tqm project

TQM PROJECT

DEEPAK SPINNERS LIMITEDBADDI (H.P.)

Group No:- 3

To increase the utilization of ringframes to 92 %.

TQM PROJECT TITLE

.

TQM PROJECT NEED (REASON TO CHOOSE THE PROJECT)

Utilization is one of the major factor for survival of any industry specially Textile. It affects over all profitability

of the Mill.

UTILIZATION IS LIFE LINE OF THE MILL

TO IMPROVE IT

UTILIZATION IS LIFE LINE

JOIN HANDS

.

FACILITATOR,TEAM LEADER & MEMBERS

Facilitator : Syt. Shantanuji Daga(Arrangements & Guide lines)Team Leader : Sh. Sudesh Tiwari (Guide lines)Members : Sh. V.B. Shrivastava(Participation- B.S.) : Sh. S.K. Thakur (Participation- B.S.) : Sh. H.S. Sharma (Data collection -”-) : Sh. M.K. Mishra (Data collection -”-)

.

ATTENDENCE SHEETS.N

. DATE Topics S.Tiwari V.B.S. S.K.T. H.S.S. M.K.M.1 20.07.11 TQM Team formation  P  P  P  P  P

2 25.07.11 Problem & mission statement  P  P  P  P  P

3 29.07.11  Project disscussion  P  P P   P  P4 02.08.11  Flow diagram  P  p  p  P  P

5 05.08.11  Brain storming  P  p  p  P  P

6 09.08.11  Evaluation of brain storming  P  p  p  P  P

7  17.08.11  Cause & effect diagram  p  p  p  P  P

8 02.09.11  Data collection & data analysis p  p   p  P  P

9 16.09.11 Test theory  p  p  p  P  P

10 30.09.11  Data analysis of test theories  p  p  p  P  P

11 19.10.11 Project review  p  p  p  P  P

Utilization is low i.e. 77% since last 12 months, leading to a production loss of 5.5T/day or Rs.25 Lac/month.

PROBLEM STATEMENT

To improve average Ring Frame utilization from 77% to 92% by

30TH Nov.2011 to save the amount of Rs.300Lacs/annum.

MISSION STATEMENT

Data for validation of problem statement

Month Utilization L/SPower

Fail Prog.Unav.Fiber

changeProgram change  Total

June-10 59.30 31.53 1.44 4.37 2.72 0.64 100July-10 70.09 19.91 1.24 4.50 3.30 0.96 100Aug-10 82.22 6.78 1.33 4.82 3.86 0.99 100Sep-10 83.59 5.80 1.49 4.98 3.45 0.69 100Oct-10 83.23 7.80 0.53 4.16 3.50 0.78 100Nov-10 77.81 14.49 0.29 4.01 3.05 0.35 100Dec-10 83.22 7.91 0.51 4.61 3.00 0.75 100

Jan-11 81.83 9.25 0.68 4.41 3.06 0.77 100Feb-11 84.97 5.85 0.97 4.50 2.93 0.78 100Mar-11 78.11 14.02 0.81 3.65 2.61 0.80 100Apr-11 70.87 21.27 1.02 3.74 2.31 0.79 100

May-11 70.87 21.27 1.02 3.83 2.29 0.72 100June-11 67.42 25.59 1.70 2.76 1.93 0.60 100July-11 71.79 20.77 1.93 2.43 2.42 0.66 100

Average 76.09 15.16 1.07 4.06 2.89 0.73

Validation of problem Statement

Detail of factors & lossesS.N. Description %age

1 Labour Short 14.152 Prog. Not available 3.713 Fiber Change 2.684 Programme Change 0.785 G.P.F. 1.49

Total loss 22.81Production loss (Per Day) 5.5 T

Loss in Rs. (Profit@Rs15/kg) 25 Lac/M

QC TOOLS USED

Brain storming Flow diagram Cause & effect diagram Pareto

• .

DIAGNOSTIC JOURNEY

Take issue R/M as per program

Start

Single Ply

End

Yes

Mixing laid

Spinning Process

Packed

Processed for

Double

NO

Inspected

OK

Not OKProcessed to rectify

fault

OKDispatch to

customer

BRAIN STORMING

.

