Control chart
Purpose: To set limit

Prevention action by timely

correction
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Graph
JSL
PRESS SHOP - REWORK CONTROL DATA
DAMAGE ITEMS

780 DAMAGE ANALYSIS - APRIL TO JULY

900

800

Purpose: A picture is
700

600

500
313

worth more then thousand

400

300
120

80

200
59

56

words 50

52

34

30
100

PART NO 71576/86 EMXI 77231/41 LCI 71154/64 LCI 71564 EMXI 64111/21 LCI 64571/81 LCI 71632/42 EMXI 65782 LCI 65538/48 EMXI 69142/52 LCI TOTAL
QTY 780 313 120 80 59 56 50 52 34 30 1574

Press team 7QC Tools

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Line graph
Purpose: To know the Trend
PRESS SHOP MONTHWISE DAMAGE CONTROL GRAPH - APRIL TO JULY
MONTH APR'05 MAY'05 JUNE'05 JULY'05 AUG'05 SEP'05 OCT'05 NOV'05 DEC'05 JAN'05 FEB'05 MAR'05 TOTAL

EMXI 289 250 230 175 944

LCI 130 200 158 142 630

MXI 0 0 0 0 0
594

DAMAGE ANALYSIS DATA-GRAPH

500

450 EMXI

400 LCI
NO O F P NLS

350
MXI
300 289

250 250
230

200 200
175
158
150 142
130

100

50

0 0 0 0 0

MONTH

S HE A R I N G M/ C U P H GR A P H

Press team
#REF !

7QC Tools
#REF !
1 000
9 00
U PH

8 00 #REF !
7 00
6 00
5 00 #REF !
4 00
3 00

1
MO N T H
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Bar graph
Purpose: To compare
JSL
PRESS SHOP - REWORK CONTROL DATA
DAMAGE ITEMS

DAMAGE ANALYSIS - APRIL TO JULY

780

900

800

700

600

500
313

400

300
120

80

200
59

56

50

52

34

30
100

PART NO 71576/86 EMXI 77231/41 LCI 71154/64 LCI 71564 EMXI 64111/21 LCI 64571/81 LCI 71632/42 EMXI 65782 LCI 65538/48 EMXI 69142/52 LCI TOTAL
QTY 780 313 120 80 59 56 50 52 34 30 1574

Press team 7QC Tools

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Pie chart
Purpose:To know the %
distribution
PRESS SHOP MONTHWISE DAMAGE CONTROL GRAPH - APRIL to JULY
MONTH APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR TOTAL
EMXI 254 253 147 90 744
LCI 157 201 322 104 784
TBI 25 5 12 4 46
594

TBI, 25, TBI, 12,

6% 2% 4, 2%
TBI, 5, 1%
EMXI,
147, 31%

LCI, 201, 90, 45%

44%
EMXI, EMXI,
LCI, 157, 104, 53%
254, 253, 55%
36% 58%

LCI, 322,
67%

Press team 7QC Tools