WELCOME QUALITY CIRCLE

GARDEN REACH SHIPBUILDERS & ENGINEERS LIMITED (MINISTRY OF DEFENCE) 43/46, GARDEN REACH ROAD, KOLKATA – 700 024

INDIA

GRSE

DISHARI-S

OUR COMPANY
 GARDEN REACH SHIPBUILDERS & ENGINEERS LTD

 CENTURY OLD GLORIOUS SHIPBUILDING ORGANISATION IN EASTERN REGION OF INDIA
 “MINI RATNA” PUBLIC SECTOR UNDERTAKING UNDER MINISTRY OF DEFENCE, GOVT OF INDIA  HAVING 4050 EMPLOYEES  PRODUCING PRODUCTS FOR THE NATION
SLIDE 2

GRSE

DISHARI-S

FRIGATE

CORVETTE

FAST PATROL VESSEL

HOVERCRAFT

SLIDE 3

GRSE DISHARI-S DECK MACHINERY EQUIPMENT DIESEL MARINE ENGINE NAVAL PUMP PORTABLE BAILEY BRIDGE SLIDE 4 .

GM(IE&P) : 08 36 04 033 : 06 : 430 (FROM 14. 2001 TO 07.GRSE DISHARI-S BRIEF HISTORY OF THE QUALITY CIRCLE : 209 : DISHARI-S/SQC4  NO OF QC TEAM IN GRSE  NAME / QUALITY CIRCLE NO.  NAME OF CONTACT PERSON  QCFI INSTITUTE MEMBERSHIP NO  NUMBER OF MEMBER IN THE CIRCLE  NUMBER OF MEETINGS HELD SINCE FORMATION OF THE CIRCLE  DAY/DURATION OF WEEKLY MEETING : SHRI K S VERMA.11) : THURSDAY / ONE HOUR (3:30 PM TO 4:30 PM) : 88% : 14  AVERAGE ATTENDANCE IN THE MEETING IN THIS PERIOD  NUMBER OF PROBLEMS SOLVED & IMPLEMENTED THE SOLUTIONS IN IN THIS PERIOD SLIDE 5 . 09.07.

INCLUDING SLIDE 6 .GRSE DISHARI-S ONLY STRUCTURAL FABRICATION SHOP AT FOJ ENGAGED IN FABRICATION OF :  ALMOST ALL STRUCTURAL OUTFITTING WORK MS & ALUMINUM PANELS (DECK & BHD) . WORK. MAST. SEAT FABRICATION OF YARD MTC. FOR VARIOUS EQUIPMENTS ETC.

A GAURAV Coordinator : Mr. S RUDRA Leader: Shri Shyamakanta Polley Deputy Leader: .GRSE DISHARI-S MEMBERS & OFFICE BEARER OF QC TEAM DISHARI – S Facilitator : Mr. Shri S Chakraborty DISHARI .Shri Aloke Kumar Ghosh Members: 1.S SLIDE 7 . Shri S Bachar 3. Shri Hiralal Roy 2.

&11) 2003&07 03 (2004 .C. MUMBAI. 2 01 (2003) 3 06 (2003.GRSE SL NO 1 ACHIEVEMENTS AREA OF COMPETITION INTERNAL. 2010 & 2011) RANKED.PAR EXCELLENCE /EXCELLENT 5 6 APPRECIATED RANKED. 09 . KOLKATA BENGALURU.& HYD. 08. BANGKOK . 08 .06. KANPUR . 04. GRSE EXTERNAL (THE ANANDA BAZAR PATRIKA. 07.(N. KERALA. GOVERNOR‟S HOUSE CHAPTER CONVENTION ON QUALITY CIRCLES – CCQC-KOLKATA. 05.09 & 10) 08 (2003. NATIONAL CONVENTION ON Q.B. 05.HYDERABAD &Vizag DISHARI-S REMARKS NUMBER OF PRESENTATION 08 (2001-2008) RANKED FIRST POSITION IN THE YEAR 2005 APPRECIATED BY QCFI. 04.OUTSTANDING / EXCELLENT 4 RANKED.06. 07 .C.Q.10.GOLD SLIDE 8 . THE ANANDA BAZAR PATRIKA & GOVERNOR OF W.) MADURAI.C.TRADE FAIR ORGANISED BY SSI ASSOCIATION. C I I COMPETITION INTERNATIONAL CONVENTION ON QC (ICQCC).

JURAN‟s 12 steps from problem identification to follow up action which is exhibited here by a PDCA cycle 12 11 10 Act Check 1 2 Plan Do 3 4 5 6 9 8 7 SLIDE 9 .GRSE DISHARI-S PDCA CYCLE WITH TWELVE STEPS FOR PROBLEM SOLVING We have followed Dr.

1 2 3 4 5 PROBLEM AREA REWORK PRODUCTION LOSS HOUSE KEEPING/SPACE DIS-SATISFACTION FACILITY NO. OF PROBLEMS 11 11 10 6 4 6 7 8 9 10 DELAY ACCIDENTAL HAZARD / SAFETY HAZARD POLLUTION / HEALTH HAZARD UTILIZATION WASTAGE/DAMAGE TOTAL 3 14 5 5 6 75 SLIDE 10 .GRSE STEP –1( A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA SLNO.

1 2 WORK RELATED PROBLEMS IN THE AREA OF REWORK REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL. NO. REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. PRESS BENDING MACHINE. SLIDE 11 1 REWORK 4 5 6 7 8 .GRSE STEP –1( A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL. NO. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. MAJOR PROBLEM AREA SL. 3 PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC. EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK.

