quality circle presentation by yusuff

together we can Quality Circle!Operations U & A

QUALITY CIRCLE

Systematic Approach To Problem Solving

Prepared By Mohamed Yusuff


Introduction to Quality Circle

• It is a small group of frontline operators who

continually control and improve the quality of

their work, products and services.

• They voluntarily meet together on a regular

basis to identify improvements in their

respective work areas using proven techniques

for analyzing and solving work related problems.• QC Circle activities are carried out as part of

Total Quality Management(TQM),


QUALITY CIRCLE FROM TQM

• Continuous Process Improvement – Kaizen, Six

Sigma

• Employee Empowerment – Quality Circle

• Benchmarking – Legally stealing other people’s

ideas

• Customer-Supplier Partnerships – JIT concept

• Management by fact.


WHY WE NEED QUALITY CIRCLE

• Its provides an opportunity for members

to develop their creative thinking

• As the members study and learn

together, their full potential is realized

• To contribute to the improvement and

development of an Organisation.


OBJECTVES OF QC

• Establishment of a pleasant workplace

• Establishment of a state of control

• Enhancement of morale

• Establishment of sound human relations

• Better income

• Improvement in Quality Assurance


• Increased productivity

• Improved quality of work life

• Boost employee morale

• Enhances creativity

• Improved teamwork

• Employee involvement

POTENTIAL BENIFITS


ORIGIN OF QC

• The first Quality Circle was organized in 1962, by Japan Nippon Telegraph company.

• It was supervised by Mr.Deming and Dr.Juran.

• Japan Started JUSE (Union of Japan Scientists and Engineers) to spread Quality control circle.


Asian Productivity Organization

• Japan• South Korea • Taiwan• Singapore• Malaysia • the Philippines• Hong Kong• India, • Indonesia• Thailand• Sri Lanka • Pakistan and Vietnam


QUALITY CIRCLE IN COIL SHOP

• In Coil shop Quality Circle successfully started on 30th March 2013.

• Total 13 team formed on 24th March 2013.

• Booklet and training provided 8th April 2013.

• Currently successfully continuing the Improve phase.


QC Team Formation-Coil shop

Line/Area Assy Brazing Tubing Coating

CAC-11 Team

13 Members2 Team

26 Members 2 Team16

MembersCAC-21 Team

6 Members1 Team

7 Members

AHU1 Team

9 Members1 Team

10 Members 1 Team9 Members

Chiller1 Team

10 Members1 Team

9 Members

Resistec1 Team

10 Members

Total Team :13


QUALITY CIRCLE IN COIL SHOP

• Assigned Leaders and sub leaders for each team.

• Team name selected by each team members

• Each team took each project from their own area. Total 13 project in progress.


Team list with Project

S.N Line Area Team nameTeam

LeaderSub Leader Project description Target description

1

CAC-1

M/C Shop Success Renji WassilTo Reduce Fin & Cu Tube damages in all stages

Current Level is 3 NCN/Month Target- 1 NCN/Month

2 Brazing-1 Rose Riders Girish ManojTo Reduce Return Bend Leak rate below 0.5%

Current return bend leak rate is 2.1%Target- 0.5 %

3 Brazing-2 Speed Riders IlyasMohsin aalam

To Reduce Return Bend Leak rate below 0.5%

Current return bend leak rate is 2.1 %Target- 0.5 %

4CAC-2

M/C Shop Fire Crackers Raj kamal Emilio To Eliminate wrong Coil assemblyCurrent Level is 3 NCN/Month Target- 1 NCN/Month

5 BrazingSeven Star

BrazersVarghese Ansar To Reduce Brazing Leak rate Below 1%

Current leak rate is 3 %Target - 1 %

6 CACTube shop

Parts Perfect Jahangir MahroofTo Reduce InProcess scraps of copper tubes

Current scrap is 12 LbsTarget to below 4 Lbs

7 Assy Brazing Bullets MonirAkbar,Sabbir

To Reduce InProcess scraps of copper tubes


8AHU

M/C Shop YIPS Express AzzizBlitz

,IliyasTo Increase Per day production by 30%

Avg daily production is 11 Target to 14

9 Brazing CourageAbdul

KhaderFakrudeen To Reduce Brazing Leak rate Below 1%

Current leak rate is 4.6 %Target- 1 %

10Chiller

M/C ShopPSDOS

(Problem solving,Developing of skill)

Krishna Kumar Jha

Erwin,MalickTo Reduce In Process scraps of Copper tubes

Current scrap is 1.8 LbsTarget to below 0.5 Lbs

11 BrazingRoyal

ChallengersAnas

Ashraful,Ajay Kumar

To Reduce Brazing Leak rate Below 1%Current leak rate is 3.1 %Target- 1 %

12Chiller Tube shop

Parts&Assy Professional Aquil HassanTo Reduce In Process scraps of Copper tubes


13 Resistec Coating Resistec X1 Thaisen Jackson To Improve Efficiency of coating lineCurrent Level is 2 NCN/Month Target- 0 NCN/Month


