COMPANY INTRODUCTION

Q C D D M S E
S
Company Name:
Motherson Automotive Technologies & Engineering
( A division of Motherson Sumi Systems Ltd. )
Company Address:
Plot No.196, Sec-4, IMT Manesar, Gurgaon, Haryana.
Postal Code-122050.
Established: Plastic Injection Molding.
October, 2005 Plastic Blow Molding.
Painting of Molded
parts.
Door trim & Console
Manufacture Automotive parts Such as Door Trim,Assembly.
Air Intake Manifold etc.

MASK NOZZLE CONSOL AIR INTAKE DOOR

H/L DEFROSTER E MANIFOLD TRIM
IM (230 T TO 2400 T)
Our Delighted & Admiring Machine Installed: (Capacity)
BM (05 L TO 110 L)
Customer:

INJECTION MOULDING BLOW MOULDING

2
 TEAM INTRODUCTION
Q C D D M S E
Function S
Coordinator 1. To Provide management support. Circle Profile
Mr. Amit Suhag 2. To ensure the smooth execution
of project. Project Launch Date : 02-Jun-16
Project No : 3
Function
Facilitator 1. To monitor & facilitate Attendance : 97%
Mr. Manoj Circle progress.
Department : Production

Function Meeting Day & Duration : Every Saturday & 1 Hrs.

Leader 1. Plan & scheduling circle activity.
Mr. Anurag 2. To arrange jobs to circle members.
Dixit 3. Chair Meeting & prepare MOM.
4. Summarization of report.

Membe
r Function
1. Data collection.
2. Implement job assigned.
3. Implement
countermeasure &
Shubham Sandeep Shyam Sanjeet verification.
1. To ensure good quality parts are produced.
Member Commitment
2. Develop & strengthen quality minds to meet customer satisfaction.
Meaning of Lakshya
L - Learn A – Action K- Knowledgeable S- Standardization
H– Habit Y- Youth A- Achievement
3
 IDENTIFICATION & CATEGORISATION OF WORK
RELATED PROBLEM
Q C D D M S E
S
S.NO. PROBLEM CATEGORY S.NO. PROBLEM CATEGORY
1 Bezel Front lock crack. A
25 IMM-29 MHI-850T High oil temperature. B
2 BMM-10 High oil temperature. B
26 IMM-29 MHI-850T Oil leakage from clamp B
3 Dimension NG in pipe air suction YP-8. A manifold.
4 Dusty bin at bin area. B 27 IMM-29 Robot not in operation. B
5 Excess heater failure in IMM. A 28 IMM-35 JSW 850T Oil leakage from valves and B
blocks.
6 Failure of Wittmann robots W drive. B
29 IMM-36 High oil temperature. B
7 Gap in roof rail. A
Glass cover YN-4 Lock broken at 30 IMM-48 Nigata 450T Robot communication error. B
8 customer end. A 31 IMM-64 Frequent refilling issue. B
9 Heater fused due to material leakage. B 32 IMM-68 Toshiba 350T back flow. B
10 Heating alarm in Haitian machines. B 33 IMM-73 Converter fault. B
11 High absenteeism of manpower. C 34 IMM-74 High breakdown in chiller. B
12 High breakdown at M/c No. BMM-06. B 35 IMM-77 Haitian-1300T High temp. of motor drive. B
13 High failure of blow moulding Granulator. B 36 IMM-81 QMC not clamping. B
14 High Material Leakage at M/c No. IMM- B 37 Low productivity of D.C.V YP-8. A
018.
38 Lubrication error in Haitian machines. B
15 High mould changeover time. A
39 N.D YP-8 welding miss. A
16 High rejection in Garnish YE-3. A
40 Panel ( K ) Clip miss at customer end. A
17 High rejection of console YBA at assembly A
line. 41 Punchout in Nozzle defroster versa. A
18 High rejection of Duct Side Demester RH. A 42 RM shortage in plant. B
19 High wastage of food in canteen area. C 43 Rough surface at shop floor. C
20 High wastage of spray in mould. A 44 Tank Versa color variation. A
21 High Water leakage at M/c No. BMM-02. A 45 Ultrasonic Welding high breakdown and cost. B
22 IMM -76 Water leakage from water B 46 Water leakage from main cooling line. B
batteries .
47 Welding NG in pipe air cleaner suction YBA. A
23 IMM-18 MHI-850T Locking drop. B
48 Wrong assembly of Hose pipe in tank. A
24 IMM-72 Safety gate not working properly. B
3 “Better to understand little than to misunderstand a lot.”
 IDENTIFICATION & CATEGORISATION OF WORK
RELATED PROBLEM
Q C D D M S E
S
3
C =3 0 2
7
2
5

