Quality Improvement Of purchased MaterialPresented by:Shambhu Parte08IM6019Guided By: Prof. J.Maiti

Out LineCompany ProfileCompany ProductWorking ProcessProblem DefinitionLiterature SurveyObjectiveScopeReference

Company ProfileBirla Power Solutions Ltd., (BPSL), established in April1984 in collaboration with globally renowned Yamaha Motor Co.The Company is presently producing a wide range of Generators catering to the power requirements of 500W to 40K.Wbeing fuelled by variety of fuel options like Kerosene , Petrol, Diesel, LPG ,CNG ,Biogas etc.The modern manufacturing unit is established near Dehradun (Uttarakhanda) in a very scenic and serene backdrop of hills & forest, with a capacity of 125,000 Smaller Gensets and 75,000 Multi Purpose Engines & Higher KVA Gensets of 20000 units per annum.

Company ProductSilent Portable Generators(Birla Eg2000A-Eg2800)Y B Series

Multi Purpose Engines (MPEs)

BatteriesHigher Capacity Silent Generators(Range 5KV-45KV)

Pump setsInverters(100VA-10KVA)Power Tiller

Working ProcessMaterial receiving in storeMaterial inspection on quality assurance dep. OKRejectRework & SegregationSend back to VendorAssembly ShopFinal Product

Problem DefinitionMaterial lot rejection (basically purchasing material), maximum rejection in engine parts just like gear, Ring gear, piston, starter, camp shaft and electrical material like wire harness, wire coating for AC and DC current.Lot of time expense in rework and segregation, here main sheet metal type material. Material name pipe exhaust, fuel tank, canopy, casting.In machine shop do not care about machine setting for casting material, casting material crank case, connecting rod, head cylinder, cam shaft. Scrap do not maintain proper way, main scrap got by machine shop like aluminium metal.

Problem

S.N.Material nameFre. Of Problem (%)Cumm.Fre. Of Problem (%)1Receiving material lot rejection38382Receiving material lot rework &segregation31693Machine setting21904Scrap in machine shop10100

Pareto Chart For problem

Literature SurveyJonathan Moules (2009) worked on this problem and suggest to set up your agreement with your supplier correctly at the start of the relationship, carry out credit checks on the company to ensure it is viable and ask to speak to its other customers. Ensure your contract allows for quality control and hire an agent.Auguston, Karen A.(1992) started thinking about developing closer relationships with its suppliers. Getting involved in a partnership makes any organization worry about losing control.

Literature SurveyChung-Chi Hsieh and Yu-Te Liu (2009) both has given a suggestion a serial supply chain that consists of one supplier and one manufacturer, each having imperfect production and inspection processes.

Objective Reducing purchased material lot rejection on vendor site.Reducing purchased material lot rework & segregation on vendor site.

Scope We have been gathering last three month all number of lot rejection material data then we find out higher rejection material data.

S.N.Material NameNo. of Lot rejectionFrequency lot Rej.(%)Cumm. Fre(%)1camp Shaft1216.6666666716.666666672Gear1013.8888888930.555555563piston912.543.055555564Carburettror811.1111111154.166666675Ring Gear79.72222222263.888888896Oil lelvel gauge79.72222222273.611111117Wire harness68.33333333381.944444448Stater56.94444444488.888888899Case fan45.55555555694.4444444410Control box45.555555556100

Pareto Chart For Material Lot Rejection

Scope..We have been gathering last three month material lot rework and segregation data then find out maximum rework and segregation material.Table for Pareto Chart

S.N.Material NameNo.of lots Rework &SegregationFre. Of R&S(%)Cumm. Fre. Of R&S (%)1Pipe Exahust 1418.1818181818.181822Stator1012.9870129931.168833canopy911.6883116942.857144Fuel tank810.3896103953.246755Casting cam shaft79.09090909162.337666Plate element79.09090909171.428577Muffler comp.79.09090909180.519488Fuel cock67.79220779288.311699Casting crank case56.49350649494.8051910Piston rings45.194805195100

Pareto Chart for Rework & Segregation

ReferencesJonathan Moules. Suffering material losses from importsFinancial Times .London (UK):Jul 18, 2009.pg. 29.Auguston, Karen A. Vendor Partnering Pays Off for Pillsbury.Modern Materials Handling.Boston:Aug 1992. Vol. 47, Iss. 9;pg. 47, 3 pgs.Chung-Chi Hsieh and Yu-Te Liu Quality investment and inspection policy in a suppliermanufacturer supply chain European Journal of Operational Research In Press, Corrected Proof,Available online 22 June 2009.

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