GRSE STEP –1(A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. 1 2 3 PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. 9 WORK RELATED PROBLEMS IN THE AREA OF REWORK 1 REWORK EXCESSIVE DISTORTION DURING FABRICATION OF AL. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE. SLIDE 12 4 . SPECIALLY DURING RAINY SEASON. NO. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. NO. 2 PRODUCTION LOSS PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIP‟S SUPERSTRUCTURE WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS 10 SL NO MAJOR PROBLEM AREA SL.

DRILLS. IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL.MAJOR WORK RELATED PROBLEM AREA OF “A”. INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR.“B”. REGULATORS. OXYGEN AND D. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. ESPECIALLY WHERE PRECISION WORK TAKE PLACE. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH. TAPS ETC. “C” & “A/K” CATEGORIES (THROUGH BRAINSTORMING) SL 1 2 PROBLEMS CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING. PROBLEM AREA ACCIDENTAL HAZARD / SAFETY DISSATISFACTION RATINGS A B 3 4 PRODUCTION LOSS RE WORK A C 5 DELAY A 6 7 8 PRODUCTION LOSS UTILIZATION DELAY A C A SLIDE 13 . REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD.A.GRSE DISHARI-S IDENTIFICATION OF PROBLEM 74 PROBLEMS IN 10.C. A.M.

GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD.GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 67 PROBLEMS EXCESSIVE DISTORTION DURING FABRICATION OF AL. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIP‟S SUPERSTRUCTURE. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER. IN SITU PREPARATION OF „C‟-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM PROBLEM AREA REWORK RATINGS A 68 69 DISSATISFACTION ACCIDENTAL HAZARD B B 70 ACCIDENTAL HAZARD A 71 72 73 FACILITY DELAY REWORK B A A 74 PRODUCTION LOSS A SLIDE 14 . PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION. INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION.

GRSE DISHARI-S IDENTIFICATION OF PROBLEM OUT OF 75 PROBLEMS WE HAVE ALREADY SOLVED 13 “A” CATEGORY PROBLEMS (EXCLUDING CURRENT PROBLEM) & 08 NOS PROBLEM RELATED TO KAIZEN AND WE ARE ENJOYING THE BENEFITS AFTER IMPLEMENTATION OF THE SOLVED PROBLEMS SLIDE 15 .

KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME.GRSE DISHARI-S SOLVED PROBLEM (13. OXYGEN AND D.“A” CATEGORY PROBLEMS) PROBLEM SL. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. PROBLEMS RATINGS 5. 21. A A A A A A A A SLIDE 16 . 50. 9. GASKET CUTTING FOR PLUMBING WORK. A. NO. 39.M. 26.A. 53. WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH DURING TIG WELDING.C. 33. PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH. REGULATORS IMPROPER UTILIZATION OF CUT PIECE MATERIAL ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED.

PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. PRESS BENDING MACHINE. PROBLEMS RATINGS 58. REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. IN-SITU PREPARATION OF „C‟-CLAMPS CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIP‟S SUPERSTRUCTURE. A 67. A 61. A 72 73 A A SLIDE 17 . IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING REWORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL. EXCESSIVE DISTORTION DURING FABRICATION OF AL.GRSE DISHARI-S SOLVED PROBLEM (13. NO.“A” CATEGORY PROBLEMS) PROBLEM SL.

DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE. 14.“A/K” KAIZEN RELATED PROBLEMS) PROBLEM SL. 42. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION IMPROPER. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC. 47. NO. HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING IT‟S OPERATION CAUSES SAFETY HAZARDS. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. A/K A/K A/K A/K A/K A/K 52. 34. A/K SLIDE 18 . BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPEING OF DAMAGE CABLE.GRSE DISHARI-S SOLVED PROBLEM (08. 24. PERSONAL/ OUTSIDERS. PROBLEMS RATINGS A/K 10. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM. 20.

PROBLEM 3. PROBLEM EXCESSIVE MANPOWER CONSUMPTION AND WASTAGE OF MATERIAL FOR GASKET CUTTING FREQUENT DAMAGE OF TIG TORCH DURING WELDING PRODUCTION LOSS AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GAUGING WORK SOLUTION CUTTING GASKET WITH THE HELP OF DIE & PUNCH USING BALL PRESS MACHINE SOLUTION INDEPENDENT SUPPLY OF WATER FROM A SEPARATE OVER HEAD TANK THROUGH MANIFOLD FOR SIMULTANEOUS SUPPLY OF WATER TO SIX TIG TORCHES. SOLUTION INTRODUCTION OF SEMIAUTOMATIC GRINDING FIXTURE FOR EDGE PREPARATION SLIDE 19 .GRSE DISHARI-S SOME OF THE IMPORTANT SOLVED PROBLEM 1. PROBLEM 2.

OF PROBLEM = 53 5 0 A B C 20 17 A : Problem can be solved by Q. Members with minimum involvement of other department.GRSE STEP –2(A) DISHARI-S SELECTION OF PROBLEM STRATIFICATION OF 52 PROBLEM IN A.C.C.B. CATEGORY 20 17 16 20 15 10 TOTAL NO.ALREADY SOLVED) SLIDE 20 . B : Problem can be solved with the help of other Dept. 16 A/K : Problem can be solved through Kaizen (08 . C : Problem can be solved with the help of management.

