Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study

IJSTE - International Journal of Science Technology & Engineering | Volume 4 | Issue 6 | December 2017 ISSN (online): 2349-784X

Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study S. R. Kulkarni A. S. Gadge Assistant Professor QC Consultant Department of Mechanical Engineering Member Governing Council Quality Circle Forum of India Shri. Ramdeobaba College of Engineering & Management, Nagpur Chapter, Nagpur Nagpur A. P. Kedar Professor Department of Mechanical Engineering Dr. Babasaheb Ambedkar College of Engineering& Research, Nagpur

Abstract The current case study is carried out at Tyre manufacturing plant by a Quality Circle (QC) team. The main focus of the work is to reduce the waste in Extruder Department. The QC team identified 52 problems after multiple brainstorming sessions. The various quality circle techniques like ABC analysis and 3P analysis are used to finalize the problem statement. The selected problem is part poly roll generation at 8x6” CFE due to difficulty in fitting parallel poly roll to first poly roll. The QC tools like Root Cause analysis, 4 W & 1 H analysis, Cause and Effect Diagram and Why-Why analysis are used to find the root causes and solution. After implementation of proposed solution the part roll generation is reduced from 15 to 0, part roll scrap is reduced from 9 to 0 and cost benefit of Rs. 3, 08,460 per year is achieved. Keywords: Quality Circle, Extruder Department, Root Cause, Part Roll Generation and Zero Scrap ________________________________________________________________________________________________________ I.

INTRODUCTION

Quality Circle (QC) is a powerful tool to solve the various work related problems in a manufacturing plant by the involvement and participation of the workers. Groups of 8-10 workers working in related areas are formed, each group being referred as a Quality Circle or a Quality Circle Team who follow a prescribed methodology right from the problem identification to the implementation of the final solution. The workers develop problem solving attitude and abilities and continue to identify and solve more problems contributing substantially to improvement in productivity, quality and safety in the plant. The role of management is to facilitate and motivate the workers. The current case study is carried out at Tyre manufacturing plant in Extruder Department. The main focus is to reduce the wastage. The quality circle team conducted multiple Brainstorming sessions and come out with 52 problems like Broad line ID on tread at 8x6” cfe, Cushion off centre in radial sizes , Part poly roll generation due to fitment problem of parallel poly roll to first poly roll, Grease and oil leakages from cushion mill guide at 8x6” cfe, Grease and oil leakages from cushion mill guide at 10x8” cfe, No proper parking area for tread leaf skids and Power wastage during beltage and radial filler extrusion at 3.5/4.5” hfe etc. II. LITERATURE REVIEW A review of the literature is carried out to understand the process of implementing the quality circle programme in an organization and the steps to be followed in solving the problems using the QC approach. Anad Jayakumar A etal. [2015] has discussed the procedure for formation and implementation of Quality Circles in an organization. The details like objectives of QCs, structure of QCs, roles and function of all the stakeholders from top management to the circle have been discussed. The use of 7 QCs tools and PDCA cycle which are at the core of solving the problems using the QC approach are discussed by Chiragkumar etal. [2014] in the context of solving the problem of rejections in the taper roller bearings using the QC approach. QC activities can fail at various stages due to organizational issues, circle formation issues, operational issues recognition issues etc. QCs awareness for the management and QC training for the workers are very important for the success for the QC programme. The support of top management and proper training to the workers are quite important for the success of the QC programme. Shantanu Welekar and Shantanu Kulkarni [2013], have discussed the use of Quality Circle to improve productivity and compared the Quality Circles with, Quality Improvement Groups and Work Groups/Project Teams. Extensive literature is available to guide the beginners to learn the basics of the quality circles and their successful implementation for solving the problems.

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Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study (IJSTE/ Volume 4 / Issue 6 / 015)

III. PROBLEM SELECTION The Quality Circle team, in extruder department started to resolve the problem like increase in cost due to losses, scrap formation and product quality improvement. The identified problems are categorized into A, B, C types depending on the involvement of other department and management. Selection of problem is done by using ABC Analysis tool where A is Minimum or NO involvement of other departments. B is Maximum Intervention or Help of other departments is required. And C is Management Intervention/Help sanction is required to implement the suggested solutions. The numbers of problems in each category as per ABC Analysis are as follows-

Fig. 1: ABC Analysis

Further the 3P Analysis is carried out for selection of specific problem statement:First stage is ‘Proprietary’ in which Groups of different problem are formed as per company specific objective and strategic plans and they are as follows- Productivity, Quality, Muri, Mura, Muda, Safety and 5S. The group members rated the problem in scale of 1 to 5. The group members gave more weightage to Problems coming under mura, muda, muri. Problems under Muri, Mura, Muda concerned become our priority as it matches with Sectional Objective.

