Team Information 1/6

1/6
1/41
Theme :- To improve overall
quality of the part through
fixture modification of oil filler
neck

Jagveer San / Bipin

San / Vijender San /
Vivek Sukla San
Leader Sanjay San
Facilitator

Avinash San Sushil / Parveen

Member Member

Dev Singh
Member Mainpal Singh San
Co-ordinator

TEAM DETAILS
REGISTRATION DATE : 21/03/2025 MEETING DETAILS
COMPLETION TIME : 1 MONTHS MEETING DAY : EVERY SATURDAY
PROJECTS COMPLETED : 1
FACILITATOR : Sanjay Sharma
MEETING TIME
MEETING PLACE
: 2:00 – 02:50 pm
: PRODUCTION PLANNING AREA
YODHA
CO-ORDINATOR : Mainpal Singh MEETING CONDUCTED : 1 No’s
PROJECT LEADER : Jagveer San / Bipin
San / Vijender San / Vivek Sukla San
OVERALL ATTENDENCE : 95.0%
Leader
 Message 2/6
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COMPANY SLOGAN

COMPANY GOAL

“ACHIEVE CUSTOMER
SATISFACTION
THROUGH SAFETY,
QUALITY, DELIVERY,
COST”
 12 steps of Quality Circle 3/6
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SYSTEMATIC QC STEPS FOLLOW UP/ REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION
QC CIRCLE
S FORSEEING PROBABLE RESISTANCE
P
S TE
QC DEVELOPMENT OF SOLUTION
IC
AT DATA ANALYSIS
EM
ST
SY ROOT CAUSE ANALYSIS
U GH
HRO IDENTIFICATION OF CAUSES
T
ANALYSIS OF PROBLEM

DEFINITION OF THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEMS

NON - SYSTEMATIC QC STEPS

IC
AT
EM
YST
S
N
O
N AY
W
 Activity Plan 4/6
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MONTH’S

S.NO ACTIVITY RESP. Jul-21 Aug-21 Sep-21 Target

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
02.07.21
1 IDENTIFICATION OF PROBLEM Team

09.07.21
2 SELECTION OF PROBLEM Team

16.07.21
3 DEFINE THE PROBLEM Team
P
23.07.21
4 ANALYSIS OF THE PROBLEM Team

06.08.21
5 IDENTIFICATION OF THE PROBABLE CAUSE Team

13.08.21
6 FINDING OUT THE ROOT CAUSES Team

20.08.21
7 DATA ANALYSIS Team
D
27.08.21
8 DEVELOPING SOLUTION Team

03.09.21
9 FORESEEING PROBABLE RESISTANCE Team
C
TRIAL IMPLEMENTATION & CHECK 10.09.21
10 Team
PERFORMANCE

17.09.21
11 REGULAR IMPLEMENTATION Team
A
24.09.21
12 FOLLOW UP/ REVIEW Team
 Identification of Problems 5/6
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Sr. No PROBLEMS A B C Sr. No PROBLEMS A B C

1 Insufficient storage (Space Issue)  11 No Screen location for storage 

2 FIFO maintaining issue  12 Ink mixing glass generating dust 
3 Part movement & Handling  Operator keep part any where on
13 conveyor belt 
4 Rejection PPM high 
5 Air Pressure low 
6 Printing shifting 
7 Bin movement & Handling 
8 Man movement 
9 Dust from shoes 
Uses of Temporary marker (reason of
10 dust) 

S.N CATEGORY(A,B,C) NO’S The problems which can be solved by

QC team members with the support
A No. Of problem falling under “A” category 09 of other departments
B No. Of problem falling under “B” category 02
C No. Of problem falling under “ C” category 02

The problems which can The problems which can be solved

be solved by Kaizens /QC by QC team members with
team members support from top management
Category - A Category - B Category - C
 Selection of Problem 6/6
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Printing Line ppm data & defect contribution data

PPM Data (Apr’21

Rej. PPM Trendto Jun’21)
350000 325229 332501
307711
300000
265403
250000

200000 200000
Defect PPM

150000

100000

50000

0
Apr'21 May'21 Jun'21 Avg.

Rej. PPM Target PPM Series3

Target Benchmarking Month

300000 251145 226485
201825
200000
100000
Printing Line PPM was varying against the
Defect PPM