SLIDE 21 . OPTION CHART.T. FOR SHORT LISTING OF 20 „A‟ CATEGORY PROBLEMS WE HAVE DECIDED TO TAKE THE HELP OF E.GRSE DISHARI-S SELECTION OF PROBLEM FROM THE BAR DIAGRAM IT IS SEEN THAT CATEGORY „A‟ CONTAINS 20 PROBLEMS WHICH IS MAXIMUM AND THE SAME CAN BE SOLVED BY OUR SELVES.C.

4 5 4 4 5 2 3 5 3 3 4 3 3 4 4 2 4 2 10 14 11 9 13 7 6 2 5 7 3 9 SLIDE 22 .T. DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE. E 4 5 5 4 3 2 4 C 4 5 4 4 2 2 5 T TOTAL 4 5 5 4 3 2 5 12 15 14 12 8 6 14 RANK 4 1 2 4 8 10 2 29 30 35 36 38 40 FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.C. SPECIALLY DURING RAINY SEASON.GRSE STEP –2(B) DISHARI-S SELECTION OF THE PROBLEM E. INSIDE SHOP FLOOR . PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL REWORK &FAILURE OF WELDING JOINTS FROM IMPROPER PLATE PREPARATION BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. OPTION CHART SL 1 3 6 8 11 23 27 LIST OF „A‟ CATEGORY PROBLEM CHANCES OF ACCIDENTAL HAZARD FROM DAMAGE WELDING CABLE DURING WELDING. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE. EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES MAN POWER LOSS.

UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM 62 63 64 74 2 3 3 5 3 3 2 5 3 3 2 5 8 9 7 15 8 7 9 1 E : Effectiveness in improving Man-hours or Quality of work C : Cost Effectiveness T : Cut Down Time RATING SCALE FOR E.T. NON AVAILABILITY OF ALARM BELL IN E. . I. CAUSES UN UTILIZATION OF BROKEN \OVER USED DRILL BITS & TAPS.G . T. OPTION CHART LIST OF „A‟ CATEGORY PROBLEM E PROBLEM FOR 3 2 4 C 3 2 3 DISHARI-S SL 43 57 60 T 2 2 3 TOTAL 8 6 10 RANK 8 10 6 IMPROPER STORING ARRANGEMENT IDENTIFICATION OF REUSABLE MATERIAL.T. & PLASMA WELDING MACHINE OF DIFFERENT MAKE. ANALYSIS 1 Does not meet criteria 2 Meet criteria fairly well 3 Meet criteria well 4 Meet criteria very well 5 Meet criteria extremely well SLIDE 23 . PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF T .C. G. /M . O. PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS. I.GRSE SELECTION OF THE PROBLEMS E. CRANE MAY CAUSES ACCIDENTAL HAZARD.C.

(SL NO 27). (SL NO 30) EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE. (SL NO 3) PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. INSIDE SHOP FLOOR .T. 5 6 HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE.C. ANALYSIS RANK 1 2 3 4 „A‟-CATEGORY PROBLEM ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM (SL NO 74) PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.(SL NO 6) ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. SPECIALLY DURING RAINY SEASON.(SL NO 38) SLIDE 24 .GRSE DISHARI-S SELECTION OF PROBLEM QC MEMBERS SHORT LISTED SIX PROBLEMS FROM 20 „A‟ CATEGORY PROBLEMS ON THE BASIS OF TOP RANKING OF PROBLEM BY E.

ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC.11.Sri S.POLLEY. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.ROY SL NO PROBLEM Shop In-charge REMARKS DATA COLLECTION FOR THE PERIOD OF 26. HOUSE KEEPING PROBLEM OF HANDLING TIG/MIG WELDING ACCESSORIES IN DISTANT PLACE.K.12.GRSE STEP –2(C) SELECTION OF PROBLEM CHECK SHEET DISHARI-S DATA WERE COLLECTED FROM SHOP / SITE FOR 4 WEEKS TO OBSERVE THE NUMBER OF OCCURRENCE OF 6 PROBLEMS. Sri H.10 TO 30. SPECIALLY DURING RAINY SEASON. 3 FROM SHOP & SITE FROM SHOP 1 2 2 1 6 FROM SHOP FROM SHOP & SITE FROM SHOP FROM SHOP 3 4 5 6 6 5 22 2 2 2 2 8 5 6 1 3 2 4 1 5 1 4 5 16 SLIDE 25 . SHOP – STRUCTURAL SHOP (FOJ ) Data collected By :. INSIDE SHOP FLOOR.10 1ST WK 2ND WK 4 3RD WK 4 4TH WK 4 TOTAL FOR THE MONTH 15 1 2 PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. Sri A.GHOSH. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE.

PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. 31 ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. 22 B C D 16 15 8 38 53 61 22 21 11 53 74 85 E 6 67 8 93 F 5 72 7 100 SLIDE 26 . SPECIALLY DURING RAINY SEASON. INSIDE SHOP FLOOR. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE.GRSE STEP –2(D) DISHARI-S SELECTION OF PROBLEM ( BY PARETO ANALYSIS ) PARETO ANALYSIS WERE DONE BASED ON AVAILABLE DATA ON THE CHECK SHEET SL NO A PROBLEM FREQUENCY INDVL CUMM 22 PERCENTAGE INDVL 31 CUMM. ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC.

B & C ARE THE VITAL FEW PROBLEMS. OUT OF WHICH PROBLEM „A‟ IS MOST IMPORTANT THAN OTHERS SLIDE 27 PERCENTAGE FREQUENCY .GRSE SELECTION OF PROBLEM PARETO DIAGRAM ( DRAWN ON THE BASIS OF PARETO ANALYSIS) CUMULATIVE % LINE DISHARI-S VITAL FEW 60 93 100 100 80 85 74 USEFUL MANY 60 40 31 53 BREAK POINT 40 20 20 0 0 A B C D PROBLEM E F IT IS OBSERVED FROM THE PARETO DIAGRAM THAT PROBLEM A.