Fig. 2: Pie Chart for Proprietary

Second Stage is ‘Priority’ in which selection of few important problems from first stage analysis according to impact and concerns within department are done. The number of problems affecting Mura, Muda, Muri, are listed below1) Broad line ID on tread at 8x6” cold feed extruder. 2) Cushion off centre in radial sizes. 3) Productivity loss in without poly sizes treads. 4) Side crack in sizes during startup extrusion with T1192 rubber compound. 5) Part poly roll generation d at 8x6” cold feed extruder due to difficulty in fitting parallel poly roll to first poly roll. 6) Die cut in truck sidewall. 7) Cushion getting lumpy on mill. 8) Mix up of colour bottles at 10x8“& 8x6” Cold Feed Extruder. 9) No liners in tractor tread trolley. 10) Muda in searching liner skids.

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Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study (IJSTE/ Volume 4 / Issue 6 / 015)

Third Stage is ‘Preference’ for Final selection of one problem statement based on actual data. Again weightage method is used to set the priority of problem with a scale of 1 to 5. The highest weightage is given to the problem of “Part poly roll generation at 8x6” CFE due to difficulty in fitting parallel poly roll to first poly roll”. The following objectives are defined for the selected problem:  Cost  Zero Scrap  Improved Product Quality  Muri reduction IV. PROBLEM SOLVING METHODOLOGY The methodology adopted included Root Cause analysis, 4 W & 1 H analysis, Cause and Elimination analysis.

Fig. 3: 4 W & 1 H analysis

Fig. 4: Cause and Elimination Analysis

Based on above analysis the three potential causes for the selected problem are- rolls not getting fit in input shafts of bracket, part rolls dirty and not in condition to use and changeover not done as per spec. Further the Why- Why analysis is carried out to find out the root causes. The root causes identified are as follows: Stress due to frequently getting down in pit for changing rolls.  No provision for changing rolls.  Gap between shaft and wall less. The effect of these causes is as shown in the graph below

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Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study (IJSTE/ Volume 4 / Issue 6 / 015)

Fig. 5: Part roll generation and scrap from Jan’17 to Apr’17

Based on the above analysis the proposed solution is to make provision for fitting two poly rolls of different sizes to avoid part roll generation and to break wall and increase gap between shaft and wall. It is decided to have a trial implantation on breaking of wall and increasing the gap between shaft and wall. After implantation for two months period and satisfactory results the implantation is done for four more months. It is observed that the part roll generation and scrap is reduced to zero. It can be seen in the given bar chart below-

Fig. 6: Part roll generated and part roll scrap

V. CONCLUSION From the above case study it is observed that in the extruder department, Part poly roll generation at 8x6” CFE is due to difficulty in fitting parallel poly roll to first poly roll. The selected problem is resolved by making provision for fitting two poly rolls of different sizes to avoid part roll generation by breaking wall and increase gap between shaft and wall. After implementing the solution on regular basis the part roll generation is reduced from 15 to 0 and part roll scrap is reduced from 9 to 0. The proposed solution is reducing the waste to zero thereby saving the expenditure by Rs. 3,08,460 per year. Apart from these tangible gains the other benefits and gains like improved motivation level, increase in team spirit, increase in awareness of QC techniques, rework reduction and reduced Muri and Muda of millman are achieved. REFERENCES [1] [2] [3] [4]

Chiragkumar S. Chauhan, Sanjay C. Shah, Shrikant P. Bharagalikar, (2014) “Improvement of Productivity by Application of Basic Seven Quality Control Tools in Manufacturing Industry”, International Journal of Advance Research in Engineering Science & Technology, pp-15-19. Anad Jayakumar A, C. Krishnaraj, (2015) “Quality Circle – Formation and Implementation” International Journal of Emerging Researches in Engineering Science & Technology, Vol – 2 Issue-2. Jyoti Prakash Majumdar, B. Murali Manohar, (2011) “How to make Quality Circle a success in Manufacturing Industries”, Asian Journal on Quality, Vol12, Issue 3 pp-244-253. Shantanu Welekar, Shantanu Kulkarni, (2013), “Quality Circle To Improve Productivity”, International Journal of Engineering Research and Applications (IJERA), Vol. 3, Issue 2, pp.814-819

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Effective Implementation of Quality Circle to Achieve Zero Scrap: A Case Study

Published on Feb 14, 2018

IJSTE

The current case study is carried out at Tyre manufacturing plant by a Quality Circle (QC) team. The main focus of the work is to reduce the waste in Extruder Department. The QC team identified 52 problems after multiple brainstorming sessions. The various quality circle techniques like ABC analysis and 3P analysis are used to finalize the problem statement. The selected problem is part poly roll generation at 8x6” CFE due to difficulty in fitting parallel poly roll to first poly roll. The QC tools like Root Cause analysis, 4 W & 1 H analysis, Cause and Effect Diagram and Why-Why analysis are used to find the root causes and solution. After implementation of proposed solution the part roll generation is reduced from 15 to 0, part roll scrap is reduced from 9 to 0 and cost benefit of Rs. 3, 08,460 per year is achieved.