0 target. So we decided to Reduce the PPM from

r 1 r 2 ge
pplie
pplie
Av
er
a
307711 to 200000 (Target Bench-marking
Su Su
g g
ir n
tin
ir n
tin Based On Other Established Screen Printing
P P

Sc
r ee
n
Sc
r ee
n
Industries).
 Selection of Problem 7/6
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7/41

Target setting

PPM reduction target at Screen

QC Objectives
Printing
400000
Actual PPM
307711  Do study of all cause and take countermeasure by Sept
300000
2021
200000
200000
 Ensure the total satisfaction of Internal / External
100000 customers.
Rejection ppm

0 
Current PPM Target PPM
To learn new things with new challenges.

Pareto Chart
95.9 97.7 98.7 99.4 99.9 100.0
200000 178030 90.0 93.0 100.0
80.2 85.8
150000 69.5 80.0
58.4
60.0
100000
40.0
50000 33889 32665
17035 12928 9246 8799 20.0
Defect PPM

5352 3181 1926 1532 415

0 0.0
en
t le er Do
t
k) ut w ar
k ag g e er p
D Ho ib ar rc lo -z pa ov tU
/
Pi
n t/
F
ac
k
( D tte kF er
m
Zi
g ar Un
c Se
tc
h iL n Bl le In g W
ra / on in
c st
/ te ati t/ /F
S
Du hi in Ou
W um e ue
Ill ag Iss
Im g
in
ndl
Ha

PPM Cumm%
Name of Defects
 Definition of The Problem 8/6
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Screen Printing Process

 Screen-printing is a form of printing ,using a
design cut out of a special film(positive),
Exposed on special fabric that has been tightly
stretched across a frame called screen . Ink is
then forced through the open meshes of the
fabric by means of a rubber blade called a
squeegee. The printing of plastic parts are use
the process of screen-printing.

Scratch at front fascia

Scratch
OK NG
Pin Hole

Dust
 Definition of The Problem 9/6
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9/41
Screen Printing
RECEIVIN
Process Flow
G& Auto Auto
Start STORAGE
OF Screen Screen PART
INK Printing Printing UNLOADI
Process 1 & 2 MOLDED MIXING (First (Second NG &
DISPLAY black) & black) & STORAGE
PANEL CURING CURING
PARTS &
INK.
Auto Auto
Process 3 & 4 Ink Mixing Screen
Printing Ink Mixing Screen
Printing
PART
UNLOADI
(Blue (blue (Black (black NG &
Smoke) Smoke) & Smoke) Smoke) & STORAGE
CURING CURING

Process 5 Manual
INK Screen FINAL PACKING
MIXING Printing INSPECTI & Storage End
(IR Blue) (IR Blue) ON
& CURING
 Identification of Causes 10/6
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Cause and Effect Diagram

MAN MACHINE
Operator is Operator not Machine vibration Suction unit not
not skilled follow OGS working
Jig fixture dusty
Training not Operator
effective Squeegee damaged
naglegancy Centering bush damage
Operator 4M not Scraper
damage Part stopper
not well followed
New Conveyer damage
operator speed high
Operator
Squeegee fitment
Competency Conveyor &
4M rule not loose / tilt
available Transfer belt dusty
Scratch/Dent
Separator Dust stuck in
Non standard
damaged screen
gloves wear
Separator miss Dust stuck on Dust in ink
part while mixing
Wrong packing Part
material used Bin & foam handling
NG Part movement
Packing Bin & damaged
trolley damaged
foam dusty Gloves not
Dusty ink packing wear Wrong packing
containers
method

MATERIAL METHOD
 Identification of Causes 11/6
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Validation of Probable Causes
Sr. no Category What (Possible cause) Where (Area) When Who How (Validation method) Result Conclusion (Valid / not valid)

1 Operator is not skilled Screen Printing Shop 23.6.2021 Shelender Check with skill card Skill card updated found INVALID

2 Training not effective Screen Printing Shop 25.6.2021 Shelender Check training review Found effective INVALID

3 Operator Negligence Screen Printing Shop 28.6.2021 Shelender Monitory operator Operator flow OGS INVALID

4 Operator not follow OGS Screen Printing Shop 5.7.2021 Shelender Monitory operator Operator Flow the OGS INVALID

5 Man Operator not well Screen Printing Shop 28.6.2021 Ankit First aid record check Good health INVALID

6 Operator capability Screen Printing Shop 30.6.2021 Shalender Inspection Standard Training VALID

7 New operator Screen Printing Shop 3.7.2021 Shelender Check record Old operator INVALID

8 4M rule not available Screen Printing Shop 25.6.2021 Shelender Check 4M sheet 4M available INVALID