GRSE DISHARI-S SELECTION OF PROBLEM “ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM” SLIDE 28 .

GRSE
 

MILESTONE CHART

DISHARI-S

MILESTONE CHART IS PREPARED OF 20 WEEKS TO COMPLETE THE PROJECT MILESTONE CHART IS HANDED OVER TO OUR CO-ORDINATOR FOR REGISTRATION OF THE PROJECT
QC MEMBERS: S. K. POLLEY, H. ROY, A. K. GHOSH, S. CHAKRABORTY, S BACHAR

QC TEAM : DISHARI ( S ) / STRUC. SHOP (FOJ ) STARTING DATE --- 06.01.11 PROJECT : ALUMINIUM ANGLES AS STRONG BACK COMPLETION DATE – 25.05.11 OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM QC STEP ACTIVITIES 1 PLAN 3 4 5 DO 6 7 8 DEFINING THE PROBLEM ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES DATA ANALYSIS DEVELOPMENT OF SOLUTION 2 3 4 5 6 7

TIME SCHEDULE IN WEEKS 8 9 10 11 12 13 14 15 16 17 18 19 20

9
CHECK 10

FORESEEING PROBABLE RESISTANCE
TRIAL IMPLEMENTATION

11 REGULAR IMPLEMENTATION ACT 12 FOLLOW-UP ACTION & REVIEW

SLIDE 29

GRSE

STEP –3(A)

DISHARI-S

DEFINING THE PROBLEM
FABRICATION & ERECTION OF AL WHEEL HOUSE IS DONE BY AL PANEL AT SITE & BRIDGE DECK OF SHIPS. SINCE ALUMINIUM ARE LIGHT IN WEIGHT AND PLATE THICKNESS IS 4MM, THERE IS A TENDENCY OF DISTORTION DURING LIFTING, TRANSPORTATION & ERECTION. TO AVOID THIS DISTORTION 4-SIDES OF ALUMINIUM PANELS ARE TEMPORARILY STRONG BACKED BY AL. ANGLES. IT IS OBSERVED THAT THE AL. STRONG BACKS GETS EITHER DISTORTED OR DEFORMED AFTER REMOVAL CAUSING WASTAGE OF MATERIAL AS WELL AS TIME.

THE SEQUENCE OF OPERATION ERECTION OF AL. WHEEL HOUSE AT SITE AND BRIDGE DECK OF SHIP BY CONVENTIONAL METHOD ARE EXHIBITED HERE WITH THE HELP OF A FLOW DIAGRAM.

SLIDE 30

GRSE

DISHARI-S

DEFINING THE PROBLEM

FINALLY WHEEL HOUSE ERECTED ON BRIDGE DECK OF SHIP
SLIDE 31

GRSE DISHARI-S DEFINING THE PROBLEM ERECTION OF ALUMINIUM WHEEL HOUSE BLOCK ERECTION OF ALUMINIUM PANELS / PARTITION WALL OF WHEEL HOUSE BLOCK AT SHIPSITE SLIDE 32 .

GRSE
DEFINING THE PROBLEM BY FLOW DIAGRAM
START
MARKING, CUTTING, DEBARRING, BUFFING OF. AL. ANGLES

DISHARI-S

TACKING/FITTING OF AL. ANGLES ON 4-SIDES OF FABRICATED PANELS FOR STRONG BACKING

LIFT AND TRANSPORT PANELS BY MOBILE CRANE AND PLACED VERTICALLY ON DECK HEAD AT SITE . ALIGN. THE PANELS ON DECK HEAD, THEN FITTING/RUNNING WELDING TO COMPLETE ERECTION REMOVE STRONG BACK S AFTER COMPLETION OF ERECTION OF WHEEL HOUSE ON BRIDGE DECK.

NOT OK
DEFORMED ANGLES

CHECK THE DEFORMATION / DISTORTION OF ANGLE

OK

MARKED THE DISTORTED ZONE

GRINDING & STRAIGHTENING THE AL. ANGLES BY FAIRING.

NOT OK
REJECTED FOR SCRAP

CHECK THE STRAIGHTNESS

OK
REUSE AS STRONG BACK

FINISH

SLIDE 33

GRSE

DISHARI-S

DEFINING THE PROBLEM

MARKING, CUTTING, DEBARRING,) BUFFING OF. 75 X 50 X 6 MM AL. ANGLES AS PER REQUIRED LENGTH.

TACKING/FITTING OF AL. ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS .

SLIDE 34

GRSE

DISHARI-S

DEFINING THE PROBLEM
ALIGN THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD, THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK.

LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE.

SLIDE 35

LIFT AND TRANSPORT THE WHEEL HOUSE BLOCK BY CRANE & POSITIONED & COMPLETE ERECTION OF WHEEL HOUSE BY ALIGN/TACKING/FITTING & RUNNING WELDING OF PANELS ON CORRECT POSITION OF SHIP‟S BRIDGE DECK.GRSE DEFINING THE PROBLEM DISHARI-S REMOVE ALL THE STRONG BACK (AL ANGLE) BY DISMANTLING FROM ERECTED PANELS . OTHER THAN OPEN SIDE OF PANELS OF WHEEL HOUSE BLOCK. SLIDE 36 .

