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

Page 1

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.

All rights reserved by www.ijste.org

79


Turn static files into dynamic content formats.

Create a flipbook
Issuu converts static files into: digital portfolios, online yearbooks, online catalogs, digital photo albums and more. Sign up and create your flipbook.