9 4M not Followed Screen Printing Shop 26.6.2021 Shelender Check training record 4M rule followed INVALID

10 Machine Vibration Screen Printing Shop 2.7.2021 Ankit PCB No breakdown INVALID

11 Jig Fixture dusty Screen Printing Shop 5.7.2021 Ankit Sticky pad No dust found INVALID

12 Centering bush damage Screen Printing Shop 1.7.2021 Ankit Magnifying glass No damage INVALID

13 Scraper damage Screen Printing Shop 28.6.2021 Ankit Scale No damage INVALID

14 Conveyer high speed Screen Printing Shop 24.6.2021 Panchanan HMI display As per spec. INVALID
Machine
15 Conveyer & transfer belt dusty Screen Printing Shop 5.7.2021 Ankit Sticky pad No dust found INVALID

16 Suction unit not working Screen Printing Shop 24.6.2021 Ankit By paper Found ok INVALID

17 Squeeze damaged Screen Printing Shop 3.7.2021 Ankit Scale & By finger feel No damage INVALID

18 Part stopper damage Screen Printing Shop 30.6.2021 Shelender Scale No damage INVALID

19 Squeegee fitment loose/ tilt Screen Printing Shop 25.6.2021 Ankit Scale Ok fit INVALID
 Identification of Causes 12/6
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Validation of Probable Causes
Sr. no Category What (Possible cause) Where (Area) When Who How (Validation method) Result Conclusion (Valid / not valid)

20 Non standard gloves wear Screen Printing Shop 3.7.2021 Shalender Visually Decided gloves INVALID

21 Part handling NG Screen Printing Shop 24.6.2021 Shalender As per OGS Part rub with palm VALID

22 Gloves not wear Screen Printing Shop 28.6.2021 Shalender Visually Gloves wear INVALID

23 Dust stuck in screen Screen Printing Shop 29.6.2021 Ankit Magnifying glass No dust INVALID
Method
24 Dust in ink while mixing Screen Printing Shop 25.6.2021 Ankit Check with mash No dust found INVALID

25 Part movement trolley damaged Screen Printing Shop 1.7.2021 Shelender Manually move Found ok INVALID

26 Wrong packing method Screen Printing Shop 3.7.2021 Panchanan As per OGS Found Ok INVALID

27 Dust stuck on part Screen Printing Shop 4.7.2021 Ankit Sticky Pad Too much Dust VALID

28 Separator damaged Screen Printing Shop 2.7.2021 Panchanan Sample inspection Found OK INVALID

29 Separator miss Screen Printing Shop 25.06.21 Ankit Sample inspection Found OK INVALID
Material
30 Wrong packing material used Screen Printing Shop 29.6.2021 Panchanan Packing std. Found OK INVALID

31 Bin & foam damaged Screen Printing Shop 6.7.2021 Ankit Sample inspection Found OK INVALID
 Root Cause Analysis 13/6
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Summary of problems

Defect Category (4M) Valid Cause

Man Operator capability

Scratch / Dent Dust stuck on part

Method
Part handling NG
 Root Cause Analysis 14/6
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Why-Why Analysis

Valid Cause 1. :- Operator capability

Why-1 Operator capability

Why-2 Hard to judge the defect limit

Why-3 limit samples not available

Why-4 Standard not clear

Root Cause Why-5 Low understanding about inspection standard

 Development of 15/6
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15/41
Solution
Brain Storming session is conducted by the CFT for the development of solutions. On the basis of that,
action plan is checked out for the implementation

Low understanding about inspection standard

 
1. Re-training provided
about standard & Display
on inspection table.
Operator
2. Limit sample provided
Change
with identification.
3. Defect gallery maintained
& Displayed.
 16/6
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Action for Cause-Kaizen 1

Before After

N/A

Low understanding about inspection standard Re-training provided about standard & Display on
inspection table.
16
 17/6
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Action for Cause-Kaizen 2

Before After

N/A

Limit sample not maintained Limit sample maintained with identification.

 18/6
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Action for Cause-Kaizen 3

Before After

N/A

Defect gallery not maintained Defect gallery maintained & Displayed.