ANGLES BY FAIRING.GRSE DEFINING THE PROBLEM SEGREGATE THE DEFORMED ANGLE DISHARI-S STRAIGHTENING THE AL. SLIDE 37 .

THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK. ALIGN. ANGLES BY FAIRING. ANGLES AS PER REQUIRED LENGTH. DEBARRING. 75 X 50 X 6 MM AL. LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE . CUTTING. THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD. BUFFING OF. NOT OK DEFORMED ANGLES CHECK THE DEFORMATION / DISTORTION OF ANGLE OK MARKED THE DISTORTED ZONE GRINDING/FILING/DRESSING & STRAIGHTENING THE AL. ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS .GRSE GRSE DISHARI-S DEFINING THE PROBLEM BY FLOW DIAGRAM DISHARI-S START MARKING. NOT OK REJECTED FOR SCRAP CHECK THE STRAIGHTNESS OK REUSE AS STRONG BACK FINISH SLIDE 38 . TACKING/FITTING OF AL. REMOVE ALL THE STRONG BACK (AL ANGLE) AFTER COMPLETION OF FABRICATION OF WHEEL HOUSE BLOCK AND ERECTION OF WHEEL HOUSE ON BRIDGE DECK.

WASTAGE OF ABOUT 50% COSTLY ALUMINIUM ANGLE DUE TO DEFORMATION AND / OR DISTORTION AFTER IT‟S REMOVAL.GRSE STEP –3(B) DISHARI-S CURRENT SITUATION AND IMPACT OF THE PROBLEM CURRENT SITUATION THE PREVAILING PRACTICE OF STRONG BACKING AL PANELS DURING ERECTION & FABRICATION OF WHEEL HOUSE INVOLVES LOSE OF PRODUCTION AS WELL AS WASTAGE OF COSTLY MATERIAL THE IMPACT OF THE PROBLEM ARE : ADDITIONAL TIME (INEFFECTIVE TIME) IS ADDED TO PRODUCTION TIME TO REMOVE THE WELDING BURRS OF AL.   DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB DUE TO INVOLVEMENT OF ADDITIONAL WORK. ANGLES BY GRINDING /DRESSING/ AND STRAIGHTENING THE AL ANGLES BY FAIRING TO REMOVE THE DISTORTION. SLIDE 39 .

GRSE STEP –3(C) DISHARI-S 1) TO INCREASE PRODUCTION / PRODUCTIVITY 2) TO REDUCE WASTAGE OF MATERIAL 3) TO IMPROVE QUALITY & WORK 4) TO MAINTAIN THE DELIVERY SCHEDULE 5) OPTIMUM UTILIZATION OF AVAILABLE RESOURCES (MAN. MATERIAL. MONEY) 6) TO REDUCE INEFFECTIVE TIME SLIDE 40 . METHOD.

ANGLES SLIDE 41 .GRSE STEP –3(D) DISHARI-S TARGET SETTING SAMPLE DATA FOR STRONG BACKING OF 5.25M X 2.0 50% AV.25M X 2.4 M PANEL BY AL ANGLE OF YARD NO 2064 DATA TABLE FOR TARGET SETTING DESCRIPTION OF WORK MAN HOUR CONSUMED /PANEL EFFECTIVE TIME STRONG BACKING OF AL PANEL (5. % REJECTION OF AL.4 M) BY AL ANGLE 9.0 IN EFFECTIVE TIME 9.

ANGLES BY FAIRING WORK AS WELL AS TO REDUCE WASTAGE OF COSTLY ALUMINIUM ANGLES. WE SET THE FOLLOWING TARGETS:- 1. TO REDUCE THE INEFFECTIVE TIME FROM 50% TO 5% BY WORK SIMPLIFICATION WITHIN 17WEEKS. 50% 10% SLIDE 42 .GRSE STEP –3(D) DISHARI-S TARGET SETTING IN ORDER TO REDUCE THE INEFFECTIVE TIME FOR REMOVING WELDING BURRS BY GRINDING & FOR REMOVING THE DISTORTION OF AL. 50% 5% 2. TO REDUCE THE WASTAGE OF COSTLY MATERIAL FROM 50% TO 10% LEVEL WITHIN 17 WEEKS.

PREVAILING PRACTICE OF STRONG BACKING THE AL. B. WHERE? WHEN? WHO? HOW? SLIDE 43 . A.GRSE STEP –4(A) DISHARI-S ANALYSIS OF THE PROBLEM WE HAVE TAKEN THE HELP OF 4-W & 1-H TECHNIQUE FOR ANALYSING OUR PROBLEM. INVOLVEMENT OF ADDITIONAL TIME( INEFFECTIVE TIME) DURING REMOVAL OF DISTORTION OF AL. 4-W & 1-H TECHNIQUE WHAT? ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM DURING AND AFTER ERECTION OF PANELS OF WHEEL HOUSE AT SITE AND BRIDGE DECK OF SHIP. WASTAGE OF COSTLY ALUMINIUM ANGLES WHICH ARE TEMPORARILY USED FOR STRONG BACKING THE PANELS. PANELS AND MAKE READY FOR RE-USE. ANGLES BY FAIRING. PANELS DURING IT‟S FABRICATION & ERECTION WITH WHEEL HOUSE. AFTER REMOVING THE STRONG BACK FROM AL.

