QUALITY CIRCLE PRESENTATION

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ABHIJEET TECHNOPLAST INDIA PVT LTD

Abhijeet Techno Plast(I)Pvt Ltd

E-57 & 58, M.I.D.C., Ambad, Nasik- 422 010.

Ultrasonic SPM
Work Station

Year of Establishment : - 2008

Phone No: 0253-6628904-
Email:technoph@abhijeetplastics.co.in
Contact Person. Manish Chulet (Plant Head)

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ABHIJEET TECHNOPLAST INDIA PVT LTD

GROUP COMPANIES IATF CERTIFICATE

ABHIJEET
INDUSTRI
ES DADRA

AIPL
SANAND
Work Station
Abhijeet
Techno Plast.
Nashik

Abhijeet Abhijeet
Ties. Plastics Pune.
Mumbai

AAAPL
Moulding Shop
Chennai

3
 VALUABLE CUSTOMER

M&M

PENTAIR GROUPO
Material FIFOC
ANTOLIN 4
 OUR PRODUCT – MAHINDRA & MAHINDRA

MARAZZO

Ultrasonic SPM

A PILLAR B PILLAR CD PILLAR

UPPER UPPER

Moulding Shop
D PILLAR OTR TRUNK SILL CLADDING 5
 OUR PRODUCT – MAHINDRA & MAHINDRA

Ultrasonic SPM

A PILLAR OTR C PILLAR TAILGATE

GARNISH GARNISH

Moulding Shop
TAILGATE C PILLAR B PILLAR 6
LOWER UPPER UPPER
 OUR PRODUCT – MAHINDRA & MAHINDRA

Ultrasonic SPM

ADDON SPLASH COVER SPLASH FOOT REST

SHIELD SHIELD BUMPER

Moulding Shop
ENGINE COVER CONDENSOR CONDENSOR 7
TOP BOTTOM
 OUR PRODUCT

Radiator Shroud

Ultrasonic SPM
Work Station

ADAPTORMoulding Shop
Material FIFOC
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 QUALITY CIRCLE PROFILE

Name RISING STARS

Quality Circle Formed Aug’20
Quality Circle Completed 4
Department Assembly
Meeting Day Tuesday ( 2:00 to 3:30 PM)
Project Started 17/08/2020 Ultrasonic SPM
Work Station
Project Completed 20/09/2020
Meeting 9
Attendance 95 %

Moulding Shop
Material FIFOC
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• Step 1:PROBLEM FOLLOW-UP AND REVIEW
IDENTIFICATION
REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING

PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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1. IDENTIFICATION OF PROBLEM
QUALITY CAMPAIGN

Ultrasonic SPM
Work Station
NEED QUALITY
AWARDS FROM
CUSTOMERS

Moulding Shop
Material FIFOC
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 1. Achievement

Our Director Sign off for Achieving MSES ‘A’ with M&M
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 1. IDENTIFICATION OF PROBLEM

Operator
Feedback

Problem Bank - 51

Gemba Daily Works

observation Management

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 1. IDENTIFICATION OF PROBLEM
PROBLEM BANK FOR QUALITY CIRCLE
1. Metal rib lock missing 27. High internal rejection due to un skill man power.
2. Frequent stoppage of machine due to unavailability of man power 28. Insufficient area for mold Storage
3. High consumable cost 29.Excess consumable(silicon Spray) to avoiding catching.
4. Non standard packing for SF storage 30. High Mold change time
5. High rejection of A Pillar OTR. 31. High Rejection Of M&M Logo
6. High Rework of painted parts. 32.High Customer Complaint of P-125 Shroud
7. High Non Moving Inventory in Plant. 33. Mold Guard spray consumption high.
8. Improper Stacking and storage of Empty PP Boxes. 34. High Man Power Cost.
9. High manpower cost for Assembly line 35. High stock verification time for FG parts
10. Non standard packing of FG Parts 36. Improper storage of Raw material in Stores
11. High Rejection of C Pillar Garnish 37. Improper Storage of empty PP boxes
12. Non standard packing of mahle parts 38. High Inventory of SF Parts
13. 100% Firewall for S201 & U321 Parts 39. Poor handling and Ultrasonic SPM
storage of polybags
14. Nozzle heater damage due to un available of locating ring. 40. High COPQ.
15. Optimizing manpower in flash related parts Work
. Station 41. High outward transport Cost
16. Abseentism of Contractual labour 42. Poor Condition of Trolleys
17. High time for physical Inventory verification 43.Insufficient storage area for PP boxes.
18. No layout for FG Storage 44. Foam Assembly at wrong location
19. Lamps formation between nozzle and mold sprue 45. Puller not cut concern in B Pillar Upper
20. High Rejection of P-126 Shroud 46. Warpage concern in Packing & Storage.
21.Non standard packing for outsourced molded parts 47. Semi Finished assembled parts due to BOP Shortage.
22.High rework in outsourced molded parts 48. High Down time of 1300 T Machine
23 Poor Condition of 5S throughout the plant 49. High lumps generation at molding shop
24. Wrong Assly Of Scuff plate 50.No accountability of PP boxes.
25.High premium freight Moulding Shop 51.High downtime due to RM not preheated.
26.High polishing downtime for tailgate garnish Material FIFOC
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 1.CATEGORISATION OF PROBLEMS