 Root Cause Analysis 19/6
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Why-Why Analysis

Valid Cause 2. :- Dust Stuck on part

Why-1 Dust Stuck on part

Why-2 Environmental dust

Why-3 Packing bin & foam dusty

Bins used to come directly for printing from the open

Why-4 space(dusty environment) & stored inside the printing shop.

Root Cause Why-5 No Separate location is identified

 Root Cause Analysis 20/6
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Why-Why Analysis

Valid Cause 2.1. :- Dust Stuck on part

Why-1 Dust Stuck on part

Why-2 Environmental dust

Why-3 Excess movement in printing area

Why-4 Bin movement person, Packer, loader & inspection

person is moving too many times for bin handling.

Root Cause Why-5 No Separate location is identified

 Development of 21/6
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21/41
Solution
Brain Storming session is conducted by the CFT for the development of solutions. On the basis of that,
action plan is checked out for the implementation

No Separate location is identified

 
Keep part New cabin for
outside of storage of bin &
printing shop Foam
 22/6
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Action for Cause-Kaizen 1

Before After
Screen Printing Shop
Storage inside the
Screen Printing Shop

Storage outside the

Screen Printing Shop

New separate
location

No Separate location is identified Bin & Tray location Is separated. We made new cabin for
(Bin & Tray Location inside the Printing shop. & Direct storage of bin & Foam (outside of Printing shop).
entry from open environment to printing). 3 layer cleaning(1st Shoe cleaning, 2nd Double door room,
3rd is Air Shower)
 23/6
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Action for Cause-Kaizen 2

Before After
Out side Printing
Screen Printing Shop
Storage area
Storage inside the
Screen Printing Shop

Conveyors
connected with
both areas
Part Loading &
unloading
outside from
Screen Printing

No Separate location is identified *Conveyor system is made for single part flow to
(All bin & foam are kept inside). reduce the dust particles bustling.
*Part loading / unloading & Part Inspection & Part
movement is now work from outside of Printing cabin.
*Double cleaning of part with ionized air.
 Root Cause Analysis 24/6
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Why-Why Analysis

Valid Cause 3. :- Part handling NG

Why-1 Part handling NG

Why-2 Finger/palm touch on part

Why-3 While process – While Pick & drop the part from bin

Why-4 No protection film at top side of part

Root Cause Why-5 Protection film down side of part (As per standard)
 Development of 25/6
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25/41
Solution
Brain Storming session is conducted by the CFT for the development of solutions. On the basis of that,
action plan is checked out for the implementation

Protection film down side of part (As per standard)

 
Standard changed &
Packing material WI provided to keep
change or part in packing foam
double side from non-wrapping
protection film side to prevent from
scratches.
 26/6
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Action for Cause-Kaizen 1

Before After

1. Standard changed & WI provided to keep part in

Protection film down side of part (As per standard) packing foam from non-wrapping side to prevent from
scratches.
2. Training Provided

26
 Other Kaizen’s 27/6
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Before After Before After

Reason of dust
1. Ink Glass quality low 1. Ink Glass quality
(plastic particles mix in changed (now plastic 1. LED light is coming 1. Magnifying glass
glass by falling off the particles not falling from bottom side of provided. Easily to
corners of the glass). from the corners). part. Hard to inspect inspect the part
2. Ink mixing glass not 2. Ink mixing glass the part
cover while movement cover provided.

Before After Before After

1. Part not coming in 1. Two parallel lines 1. Mat placed on door 1. Sticky mat placed on
sequence & some marked on belt & to clean the shoes both sides of air
parts hit at corners of instruction given to before entering in shower, before
supporting walls on operator(after printing shop. entering in printing
conveyor. inspection), Place the shop. (Two times
part inside the both cleaning)
parallel lines.
 Other Kaizen’s 28/6
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Before After Before After

1. Screen storage not 1. Screen Stand made 1. We are using 1. We restricted the
defined With cover to prevent temporary marker for marker uses in
from dust & handling data recording. When printing shop.
issues. we cleaned the board,
huge amount of dust
generate from this.