PARTITION BHD. PARTITION BHD.(S) SIDE BHD. SIZE IN mm 8300 X 2400 5250 X 2400 3800 X2400 5006 X 2600 2500 X 2400 1400 X 2400 2500 X 2400 1450 X 2400 940 X 2400 1560 X 2400 QUANTITY 2 1 1 1 1 2 1 1 1 1 SLIDE 44 . 1 2 3 4 5 6 7 8 9 10 DESCRIPTION OF ITEMS SIDE BHD.(S&P) SIDE BHD. THE AVAILABLE DATA REVEALS THAT EACH WHEEL HOUSE COMPRISES OF 12 NO. OF VARIOUS SIZES AL. AFT. BHS. PARTITION BHD. PARTITION BHD.(P) FORD.GRSE STEP –4(B) DISHARI-S ANALYSIS OF THE PROBLEM DATA WERE COLLECTED FROM DETAILED DRAWING OF WHEEL HOUSE FOR IPV CLASS OF SHIPS. NO. BHD. PANELS TO BUILT BULK HEADS AND PARTITION WALLS AS SHOWN BELOW:SL. PARTITION BHD.

DESCRIPTION OF WORK REQUIRED FOR STRONG BACKING 138 137 126 125 REJECTED AFTER REMOVING 70 66 63 65 MAN-DAYS SPENT(IN EFFECTIVE TIME) FOR REMOVING WELDING BURRS & STRAIGHTENING THE ANGLE 16 15 15 14 SLIDE 45 WJ FAC/2063 WJ FAC/2064 IPV/2075 APV/2076 STRONG BACKING OF AL. WITH THE HELP OF AVAILABLE DATA A RUN CHART & A LINE & BAR DIAGRAM WERE PREPARED. DATA TABLE TOTAL LENGTH IN METER OF AL.NO. PANELS FOR TRANSPORTATIO N & ERECTION OF WHEEL HOUSE. ANGLES OF VARIOUS SIZES ARE REQUIRED VIS-À-VIS REJECTED AS WELL AS TIME CONSUMED FOR REMOVING THE WELD METALS & FAIRING THE ANGLES FOR STRAIGHTENING ARE SHOWN IN THE DATA TABLE.GRSE STEP –4(C) DISHARI-S ANALYSIS OF THE PROBLEM SHIP WISE PAST PRODUCTION DATA WERE COLLECTED FOR TOTAL LENGTH OF AL. . ANGLES (75 X 50 X 6mm) SHIP/ CONST.

20 18 16 14 12 10 2064 2065 2073 2074 16 15 15 14 70 66 63 65 2064 2065 2073 2074 REQUIRED FOR STRONG BACKING REJECTED AFTER REMOVING SHIP NO. ANGLES PER SHIP = 50%  AVERAGE INEFFECTIVE TIME = 15 MAN DAYS SO WE HAVE TO FIND OUT THE REASONS BEHIND THE PROBLEM SLIDE 46 . OBSERVATION :  WASTAGE OF AL. AVERAGE INEFFECTIVE TIME = 15 MANDAYS ON AND AVERAGE WASTAGE OF ALUMINIUM ANGLE/SHIP = 66 Mtr.GRSE DISHARI-S ANALYSIS OF THE PROBLEM 200 180 RUN CHART 138 137 126 126 160 140 120 100 80 60 40 20 0 INEFFECTIVE TIME(MANDAYS) LENGTH IN Mtr.

FREE FLOWING OF VARIOUS VIEWS FROM QC MEMBERS ENABLED US TO GET A LARGE NUMBER OF IDEAS.GRSE DISHARI-S STEP –5 PROBABLE CAUSES OF PROBLEM TO DRAW CAUSE & EFFECT DIAGRAM & TO FIND OUT ALL THE POSSIBLE CAUSES INFLUENCING THE EFFECT. SLIDE 47 . QC MEMBERS CARRIED OUT BRAINSTORMING WITHOUT ANY RESTRICTION.

Additional time is spent to remove distortion & Weld metal from Strong Back after removal. Improper lifting & handling of panels. 4. 3) Non availability of dead weight during fabrication of panel 4) Work is performed by Trainees. 6. BY STRATIFICATION. Angles leads to Rejection 4.Ignorance of proper sequence of tacking/fitting. 3. Non-adherence to the recommended practice . Distortion due to self weight during lifting by crane. Generation of heat during tacking & running welding of Panels during Erection leads to distortion TRANSPORTATION OF AL. 2. SUB CAUSE & SUB-SUB CAUSES ETC. 1. HEADER / MAIN CAUSE OPERATOR SUB. Improper attention. 2. 3.GRSE STEP –5(A) PROBABLE CAUSES OF THE PROBLEM DISHARI-S AFTER ELIMINATING SUPERFLUOUS AND IRRELEVANT CAUSES BASED ON DISCUSSION. FINALLY ISHIKAWA DIAGRAM WAS DRAWN (CAUSE ENUMERATION TYPE). 2. 3. panel 2) Non-availability of scrap material in the yard. Inherent material defect. Non availability of crane for handling. ELIMINATED SUPERFLUOUS AND IRRELEVANT CAUSES 1) Tedious & primitive method of fabrication of Al. Lack of knowledge about the fairing work. Use of softer & costly Material. Improper Dismantling of Strong Back (Al. PANELS TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK MATERIAL (USED FOR STRONG BACK) 1. 4. 1. Lack of Skill ERECTION PROCEDURE. Angles) leads to high Distortion. 3. WE ORGANIZED THE REMAINING VARIOUS PROBABLE CAUSES INTO MAIN CAUSE. Excessive softness of material . 7. Material not at per specification. 5.CAUSE / SUB-SUB-CAUSE 1. High Distortion/ Deformation of Al. Non use of any alternative Harder & chipper Material SLIDE 48 . Incorrect tacking/fitting 1. 2. distortion during positioning/alignment by pulling the panels by bottle screw 2. Improper protection against excessive distortion during tacking/fitting.