GANT CHART-Full Program

Description Plan/ Actual

WK-12WK-

13,14

WK-15,16,1

7

WK-18,19,

WK20-48

WK-48-52

WK-52

Intro+ education+ team formation

PLAN

ACTUAL

Define phase Training + project assign

PLAN

ACTUAL

Measure phase training + data collection+ Brainstorming

PLAN

ACTUAL

Analyze(Training+Pareto chart)

PLAN

ACTUAL

Improve Phase(Implementation)

PLAN

ACTUAL

Control Phase training+ implement

PLAN

ACTUAL

-Planned -Completed


ABOUT PROJECTS

• Format used – DMAIC

Define, Measure, Analyze, Improve &

Control

• Periodical training & meeting conducted.

• Internal meeting conducted by team

leaders in work place every month to

define their own stage problems.


ABOUT PROJECTS

• Tools used

- Pareto chart

- Cause and Effect diagram

- FDM(Function Deployment Matrix)

- Brainstorming

- Check sheets


• Each Project working on minimum 2

problems which is to improve on their

stage.

• Total 32 improvements related to their

own stage is in progress.

Improvements observed


Major improvements

Return Bend Leak rate reduction in CAC-1 (Team-Rose riders & speed riders)

Action Taken:1.Check sheet displayed to monitor the leak from every stage.

2.Input Butane pressure regularized by placing adjustable pressure gauge.

3.Practicing Pre heat to reduce oil level in flare.(if found more oil on flares)

4.Continual feed back system by internal operator itself.

Brazing Leak reduction in AHU & Applied Coil shop(Team-Seven star brazers, Courage& Royal challengers)

Leak rate-1.1%Leak rate-2.1%

Leak rate-1.0%Leak rate-3.0%


Before Improvement After Improvement

Location:CAC-1 Brazing Area Team-Rose riders

Type: Quality Improvement (Leak rate reduction)

Effect on implementation: Return bend leak rate will be reduce

Dust and moisture accumulate on return bend which is stored in box can creates corrosion and cause leak

Return bend stored box will arrange and N2 gas will insert in serial to all box, so that external moisture will not enter.

IMPROVEMENTS

Improve18

N2 IN N2 OUT

Return bend storage box



In progress



Location: CAC2 Machine shop Team- Fire Crackers

Type: Productivity Improvement

Effect on implementation: Wrong coil assembly will reduce

After Process sheet obtain from scheduling, in coil shop there exist manual editing for coil size and hair pin Qty which creates wrong coil due to wrong entry.

With the help of Scheduling process sheet changed with required data to produce coil without manual editing

IMPROVEMENTS

Improve19

Photos attached on next slide

Photos attached on next slide

Process In progress


Process sheet-Current


Modified Process sheet



Location: AHU Brazing Area Team-Royal Challengers

Type: Quality Improvement (Leak rate reduction)

Effect on implementation: Constant gas pressure obtain thus leak rate will reduce

Gas pressure was not proper due to flux blockage ,lengthy hose and hose frequent damage.

Brazing hose arranged and standardized by extending steel pipe up to brazing stage to make hose length short and constant gas pressure.

IMPROVEMENTS

Improve22



Location: Resistec Team-Resistec 11

Type: Productivity Improvement

Effect on implementation: Process time reduction with improved Quality

Coils were coated by keeping on drums. Coating done on one face and hold it for drying about 6 hrs and then coating on the opposite side..

Moving trolley made with hanging system, Now coils will coat/spray and directly move to the oven without lifting the coils

IMPROVEMENTS

Improve23



Location: Chiller Team-Courage

Type: Productivity and Quality Improvement

Effect on implementation: Process time reduction with improved Quality

During Crimping for valve insertion in Evap coil, there no flare exist, which cause difficulties in brazing tends to leak occur

Design of crimping tool need to alter by cutting a slot in tool of flare rest area.

IMPROVEMENTS

Improve24

In Progress



Location: CAC Tube Shop Team-Perfect Type

Productivity and scrap reduction Improvement

Effect on implementation: Cu tube Scrap due to roll end will totally eliminate.

In straight tube cutting machine roll end tube not able to cut due to machine limitation

Manual cutting machine ordered so as to cut roll end tube at instant, by this minimum length can be cut according to our process requirement.

IMPROVEMENTS

Improve25


Various improvements

• CU Scrap reduction by introducing

– Tube clamping system to standardize the cutting angle.

• Process improvement

– AHU brazing carried out in sequence table to increase

productivity

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