2 1
A = 18 0 8

No.
1
5

1
0

5 3
B = 27
0
A B C
Category

A Type: Problem which can be solved with no / little help of other department.

B Type: Problem which can only be solved with help of other department.

C Type: Problem which can only be solved by management sanction.

“Better to understand little than to misunderstand a lot.”

4
SELECTION OF PROBLEM
Q C D D M S E
S

Talash Team working

WE
35 3 Kriti Team working 3 3
26 Sangharsh Team working 2
30 1 2 0
25 2 1 2 2 1 9
20 17 1
15 1 1 1 8 0 0 8 11
17 7 7
10 3 2 3
5
0

To Reduce Rejection Of Console YBA At Assembly Line.

5
 What Is Console YBA?
Q C D D M S E
S
Console YBA is the assembly component for newly launched car from Maruti Suzuki named
Maruti Suzuki Vitara Brezza. Console is a storage compartment or cabinet which gives
comfort to user and it serves the purpose of an armrest and aesthetic housing for the cup
holder and
Slider hand brake
Lower Cover assembly.
Box Base Uppe Lower
Hinges Latch Guide Rail
Substrat floor floor floor r Substrate
e Consol Consol Consol Substrat R
e e e e

Mountin
g Base
Armrest

Rubbe
r
Stoppe
r

Felt Pad

Round Flat Slide Slide Rubber Damper

Shaft EPDM pad Hinge Latch
head head r r Stopper plate
Spring Spring
Screw Scre Spring Spring Spring
6
w 2 1
ACTIVITY PLAN
Q C D D M S E
S
Prime Plan Jun-16 Jul-16 Aug-16
QC Tools
Sr. No. Activity / Week /Technique Responsibili Vs
ty Actual
W1 W2 W3 W4 W1 W2 W3 W4 W5 W1 W2 W3 W4

Identification & Plan

1 Categorisation of Work Check sheet Sanjeet
related problem Actual
2 Check sheet Sandeep Plan
Selection of problem /Rating Actual
Flow Plan
3 Define of the problem Chart/Gantt Sanjeet
Chart Actual
Pie Plan
4 Analysis of the problem Chart/Pareto Shubham
graph Actual
5 C & E Diagram Sandeep Plan
Identification of causes
,Check sheet Actual
6 Finding out the Why-Why Anurag Plan
root cause Actual
Checksheet, Plan
7 Data analysis Brainstorming, Sandeep Actual
8 Check sheet / Shyampal Plan
Developing solution 5W-1H Actual
9 Foreseeing probable Check sheet, Manoj Plan
Resistance Brainstorming Sharma Actual
10 Trial , Implementation Check sheet Sandeep Plan
and check performance Actual
11 Regular implementation SOP, Check Shyam Plan
sheet Actual
12 Follow up & Review Data Sheet, Line Sandeep Plan
Graph Actual
7
DEFINING OF THE PROBLEM
Q C D D M S E
A S
Start
Part Assembly
Material receipt
at store Sub Assembly of Armrest
Sent to supplier

lower

Focus
Material

Area
N.G Sub Assembly of Mounting
Check at base armrest
IQC
O. Assembly of armrest and
base floor console with box
K.
floor console
Material Issue

Reject
from store Assembly of armrest with
Material pour into base floor cover
Hopper
N.G
N.G Final 1.IFC CHECKCHEET
Mold loading Rework Inspection FOR YBA
Station O.K.
O
.K.
Part Molding Move to PDI