Incorrect tacking/fitting TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK MATERIAL (USED FOR STRONG BACK) SLIDE 49 . Angles leads to Rejection EFFECT EFFECT Use of softer & costly Material Improper Dismantling of Strong Back(Al. ERECTION PROCEDURE distortion during positioning/alignment by pulling the panels by bottle screw . Angles) leads to high Distortion Ignorance of proper sequence of tacking/fitting Inherent material defect Material not at per specification Non use of any alternative Harder & chipper Material. Lack of Skill Non-adherence to the recommended practice Lack of knowledge about the fairing work TRANSPORTATION OF AL.GRSE ISHIKAWA DIAGRAM (CAUSE ENUMERATION TYPE) STEP –5(B) OPERATOR DISHARI-S Mapping out all the probable Sub &Sub-Sub causes under each Headers (Main Causes) and Relate the Logical Linkage. PANELS Distortion due to self weight during lifting by crane Non availability of crane for handling Generation of heat during tacking & running welding of Panels during Erection leads to distortion Improper lifting & handling of panels Improper attention EFFECT EFFECT EFFECT Improper protection against excessive distortion during tacking/fitting Additional time is spent to remove distortion & Weld metal from Strong Back after removal High Distortion/Deformation of Al.

Inherent material defect ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM TRANSPORTATION OF AL. Angles) leads to high Distortion Improper protection against excessive distortion during tacking/fitting Improper lifting & handling of panels Distortion due to self weight during lifting by crane Non availability of crane for handling High Distortion/Deformation of Al.GRSE STEP –5(C) OPERATOR Improper attention Non-adherence to the recommended practice ISHIKAWA DIAGRAM (CAUSE ENUMERATION TYPE) ERECTION PROCEDURE Generation of heat during tacking & running welding of Panels during Erection leads to distortion Lack of Skill DISHARI-S Finally we drew the ISHIKAWA DIAGRAM TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK distortion during positioning/alignment by pulling the panels by bottle screw Ignorance of proper sequence of tacking/fitting Incorrect tacking/fitting Lack of knowledge about the fairing work Improper Dismantling of Strong Back (Al. PANELS MATERIAL USED FOR STRONG BACK SLIDE 50 . Angles leads to Rejection Use of softer & costly Material not at per Material specification Additional time is spent to remove distortion & Weld Non use of any metal from Strong Back after alternative Harder removal & chipper Material.

GRSE STEP –6 DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM BY WHY WHY ANALYSIS BY FURTHER BRAINSTORMING WE HAVE DECIDED TO MAKE AN EXTENSIVE INVESTIGATION FOR SEVEN DAYS TO FIND OUT THE ROOT CAUSE OF THE PROBLEM.WHY ANALYSIS WE FIND OUT THE ROOT CAUSE OF THE PROBLEM BY VALIDATING THE PROBABLE CAUSES SEQUENTIALLY: SLIDE 51 . WE ANALYZE THE AVAILABLE INFORMATION AND WITH THE HELP OF WHY.

PROBLEM ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM REASON /SUB CAUSE IS IT DUE TO OPERATOR ? Y N WHY? THE OPERATOR IS COMPETENT ENOUGH TO WORK WITH THE EXISTING METHOD. ANGLES AS STRONG BACK IS THE MAIN REASON BEHIND THE PROBLEM (DISTORTION/ DEFORMATION) WHY? IS IT DUE TO MATERIAL( USED FOR STRONG BACK) ? Y N WHY? SLIDE 52 . IS IT DUE TO ERECTION PROCEDURE ? Y N WHY? IS IT DURING TRANSPORTATION OF AL.GRSE STEP –6 ( A ) BY WHY -WHY ANALYSIS DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. THERE IS NO SUCH PROBLEM DURING TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK. HIGHLY MALLEABLE & LIGHTER IN WEIGHT AL. PANELS ? IS IT DUE TO TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK ? Y Y N N WHY? THE PANELS ARE CAREFULLY HANDLED DURING IT‟S TRANSPORTATION & ERECTION TO AVOID ANY DISTORTION. THERE IS NO SUCH PROBLEM DURING ERECTION OF PANELS. USE OF SOFT .

    IMPROPER ATTENTION.THE OPERATOR IS COMPETENT ENOUGH TO WORK WITH THE EXISTING METHOD.GRSE STEP –6 ( B ) BY WHY -WHY ANALYSIS DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. VALIDATION REASON OPERATOR HAS GOT ADEQUATE SKILL TO PERFORM THE JOB. SLIDE 53 . PROPER ATTENTION IS GIVEN DURING PERFORMING THE JOB. THE RECOMMENDED PRACTICE FOR REMOVING THE STRONG BACK IS FOLLOWED THERE IS NO LACK OF KNOWLEDGE ABOUT THE FAIRING WORK ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM. NON-ADHERENCE TO THE RECOMMENDED PRACTICE LACK OF KNOWLEDGE ABOUT THE FAIRING WORK REASON / SUB-CAUSE :. VALIDATION THE PROBABLE CAUSES SEQUENTIALLY IS IT DUE TO OPERATOR ? Y N WHY? OPERATOR EFFECT SUB-CAUSES LACK OF SKILL.