CATEGORY NO. OF PROBLEMS

A 38

B 9

C 04
Ultrasonic SPM
Work Station

Moulding Shop
Material FIFOC
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 2. SELECTION OF PROBLEM

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING

PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 2. SELECTION OF PROBLEM

Customer Complaint For Joint Mouting Loose

16.08.20

Ultrasonic SPM
Work Station

16.08.20

Moulding Shop
Material FIFOC
2. SELECTION OF PROBLEM

WHY THIS PROBLEM IS SELECTED ?

Impact of problem

High Cost
Of Rework

Fitment
Failure at Ultrasonic SPM
Customer End Parts of
Prestigious
Project of M
&M

Poor Cost Of
Quality
Moulding Shop
Material FIFOC
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 3. DEFINATION OF PROBLEM

Step 3:DEFINATION OF PROBLEM

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 3. DEFINING THE PROBLEM

Description Details
Part Name: P-125 Radiator
Shroud
Part Number: 0304FAB00710
Customer name Mahindra & Mahindra
Ltd
Customer plant Nashik / Kandivali /
Location : Haridwar /
zahirabad / Chakan
Vehicle / Model : Bolero
Ultrasonic SPM
P125 Shroud Fittment on Vehicle Stages where Molding, Assembly,
problem is detected Final Insp,Firewall
: Insp,Dock Insp.
Other similar parts NO
having the problem:
Operation Assembly Process

Material FIFOC
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P125 Radiator Shroud
 3. DEFINING THE PROBLEM

Ultrasonic SPM

Wrong Orientation of
Top to Top Assembly U Clip

Assembly Defect of P-125 Shroud 21

 3. DEFINING THE PROBLEM

What ? Reduce Rejection of P-

125 Shroud

P-125 Shroud rework No’s FROM 2 No’s

How Much ? TO 0
P-125 Shroud Ultrasonic SPM
140
2 Work Station
120

100

80 When ? By sept-2020
60

40

20
0
0
Aug-20 Sep-20 Oct-20

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 QUALITY CIRCLE TEAM

FACILATOR: Mr. MANISH CHULET COORDINATOR: SHOBHA SHELAR LEADER :KISHOR WAKTE

Work Station

MEMBER: SANJEET KUMAR MEMBER : ANJU GAIKWAD MEMBER:PRADIP NAGARE

Moulding Shop
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 4. ANALYSE THE PROBLEM

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 4. ANALYSIS OF PROBLEM

Inspection of Storage of Material

BOP BOP / RM movement to m/c

Injection Preheating
Setup Approval
Molding Material

Assembly of Final
Firewall
child part Inspection

Dock Audit FG Storage Packaging

Moulding Shop
Material FIFOC
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 5. IDENTIFICATION OF CAUSES

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 5. IDENTIFICATION OF CAUSES
Brain Storming Session

WHEN WHO WHY HOW

WHERE
WHAT

Team Came with an Idea to modify the

clip fitment area

Moulding Shop
Material FIFOC
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 5. IDENTIFICATION OF CAUSES
Brain Storming Session
Validation Report - Potential causes
VALIDATION METHOD