Before After Before After

1.No dust control 1. Shoes cleaning m/c

1. Inspection do 1. Black film(scratches from entrance of install at entrance gate
without assy. easily visible)sheet printing. Only mat of printing area. Deep
attached with unit& fix placed for shoe cleaning of shoes
in inspection table for cleaning
inspection purpose.
 Standardization 29/6
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1. Layout changed With Management Approval – (PCRN/21/E/002)

2. Control Plan update – (PCRN/21/E/002)

 Foreseeing Probable Resistance 30/6
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Sl. Counter Measure Possible resistance Plan to overcome Status

No the resistance

1. Standard changed & WI provided to

keep part in packing foam from non- Countermeasure
1 wrapping side to prevent from NA NA agreed
scratches.
2. Training Provided

1. Re-training provided about standard

& Display on inspection table.
2
2. Limit sample provided with
NA NA Countermeasure
identification. agreed
3. Defect gallery maintained &
Displayed.

Bin & Tray location Is separated. We

made new cabin for storage of bin &
Need budget & management Take management Countermeasure
3 Foam (outside of Printing shop). approval & start to build
3 layer cleaning(1st Shoe cleaning, 2nd approval. new cabin agreed
Double door room, 3rd is Air Shower)

1. Conveyor system is made for single

part flow to reduce the dust particles
bustling. Take management
4
2. Part loading / unloading & Part Need budget & management approval & start to build Countermeasure
Inspection & Part movement is now approval. conveyor system (in- agreed
work from outside of Printing cabin. house).
*Double cleaning of part with ionized
air.
 Trial Implementation 31/6
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Trial & Implementation Plan

Sl. ( WHAT ) (WHERE) ( WHEN) ( WHO ) ( HOW )

No Root Cause Countermeasure Status
Area Target Responsibility

1. Standard changed & WI provided to keep

Protection film down
Screen part in packing foam from non-wrapping
1 side of part (As per 21.08.21 Team Done
Printing side to prevent from scratches.
standard)
2. Training Provided

1. Re-training provided about standard &

Low understanding
Screen Display on inspection table.
2 about inspection 21.08.21 Team Done
Printing 2. Limit sample provided with identification.
standard
3. Defect gallery maintained & Displayed.

Bin & Tray location Is separated. We made

new cabin for storage of bin & Foam
No Separate location is Screen
3 27.08.21 Team (outside of Printing shop). Done
identified Printing
3 layer cleaning(1st Shoe cleaning, 2nd
Double door room, 3rd is Air Shower)

1. Conveyor system is made for single part

flow to reduce the dust particles bustling.
No Separate location is Screen 2. Part loading / unloading & Part
4 27.08.21 Team Done
identified Printing Inspection & Part movement is now work
from outside of Printing cabin. *Double
cleaning of part with ionized air.
 Activity Plan 32/6
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MONTH’S

S.NO ACTIVITY RESP. Jul-21 Aug-21 Sep-21 Target

W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
02.07.21
1 IDENTIFICATION OF PROBLEM Team
02.07.21

09.07.21
2 SELECTION OF PROBLEM Team
09.07.21

16.07.21
3 DEFINE THE PROBLEM Team
16.07.21
P
23.07.21
4 ANALYSIS OF THE PROBLEM Team
23.07.21

06.08.21
5 IDENTIFICATION OF THE PROBABLE CAUSE Team
06.08.21

13.08.21
6 FINDING OUT THE ROOT CAUSES Team
13.08.21

20.08.21
7 DATA ANALYSIS Team
20.08.21
D
27.08.21
8 DEVELOPING SOLUTION Team
27.08.21

03.09.21
9 FORESEEING PROBABLE RESISTANCE Team
03.09.21
C
TRIAL IMPLEMENTATION & CHECK 10.09.21
10 Team
PERFORMANCE 10.09.21

17.09.21
11 REGULAR IMPLEMENTATION Team
17.09.21
A
24.09.21
12 FOLLOW UP/ REVIEW Team
24.09.21
 Follow-up & Review 33/6
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Screen Printing PPM Data (Before & After)

Before PPM Rej. Trend After PPM
400000 366000 A
332501 340000 Ka fter A
350000 325229 ize Ka fter
n ize
300000 n
265403
250000 200000 200000 200000 200000 200000 200000 200000 200000
200000 192175.3476313
PPM
93 164883 158810
150000
100000
50000
0
After implementation of Apr'21 May'21 Jun'21 July'21 Aug'21 Sep'21 Oct'21 Nov'21
countermeasures,
Actual Rejection % Target
Scratch PPM is reduced
Months
400000

307711
300000

200000
200000 192175

100000

0
Earlier PPM Target PPM Achieved

After all C/M implementation, PPM reduced 307711 to 192175

 Tools & Techniques Used 34/6
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S.N CATEGORY(A,B,C) NO’S Input to Gemba photo