N.G
Rework

PDI
N.G
Reject

Part Inspection
Inspection
O.K.
O.K.
FG Storage
De-flashing

Stop
A
8
TARGET SETTING
Q C D D M S E
S
Last Three Month Rejection
8.5 %
8.05
8 7.85

7.5
Rej. %

7 6.81

6.5

6
Mar-16 Apr-16 May-16

8% 7.57%
Target
CHALLENGE Q uality
6%
Team decided to C ost
reduce the D elivery
Rej. %

4% rejection from
7.57 % to 0.5% on D evelopment
2%
the basis of M anagement
0.5% QCDDMSES by
31st August 2016. S afety
0% E nvironment
Average Rejection Target S
ustainability
“Great Minds Must Be Ready Not Only To Take Opportunities, But To Make Them.”
9
ANALYSIS OF THE PROBLEM
Q C D D M S E
S
S.No. Defects Qty. Relative % Cumm % Cost
Defect Distribution
1 Force NG 204 45.3 45.3 304813
1% 1 0
2 Gap 174 38.7 84.0 259987 4 2% % % Force NG
%
3 Noise 35 7.8 91.8 52296 Gap
8
4 Flow line 18 4.0 95.8 26895 % Noise
45 Flow line
5 Scratches 10 2.2 98.0 14942
%
Scratche
6 Air Bubble 5 1.1 99.1 7471
39 s Air
7 Flow mark 2 0.4 99.6 2988 % Bubble
8 Rib 2 0.4 100.0 2988 Flow
damage
mark
TOTAL 450 100 672381
Rib
Analyzing Defects of Console
99.
YBA 99. 100.
damage
95. 98.
45 91. 0 1 6 0 100.
8
0 84. 8 0
0
40 90.0
5 80.0
Defects Qty.

36 70.0

Cumm. %
27
0 45.
0 60.0
31 3
22 50.0
5
5 40.0
18 30.0
20 17
0 3
4 4 1 1 20.0
13 5 5 2 2
8 0 10.0
5
Force NG Gap Noise Flow line Scratches Air Bubble Flow mark Rib 0.0
90
damage
45 Defects
0
10
IDENTIFICATION OF THE PROBABLE CAUSES
Q C D D M S E
S
Method Man
Loose fi tment of spring 1 and 2 Unskill manpower deployment
Manual Screwing of Hinge Shaft System Bypass
Hinge Spring Loose fitment
Human Error
Improper greased
Negligence
Collecti ng all Probable
causes
FORCE NG
Toggle loose
Interference b/w slider Air pressure variation
and upper assy. Screw driver bit wear
Parting line flash in Child Parts Failure in Torque controller
Child part warpage

Material Equipment

Method Man
Improper fi tment of ALS rear Negligence
Wrong screw Skill
Manual fitment Human Error
Loose fitment
Untrained operator
Collecting all Probable
causes GAP
Toggle loose
Rubbing between ALS rear
and Mounti ng Base Screw driver bit wear
Incorrect leather wraping Torque variation
Part dimension variation
BOP part miss Improper cooling fixture

Material Equipment

11
IDENTIFICATION OF THE PROBABLE CAUSES
Q C D D M S E
S

Method Man
Checking Method Negligence
Wrong
Cutting of Rubber Damper Skills
Improper tightening of Human Error
screw
Negligence in cutting
Improper fitment of ALS rear on ALS
of damper
Front Collecting all
Probable
NOISE
Air pressure variation
causes
Dimensional variation in child part Improper Torque Controller
Substrate assembly movement Screw driver bit
tight wear Improper Cooling
Rubber Damper tail Fixture
Material Grade of slider Spring 2 teared cutter for Rubber
MaterialDamper Equipment

01) Improper greased surface

Grease
applying Observation : : On checking the
area Armrest greasing surface on Lower Substrate
lower FR we found improper greasing in 10
substrate out of 50 parts.
front
 Conclusion Valid Cause
12
VALIDATION OF CAUSES
Q C D D M S E
S
02) Interference between slider Assembled slider with
and  Conclusion Valid Cause
upper assy.
LWR.
Substrate Front
Slider Observation : On
checking 50 parts
physically we found
slider intervene with
upper Assembly
operation.