DURATI SAMPL POTENTIAL

SR. NO. POSSIBLE CAUSES Compon TESTING OBSERVATIONS
3G Process Factori ON E QTY CAUSES
ent PPS B Vs C Other
Method Audit al DOE
Search

1
Less torque of pneumatic               30 Min 8
Torque found within Specs 3~4
Non Significant
gun NM.3.6 NM

Untrained Operator Operator Sanjeet Kumar is working

2             10 Min 10 Non Significant
since7 years in molding
 
Air pressure is with Specs 7.5 bars
3 Low air pressure               10 Min 5
( 7±1 bars)
Non Significant

4
Gap between top and               10 Min 10 6 parts found at dock audit with Gap. Significant
bottom
5 Screwing hole short mold               10 Min 5 No short mold at screwing area Non Significant

6
U Clip thread missing               1 Hour 200 200 no's verified.No thread missing Non Significant

7 Screw thread missing               1 Hour 200 200 no's verified.No thread missing Non Significant

8 Mishandling of boxes               10 Min 10 Verified box handling .SOP followed Non Significant

Verified 100 no's. No top top assembly

9 Top top assembly               30 Min 100
found
Non Significant

10 Mounting hole mismatch               30 Min 2 No mismatch in mounting holes Significant

11 Wrong screw used               30 Min 2 Verified only M6 Screw used Non Significant

Verified and found screw OD is within

12 Screw less OD               30 Min 10
Specs.5.85 mm
Non Significant

Verified and found clip ID is within

13 Clip ID more               30 Min 10
Specs.5.85 mm
Non Significant

Moulding Shop
14 Less length of screw              
Material
30 Min 2
FIFOC
Verified and found screw length is
19.9 mm
Non Significant

15 wrong gun used               30 Min 2 Ingersoll Rand Gun used 28

Non Significant
 6. FINDING ROOT CAUSE

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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6. FINDING THE ROOT CAUSE

Unable to fit shroud on

vehicle

Why ?

Mounting hole mismatch

Why ?

Due to top & top part

Assembly

Why ?

Difficult to distinguish of top & bottom part

While Assembly
The root cause is
Moulding Shop
related to Human error
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Prone Process
6. FINDING THE ROOT CAUSE
Problem Analysis
RADIATOR SHROUD JOINT
LOOSE

Why ?

GAP BETWEEN TOP & BOTTOM

PART

Why ?
WRONG ORIENTATION OF CLIP ASSEMBLY

Why ?

POSSIBILITY OF CLIP BEING

FITTED WITH WRONG
ORIENTATION BY OPERATOR

The root cause is related to

MouldingHuman
Shop error Prone Process
Material FIFOC
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 8. DEVELOPING SOLUTION

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 8. DEVELOPING SOLUTION
Problem Analysis

Moulding Shop
33
 8. Developing Solution

Sr.
No Root Cause Actions Resp Target Dt Status
.
Assembly fixture to be
Difficult to Distinguish
Top & Bottom Parts developed such that one 10.09.202
Sandeep Completed
While Assembly. top & one bottom will be 0
fitted & Assembled

2 Rib width to be increase by

Possibility of U Clip 5mm such that clip will not be
fully inserted & screwing Sandeep 10.09.202
Being Fitted Wrong operation will not be possible Completed
/Kishor 0
by Operator. due to part & clip screwing
hole mismatch

Moulding Shop
Material FIFOC
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 10. Trial & Implementation

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

35
3626 36
 10. Trial & Implementation

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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10. Trial And Implementation

Before

Ultrasonic SPM

Material FIFOC
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10. Trial And Implementation
After

Ultrasonic SPM

Material FIFOC
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 10. Trial And Implementation
Before After

Rib width 2 MM Rib width 5 MM

Ultrasonic SPM

Material FIFOC
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 10. Trial And Implementation
Before After

Hole Miss Match due to Hole Match with Correct

Wrong Orientation of Clip Orientation of Clip

Ultrasonic SPM

Material FIFOC
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 10 . REGULAR IMPLEMENTATION

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING

PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

42
 11. Regular Implementation

Revision in SOP

Ultrasonic SPM

Moulding Shop
Material FIFOC
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 11. Regular Implementation