REFLECTED POINT OF BRAIN STORMING

1. On roll labour shortage 2. Labour negligent.3. In disciplined labour.4. Late reporting & early leaving labour.5. Taking out lighter doffs & delaying doffs.6. Working idle spindles.7. Poor training of workers.8. Poor water quality.9. Scaling problem.10.High moisture in the raw material.11.Higher breakage rate.12.Higher cuts/ faults at autoconer.13.Sub standard recipe.14.Scheduled machine spares delayed.15.Sub standard spares.16.Machine setting disturbed.17.Frequent program change.18.High turnover of skilled labour.19.Frequent setup change.20.Communication gap

METHOD MAN

MACHINE MATERIAL

CommunicationPoor

Production Planning

High Turn Over of Skilled Worker

Indiscipline

On Roll labor shortage

High moisture in raw material

Poor Water Quality

Frequent Set Up Change

Change In Programme

Poor Training

High Work Load

Miscommunication

Delay

Idle Spindle

Deliberately Slow Down M/C

36 Hour & more Duty

Not Habitual of Night Duty Late Reporting

Early Leaving

Non Standard spare

Delayed Supply

Poor WorkingScaling Problem

Poor Working

Scaling

Cause & Effect Diagram

LOW R/F UTILIZATION

Delay Doff

Light Doff

Negligency

Lack of ownership at

shop floorImproper Production

Monitoring

Poor charge

Sub Standard RecipeHigh Waste Generation

Poor Working

High Breakage

High A/C Cuts

M/C Spares

Automation System Failure

M/C Setting Disturb

Production Loss

Low Ringframe Utilization

JUN 10

JUL 1

0

AUG 10

SEP 10

OCT 10

NOV 10

DEC 10

JAN 11

FEB 11

MAR 11

APR 11

MAY 11

JUN 11

JUL

11

AUG 11

SEP 11

OCT 11

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

L/SProg.Unav.Fiber ChangeG.P.F.Prog.Change

GROUPED BAR GRAPHFACTORS AFFECTING UTILIZATION

JUN 10

JUL 10

AUG 10

SEP 10

OCT 10

NOV 10

DEC 10

JAN 11

FEB 11

MAR 11

APR 11

MAY 11

JUN 11

JUL 11

AUG 11

SEP 11

OCT 11

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

45.00

Prog.Change

G.P.F.

Fiber Change

Prog.Unav.

L/S

STACKED BAR GRAPHFACTORS AFFECTING UTILIZATION

• .• .

PARETO ANALYSIS

L/S Prog. N/A Fiber Change

G.P.F. Recipe Change

0100200300400500600700800900

1000

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

freq. Cum.%age

USEFUL MANY

REASONS FOR LOW UTILIZATION

Freq

uenc

y

Reason

Cum. %

age

VITAL FEW

REMEDIAL JOURNEY

PRIORITAZATION OF CAUSES SELECTED FROM BRAINSTORMING & GRAPH

Labour short Program not available

REMEDY OF CAUSE (TO MINIMIZE L/S)

1. Facilities of workers should be increased & should be reviewed from time to time.

2. Revise wages annually according to industry standard.3. Strength of female workers should be maintained at 10 % of workforce. 4. Transport facility should be provided for commute of female workers. 5. Search & recruit workers from non – traditional areas such as Nepal &

Assam. 6. Implement incentive schemes to increase daily attendance of workers

and discourage them from long leaves.7. Incentive schemes for maintaining on roll are implemented for jobbers. 8. Hostel facility for female workers is provided & new hostel is under

construction. 9. Various motivational activities have been started.

REMEDY OF CAUSEFollowing points are under consideration for

remedy of other causes like non availability of Program, recipe change & Program change.

1. To build customers of big houses to get large orders.

2. Collaborate with purchase department in order to reduce losses due to change in recipe.

3. To search new stations for marketing to achieve higher realization.

Validation of gains (After)

Month UTI. L/S G.PF.Prog.Unav.

Fiber change

Prog.change  

Aug-11 81.67 7.74 3.02 3.67 2.88 1.02 100

Sep-11 88.61 1.63 3.45 3.05 2.60 0.66 100

Oct-11 88.95 0.56 3.50 3.62 2.58 0.79 100

Nov-11 89.83 1.73 2.20 3.01 2.48 0.75 100

Average 87.27 2.92 3.04 3.34 2.64 0.81  100

GAIN AFTER IMPLEMENTATION

JUN 10 JUL 10 AUG 10

SEP 10 OCT 10 NOV 10

DEC 10 JAN 11 FEB 11 MAR 11

APR 11 MAY 11

JUN 11 JUL 11 AUG 11

SEP 11 OCT 1150.00

60.00

70.00

80.00

90.00

100.00Utilization

Utilizationmonth & year

utili

zatio

n %

age

Avg 77.19% before implementation

Avg 86.41% after implementation

Validation of gains(Aug to Nov. 2010 & 2011)

Utilization L/S0

10

20

30

40

50

60

70

80

90

100

Aug-10 to Nov-10Aug-11 to Nov-11

HOLDING THE GAINS1. Worker’s retention to be increased by 10% and above.2. Facilities like residence , hostel will be completed till

31st of march.3. Various motivational incentives to maintain on roll

strength will be continued.4. Inflow of workers from other areas like Nepal will be

continued & new areas like Assam, W.B. will be explored.

5. Strength of female workers 7 to 10% will be maintained.

6. Transport facility will be continued & maintained.7. Trainee strength will be maintained according to

turnover , it would be continuously monitored & and new recruitments will be done regularly.

8. Extra precaution will be taken during festival season & peak labour shortage period.