3) Substrate assembly
movement rough.
 Conclusion Valid Cause

Observation : On checking 10 parts with the help of

push pull gauge we found substrate assembly move
tightly and hence noise issue arise.

4) Rubbing between ALS rear and Mounting  Conclusion Valid Cause

Base
Observation : On checking 10 parts with the help of
sleeve gauge found less gap between the ALS rear and
Mounting base armrest .

13
VALIDATION OF CAUSES
Q C D D M S E
S
Cause Validation
Related or Not
S. No. Cause Sub-Cause Checking Method Actual Who
Related
1 Negligence Follow W.I OK Sandeep Not a Cause
2 Unskill manpower deployment Skill Matrix OK Anurag Not a Cause
MAN

3 System Bypass Trial OK Anurag Not a Cause

4 Skill Skill Matrix OK Shubham Not a Cause
5 Toggle loose Visually OK Shyam Not a Cause
EQUIPMENT

6 Air pressure variation Pressure Gauge OK Shubham Not a Cause

7 Screw driver bit wear Visually OK Shyam Not a Cause
8 Failure in Torque Controller Torque metre OK Anurag Not a Cause
9 Torque variation Torque metre OK Sandeep Not a Cause
10 Teared Cutter for Rubber Damper. Visually OK Anurag Not a Cause
11 Loose fitment of spring 1 & 2. Visually OK Sandeep Not a Cause
12 Manual screwing of Hinge shaft. Visually OK Shyam Not a Cause
13 Hinge spring loose fitment Visually OK Shyam Not a Cause
METHOD

14 Improper fitment of ALS RR Visually OK Sandeep Not a Cause

15 Wrong Screw Visually OK Shubham Not a Cause
16 Improper Greasing Visually NOT OK Sanjeet Cause
17 Checking Method Wrong Visually OK Sandeep Not a Cause
18 Cutting of Rubber Damper Visually OK Anurag Not a Cause
19 Improper fitment of ALS RR on ALS FR Visually OK Sandeep Not a Cause
20 Interference b/w slider & upper Assy. Trial NOT OK Sandeep Cause
21 Parting line flash in child parts Visually OK Sandeep Not a Cause
22 Child part warpage As per Standard OK Shyam Not a Cause
23 Rubbing between ALS RR and Mounting Base As per Standard NOT OK Anurag Cause
MATERIAL

24 Incorrect leather Wrapping As per Standard OK Shubham Not a Cause

25 Part Dimension Variation As per Standard OK Shubham Not a Cause
26 BOP Part miss Physically OK Sandeep Not a Cause
27 Dimension variation in child part As per Standard OK Shubham Not a Cause
28 Substrate Assembly movement tight As per Standard NOT OK Anurag Cause
29 Rubber Damper Tail Visually OK Shyam Not a Cause
30 Material Grade of slider spring 2 As per Standard OK Shyam Not a Cause
14
FINDING OUT THE ROOT CAUSE
Q C D D M S E
S
Sr. No. Cause Why Why Why Root Cause

Improper Uneven layer of

No any automation
1 greasing on the grease formed on Grease not applied Greasing done
properly. manually. process of
surface of ALS the applied surface greasing.
front. of ALS front

Interference
between slider Slider not at its Dimensional Slider spring 2 Slider spring 2
2 and upper actual position. Variation in Slider deform during unable to bear
assembly. spring 2. operation. applied stress .

Slider not properly

Substrate Substrate assembly
coincide with the Slider shrinks after Process Variation.
3 assembly not align with molding.
slider. guide rail surface
movement
rough. of substrate
assembly.

Rubbing
Less gap between Gas channel not
4 between ALS Warpage in Gas not properly
ALS Rear and properly defined in
rear and mounting base. filled in part. tool.
mounting base.
Mounting Base.