Revision In Documents

1. DFMEA & PROCESS FMEA

2. CONTROL PLAN

3. TGR TGW
4. PTDB
6. MOLD CHANGE SOP Ultrasonic SPM
5. PROCESS CHANGEWork
MANGEMENT
Station

Moulding Shop
Material FIFOC
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 Tangible Benefits

Reduction in customer return Parts:- 14 Parts per Month

Cost of Rework per visit :- Rs.15000/visit at haridwar & zahirabad
Total Saving : Rs.30000 /Month

Total Saving : Rs.30000/Month

Ultrasonic SPM
Work Station

Fixture Developed in house with scrap

material

Moulding Shop
Material FIFOC
45
 Intangible Benefits

1. CUSTOMER SATISFACTION IMPROVED

2. MOTIVATION IMPROVED

3. USE OF 7QC TOOLS UNDERSTOOD

4. EFFECTIVE TEAM WORKING

5. USE OF MINI TAB SOFTWARE

Ultrasonic SPM
6. IMPROVEMENT IN PROBLEM SOLVING TECHNIQUES

7. GAINING OF SELF CONFIDENCE

Moulding Shop
Material FIFOC
46
 Tools Learned

Sr. QC TOOLS Used Sr. QC TOOLS Used

1 Check Sheet 1 Human Error Prevention

2 Pareto diagram 2 Brain Storming

3 Cause & Effect diagram 3 Why-Why Analysis
4 Stratification 4 Gemba Analysis
Graph & ControlWork Station
5 5 PQCDSM
Charts
6 Histogram
7 Scatter Diagram
Moulding Shop
Material FIFOC
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 11. FOLLOW UP AND REVIEW

FOLLOW-UP AND REVIEW

REGULAR IMPLEMENTATION

TRIAL IMPLEMENTATION AND CHECKING

PERFORMANCE.

FORESEEING THE PROBABLE RESISTANCE

DEVELOPING SOLUTION

DATA ANALYSIS

FINDING THE ROOT CAUSES

IDENTIFICATION OF CAUSES

ANALYSE THE PROBLEM

DEFINING THE PROBLEM

SELECTION OF PROBLEM

IDENTIFICATION OF PROBLEM

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 Planned V/S Actual

SCP Activity Planning Aug 2020 TO Oct -20

What PLAN &
Sr.No Who ACTUAL W1 W2 W3 W4 W5 W6 W7 W8 W9 W 10 W 11
Identification of PLAN                      
1 Problem  TEAM ACTUAL                      
Selection of PLAN                      
2 Problem  TEAM ACTUAL                      
Define the PLAN  
3
Problem TEAM ACTUAL                      
Analysis of the PLAN                      
4 Problem  TEAM ACTUAL                      
Finding out the PLAN                      
5 Causes  TEAM ACTUAL                      
Root Cause PLAN                      
6 Analysis  TEAM ACTUAL            
Ultrasonic
   
SPM
     
PLAN
7 Data Analysis Work Station
TEAM ACTUAL
Development of PLAN                      
8 Solution  TEAM ACTUAL                      
PLAN                      
Trial
Implementation &  KISHOR
9 Check & DIPAK ACTUAL                      
PLAN                      
Foreseeing
Probable
10 Resistance  TEAM ACTUAL                      
Regular PLAN                      
11 Implementation Moulding Shop
KIRAN ACTUAL                      
Review & Follow PLAN           Material
    FIFOC
       
49
12 Up  SACHIN ACTUAL                      
11. FOLLOW UP AND REVIEW

To Reduce In Process Rejection

For:
1 Scuff Plate
2. Adaptor
3. A pillar Upper .
4. B Pillar Upper

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OUR SINCERE THANKS TO…

 PANEL OF JUDGES
 OUR MANAGEMENT
 ALL THE DEPARTMENTS Ultrasonic SPM
Work Station
 ALL QCC PARTICIPANTS & AUDIENCE
WHO HAVE CO-OPERATED IN SUCCESSFUL
ACHIEVEMENT OF OUR TARGETS

Moulding Shop
Material FIFOC
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 THANK YOU

Ultrasonic SPM
Work Station

YOUR QUESTIONS AND

SUGGESTIONS
Moulding Shop ARE WELCOME
Material FIFOC
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