No. Of problem falling
A under “A” category
--- Start
A

Height
Check
B

1st sample
check
C

Is it OK

No

No. Of problem falling

Label
receiving
No

B
Yes

---
No Cup
Is it OK Is it OK Attachment

Material
Arrangement

under “B” category

Yes Yes

Looping & Putting

Wire with label.
Cutter Time Form
Setting Entry
Wire Feeding

No

---
End

No. Of problem falling

C
Applicator Is it OK
Production
Setting

Yes

under “C” category JAN FEB JUNE

Height
Data entry in Inspection
Setting
computer

C
A B

STRATIFCATION GRAPH FLOW CHART

When Who How

What was the Where was the was the identified much is
problem? problem? problem the the
identified problem? variation?
?

4W1H ANALYSIS
PIE CHART BRAIN STORMING
CHECK SHEET
PROJECT :" Reduction of Dimension NG" SHIFT : General SECTION :Etios -petrol Line QC Name : Quest Duration:3rd WK-Mar 12to 15 th WKMar 12 SL Cause Why Why Why Why Why
SL NO

1 Lack of skill
REASON
9-Mar-12

0
10-Mar-12

0
11-Mar-12 12-Mar-12

0
13-Mar-12

0
14-Mar-12

0
15-Mar-12

0
16-Mar-12

0
17-Mar-12

0
18-Mar-12
DATES
19-Mar-12

0
20-Mar-12

0
21-Mar-12

0
22-Mar-12

0
23-Mar-12

0
24-Mar-12

0
25-Mar-12 26-Mar-12

0
27-Mar-12

0
28-Mar-12

0
29-Mar-12

0
TOTAL

0
No
2 Improper usage of Jigs 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

3 Work sequence not followed 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

4 Not using jigs for fixing operation 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

5 New Operator 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

6 Clamp cutting gun not used properly 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

7 Urgency 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

8 Loose Taping 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

9 Difficulty in branch making 1 0 0 0 0 1 1 0 0 0 1 0 0 0 0 0 0 0 4

10 Jig position wrong in final assembly board 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

11 Wire length variation 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1.

12 Branch making method wrong 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

13 Grommet not assembled over point tape 0 1 0 0 1 0 0 0 1 0 0 1 0 1 1 0 1 0 7

14 Clamp Loose 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

15 Station Crossing 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

16 Improper work distribution 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

17 COT Tube length variation. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

18 Difficulty in optional taping 0 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1

19 Confusion to associate for referring the jig 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

20 Play observed in jigs 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

21 Circuit jig layout wrong 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

22 Conveyor height more 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

23 Clamp movement during clamp cutting 0 1 0 0 1 0 0 1 0 0 0 0 1 0 0 1 0 0 5

24

25
Lay up sequence wrong

Workability problem during branch making

0

0
0

0
0

1
0

0
0

0
0

0
0

0
0

0
0

0
0

0
0

1
0

0
0

0
0

0
0

0
0

1
0

0
0

0
0

3
2
26 Clamp jig bend 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

27 Clamp jig loose 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

28 Wrong jig used while taping 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

29 Branch was sag 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

30 Lack of training 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

31 Tape loose 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Total 1 3 0 1 0 2 1 1 1 0 1 0 2 1 1 1 0 1 2 1 0 20

CHECK SHEET Why Why Analysis CAUSE AND EFFECT DIAGRAM

 Benefits 35/6
35/6
35/41

Benefits Details
Quality PPM reduced to 307711 PPM
to 192175 PPM

Productivity 7% Productivity Improved

COST 3.8 Lacs. /- per month

Delivery 100% delivery

Safety 0 accident

Moral High Morale by good team

work
 Benefits 36/6
36/6
36/41

Knowledg Self &

e mutual
enrichmen developm
t ent

Improved
inter Confidence
department build up
communicat
ion

Enhanced Knowledg
problem e of
solving standards
capability
Improved
computer
knowledg
e
 Our Colleagues Feedback 37/6
37/6
37/41

After this QCC, we found less

scratch problem at final inspection After implementation of countermeasures,
not getting the high rejection of scratches

Mr. Panchanan Mr. Ved Prakash

Inspection Quality

Our colleagues are very happy with the counter measures implemented.

OUR NEXT PROJECT