15
DATA ANALYSIS, DEVELOPING SOLUTION &
FORESEEING PROBABLE RESISTANCE Q C D D M S E
S

Cause 1 Root Cause Data Analysis:

Improper greasing No any automation Observation: Trial parts Qty.= 50,
on surface process of greasing. During analysis we found that
unequal qty. of grease applied on the
surface of Armrest lower substrate
and also non- uniformly spread by
brush. The Actual weight of applied
grease = 7-10 gram against the
standard weight = 4 gram

Solution: 1- We have to provide equipment

in which equal qty. of grease eject as
per requirement.

FPR:(DISADVANTAGE) Responsibility: Target Date:

NO Manoj Sharma 01/08/2016
16
DATA ANALYSIS, DEVELOPING SOLUTION &
FORESEEING PROBABLE RESISTANCE Q C D D M S E
S

Cause 2 Root Cause Data Analysis:

Interference Slider spring 2 Observation: Trial parts Qty.= 50,
between slider and unable to bear During analysis with the help of pull push
upper assembly. applied stress.
metre we found uneven force during
sliding backward and forward movement
of substrate assembly and slider spring 2
curvature height deform from 8.2 to 7.8

Solution: 1- To increase the hardness and

strength.
2- To make Gauge to segregate
2 and check the slider spring 2
dimensionally before assembling to the
slider.

FPR:(DISADVANTAGE) Responsibility: Target Date:

NO Anurag Dixit 02/08/2016
17
DATA ANALYSIS, DEVELOPING SOLUTION &
FORESEEING PROBABLE RESISTANCE Q C D D M S E
S

Cause 3 Data Analysis: Trial parts Qty.=50,

Substrate assembly Root Cause During
analysis we found that during
movement tight. Process Variation moulding slider dimension was as
per standard but after 24 Hrs. slider
shrinks and observed dimension was
no as per standard

Solution: 1- Increase the rib length in slider for

proper coinciding of slider with sliding
surface of guide rail after shrinkage.

FPR:(DISADVANTAGE) Responsibility: Target Date:

NO Sanjeet 04/08/2016
18
DATA ANALYSIS, DEVELOPING SOLUTION &
FORESEEING PROBABLE RESISTANCE Q C D D M S E
S

Cause 4 Root Cause Data Analysis: Trial Parts= 100

Rubbing between Gas channel not During Analysis with P.E at Gemba found per part
ALS rear and properly defined in weight coming above 25-40 gram against the
Mounting Base tool. standard weight.
P.E team share this issue to tool expert and
during analysis tool expert check the design of
tool and told that design constraint in tool as gas
pin not located properly
Solution: 1:- To make new tool.
2:- Flatness to be controlled in process, by
doing
more cooling time.
3:- Cooling fixture to be made to
controlled process variation &
dimension variation.

Reason:
1: Time
impact,
Cost
impact
2.Increase
cooling time
reduce hourly
FPR:(DISADVANTAGE) Responsibility: Target Date:
production rate
NO Sandeep 05/08/2016
and we are in
19
phase where
 DATA COLLECTION
Q C D D M S E
S
1.
AFTER IMPROVEMENT - TRIAL 6 1.4
1.
4
1.
Tota Forc 2
Shif Gap Noise 1
l OK Part e

Rej %
t Production Others 0.
Rejection NG 8 0.5
A 110 108 0. 1 1 0 0.
6
B 2.0 0
0. 2 0 1 0.
4 0.2
A 95 92 0
0. 1 0 0 0.
3.0 2
B 0
0. 2 1 0 0
Gap Noise Others
107 106
Tot 414 405 9.0 0 6 2 1 Defects
1.0
. 0.0 1.4 0.5
102 99
8 7.57% Rej % 2.2 0.0 0.2
3.0 Result Comparison
% Gap: Our Quality Circle share this
6 with Quality team and ask to
% Failed In disassemble the part and check the gap
Achievin and found less gap.
4
g the
Rej %

% Noise: Our Quality Circle share this

2.20% Target
2 with
Quality team and ask to disassemble
% 0.50% the
and part
found screw miss and loose
0 in
assembly of mountingbase armrest
% Befor After and
substrate
e Target
assembly.
Trust on your self , You can do
20 anything !
DEVELOPING SOLUTION
Q C D D M S E
S
WHY WHAT WHERE WHEN WHO HOW HOW
ACTIVITY MUCH
Warpage in B/W
mounting Mountin 0.6
Les After Mountin
Less base g Base Warpag mm
s Assembl g
gap b/w armrest. and ALS e
Difference Gap y Base
ALS Rear
Rear & in wall
mountin thickness.
g base
Nitrogen gas
not properly
filled
internally.

Team discussed within

the department and
generate new innovative
ideas for countering the
issue without changing in
tool of critical
armrest mounting base .

21
 DEVELOPING SOLUTION

Upper Slide
Mounting Substrate r Lower
Assy. Mounting Base With Slider Substrate
Base Substrate
Assy. Assy.
Assy. with
guide rail

Gap Step 1.= Armrest Upper Substrate +

Armrest Lower Substrate
Step 2.=Fitment of Guide Rail in
Armrest
Lower substrate
Step 3.= Insert Slider in above
assembled
parts.
Step 4.= Cover the Armrest Lower
Substrate Front with Armrest Lower
Substrate Rear to inhibit the slider
from escaping
Complete Console
Step 5.= Assembly of Mounting
Assembly
22
base Armrest with Substrate
DEVELOPING SOLUTION
Q C D D M S E
S

Substrate Assembly Our QC team analyze and

discussed with engineering
Scre
team and engineering team
Bosse given proposal to Customer .
0.9-

w
1.4

s Customer approved the

Mount Base Armrest
proposal
Armrest Spec. is 2.5±1.0 for height projection
Lower
mm
Substrate
Rear Substrate Assembly Z-Axis
Slide Direction
r
2.3-

Bosses Scre
2.7

w A
Mount Base Armrest
To increase the height of bosses
in Z
direction
A -0.6
mm B-
1.2 mm B
Problem 2: Screw loose & Screw missing
Our Quality Circle team suggest to horizontally
deploy POKA YOKE system as implemented on
Door Trim Assy. line

23
REGULAR IMPLEMENTATION
Q C D D M S E
S
Grease Application with Befor
Brush(Manually)
e
Grease - High Cycle
applyin time
- Excess of
Befor

g area
Armrest grease usage
lower - Non
e

substrat standard
e front Method
-No Tracking of
Grease
presence

Grease Application with Grease Dispensing SPM Features:- Afte

LCD Display -Digital Timer
- Adjustable vacuum suck
r
back
- PLC based interfacing
Pressure Gauge ( for grease miss POKA
-Usage of define
Afte

Time -Operated by foot

YOKE) qty.
r switch
-Less cycle time
r

- Lightweight
Pressure Process Parameter: -Consistency
knob in Qty applied
Vacuum Qty. dispenses : 0.25
knob gram in shot
Dispensin Pressur : 4-5 bar
g e : 0.400
cylinder Time sec
24
REGULAR IMPLEMENTATION
Q C D D M S E
S

Befor
e
Warpage of approx.
1mm at flat
Befor

surface and
dimensional
variation of 3.5 mm
e

observed at leg
side of mounting
base

Afte
r

A cooling Fixture
Afte

made to counter the

warpage in
r

mounting base
armrest .

25
REGULAR IMPLEMENTATION
Q C D D M S E
S
Less Befor
Gap
e
Less Gap b/w
Mounting Base
Befor

Armrest and
Armrest Lower
Substrate Rear due
e

to warpage in
Mounting Base
Armrest.

0.6 1.2 Afte

mm mm
r
In slider we have
0.6
mm increased the height
of all 4 pips where
Afte

this mounting base

is assembled. This
r

height counter the

0.6 mm Warpage in
mounting base
1.2
mm

26
 REGULAR IMPLEMENTATION
Q C D D M S E
S

Befor
e
Play in substrate
assembly as slider
follow uneven path
Befor

in guide rail due to

improper meeting
e

of slider at the
surface of guide
rail

Afte
r

Increase the ribs of

Afte

slider at four corner

of radii by 0.2 mm
r

for proper
alignment

27
REGULAR IMPLEMENTATION
Q C D D M S E
S

Heigh Befor
t e
Bend 1. The hardness of
Slider Spring 2
lies between 40-
Befor

44 HRC due to
which the spring
deform and
e

bend.
2. Dimension
variation in
slider spring 2.

After
1. Increase the
hardness
of slider spring 2 from
40-44 to 50-55
Afte

HRC.
r

2.To prevent the

wrong
assembly of Slider
Spring 2 N.G part
with slider. A GO
and No GO Gauge
made to check the
28 part dimensionally
 REGULAR IMPLEMENTATION
Q C D D M S E
S

Before
Final inspection
station was in line
with the console
assembly line due
Before

to which Actual
part mixed with
N.G part (screw
loose and miss)
and mixing
problem arise as
final
inspector unable
to identify the
internal missed
Chute Stand screw parts

After
Afte

A separate cabin
made for final
r

inspection of the
part and a Poka -
Chute Door Yoke system
implemented to
Cabin avoid the passing of
N.G part to the next
29
station as chute
 REGULAR IMPLEMENTATION
Q C D D M S E
S

Disassembling the Befor

part e
Screw loose and
Screw missing
Befor

problem arise due to

which we have to
disassemble the
e

part and hence

reworking time
increase.

After
Screw counter meter
installed at every
station to prevent
the screw miss
bypass . The screw
Afte

driver at next
station for
r

assembling inline
Screw Driver part next to the
previous station not
work until and
Screw Counter unless the required
quantity of screw
tighten at previous
30
station.
RESULT COMPARISON
Q C D D M S E
S
AFTER IMPROVEMENT - TRIAL
Total
Shift OK Part Rejection Force NG Gap Noise Others
Production
G 180 179 1 0 0 0 1
G 176 176 0 0 0 0 0
G 179 178 1 0 0 0 1
G 180 180 0 0 0 0 0
G 178 178 0 0 0 0 0
G 180 180 0 0 0 0 0
Total 1073 1071 2 0 0 0 2
Rej % 0.2 0.0 0.0 0.0 0.2
8 7.57%
%
7
%
6
Rej %

%
5
GOAL
% ACHIEVED
4 0.50% 0.20%
%
3 Befor Targe Achieve
% e t d
31
2
AFTER ACTIVITY CHART
Q C D D M S E
S

Analysis problem
encountered that arise
during verification
.

Trial Delay because

of ECN proposal
approved after 2
weeks by customer

Continuous
monitoring

32
STANDARDIZATION & USE OF QUALITY TOOLS
Q C D D M S E
S CHECK SHEET
1 Update the ECN. PIE CHART Find Out The List
of problem
Selection Of
Problem FLOW CHART

Define the
PARETO CHART Problem
Analysis Of CAUSE & EFFECT
Problem DIAGRAM
Identification of
2 Revised the S.O.P. WHY-WHY
Causes
ANALYSIS
Finding Out Root
Causes 3G, SOP, BRAIN
STORMING
5W-1H Data Analysis

Developing
solution BRAIN STORMING
Foreseeing
probable
3 POKA-YOKE CHECKSHEET CHECK SHEET
resistance
Trial implementation
& check performance SOP
Regular
LINE GRAPH Implementation
Follow up &
Review

Lakshya Quality Circle

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FOLLOW UP & TANGIBLE BENEFIT
Q C D D M S E
S

QC Result Before and

10.0
9.0 7.7 After
8.1 7.9 7.5
8.0 6.8
7.0
6.0 8.3 4.9
Rej %

5.0 During QC
4.0
3.0 Before QC Working
2.0 Working 0.9
1.0 0.2
0.0
Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16
Months

34
 INTANGIBLE BENEFIT
Q C D D M S E
S

Customer Society

 100 % Satisfaction
 Clean India

 Appreciation
Employee Next Project
 Save Tree
Adjudged as WINNER for
best technical projects
(2015-2016)  To Reduce Rejection of Glass
 Learn about measuring device such as Micrometer Cover YP-8 at assembly Line .
 Learn Computer Aided Design
 Basic QC Knowledge Improved
 Increased team Confidence

Thanks To Maintenance, Quality, P.E & Tool Room Department For Kind Support.
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