WHY? ERECTION PROCEDURE EFFECT SUB-CAUSES GENERATION OF HEAT DURING TACKING & RUNNING WELDING OF PANELS DURING ERECTION LEADS TO DISTORTION DISTORTION DURING POSITIONING/ALIGNMEN T BY PULLING THE PANELS BY BOTTLE SCREW . ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM   REASON / SUB-CAUSE :.THERE IS NO SUCH PROBLEM DURING ERECTION OF PANELS. SLIDE 54 .GRSE STEP –6 ( B ) BY WHY WHY ANALYSIS VALIDATION THE PROBABLE CAUSES SEQUENTIALLY IS IT DUE TO ERECTION PROCEDURE ? Y N DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. VALIDATION REASON GENERATION OF HEAT DURING TACKING & RUNNING WELDING OF PANELS DURING ERECTION IS NOT RESPONSIBLE FOR DISTORTION OF STRONG BACKS PULLING THE PANELS BY BOTTLE SCREW DURING POSITIONING/ALIGNMENT IS NOT RESPONSIBLE FOR DISTORTION OF STRONG BACKS OF PANELS .

ANGLES REASON/SUB-CAUSE:.THE PANELS ARE CAREFULLY HANDLED DURING IT‟S TRANSPORTATION & ERECTION TO AVOID ANY DISTORTION.   THERE IS NO SUCH PROBLEMS FROM NON AVAILABILITY OF MOBILE CRANE. SLIDE 55 . PANELS EFFECT SUB-CAUSES IMPROPER LIFTING & TRANSPORTATION OF PANELS VALIDATION REASON PRECAUTION IS TAKEN DURING LIFTING & TRANSPORTATION OF PANELS. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM  NON AVAILABILITY OF CRANE FOR HANDLING DISTORTION DUE TO SELF WEIGHT DURING LIFTING BY CRANE. PANELS ? DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. Y N WHY? TRANSPORTATION OF AL. TO AVOID DISTORTION DUE TO SELF WEIGHT DURING LIFTING BY CRANE ALL THE 4-SIDES OF PANELS ARE STRONG BACKED BY AL.GRSE STEP –6 ( B ) BY WHY WHY ANALYSIS VALIDATION THE PROBABLE CAUSES SEQUENTIALLY IS IT DURING TRANSPORTATION OF AL.

ANGLES) IS DISMANTLED BY USING FORK. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM     REASON / SUB-CAUSE :. VALIDATION REASON PROPER SEQUENCE OF TACKING/FITTING IS MAINTAINED TACKING/ FITTING IS DONE AS REQUIRED. SLIDE 56 .THERE IS NO SUCH PROBLEM DURING TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK. EFFECT SUB-CAUSES IGNORANCE OF PROPER SEQUENCE OF TACKING/FITTING INCORRECT TACKING/FITTING IMPROPER DISMANTLING OF STRONG BACK (AL. STRONG BACK (AL.GRSE STEP –6 ( B ) BY WHY WHY ANALYSIS DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. PROPER PROTECTION AGAINST DISTORTION DURING TACKING/FITTING WERE TAKEN. VALIDATION THE PROBABLE CAUSES SEQUENTIALLY IS IT DUE TO TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK ? Y N WHY? TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK. ANGLES) LEADS TO HIGH DISTORTION IMPROPER PROTECTION AGAINST EXCESSIVE DISTORTION DURING TACKING/FITTING.

ADDITION OF INEFFECTIVE TIME TO PRODUCTION TIME CAUSES DELAY IN DELIVERY OF FINISHED PRODUCT. Y N WHY? √ ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM x x √ √ √ √ REASON / SUB-CAUSE :. IS IT DUE TO MATERIAL( USED FOR STRONG BACK) ? MATERIAL( USED FOR STRONG BACK) EFFECT SUB-CAUSES USE OF SOFTER & COSTLY MATERIAL INHERENT MATERIAL DEFECT.USE OF SOFT . HIGH MALLEABLE & LIGHTER IN WEIGHT AL. HIGHLY MALLEABLE & LIGHTER IN WEIGHT . MATERIAL IS NOT DEFECTIVE. MATERIAL NOT AT PER SPECIFICATION ADDITIONAL TIME IS SPENT TO REMOVE DISTORTION FROM STRONG BACK AFTER REMOVAL HIGH DISTORTION/DEFORMATION OF AL. ANGLES IS UNSUITABLE FOR REUSE . ANGLES LEADS TO REJECTION HIGH INEFFECTIVE TIME DUE TO FAIRING FOR REMOVAL OF DISTORTION NON USE OF ANY ALTERNATIVE HARDER & CHIPPER MATERIAL VALIDATION REASON DISTORTION AFTER REMOVAL OF STRONG BACK SINCE ALUMINIUM IS SOFT. USE OF ANY HARD.GRSE STEP –6 ( B ) BY WHY WHY ANALYSIS VALIDATION THE PROBABLE CAUSES SEQUENTIALLY DISHARI-S FINDING OUT THE ROOT CAUSE OF THE PROBLEM. ANGLES AS STRONG BACK IS THE MAIN REASON BEHIND THE PROBLEM (DISTORTION/ DEFORMATION SLIDE 57 . LESS MALLEABLE & HEAVER WEIGHT THAN ALUMINIUM ANGLES CAN ELIMINATE THE EXISTING PROBLEM. MATERIAL IS AS PER SPECIFICATION ADDITIONAL TIME IS SPENT TO REMOVE WELD MATERIAL & DISTORTION BY FAIRING WORK FROM STRONG BACK AFTER REMOVAL HIGHLY DISTORTED & DEFORMED AL.

c) CUT & REJECT THE DEFORMED ANGELS d) REMOVE WELDING BURRS ON ANGLES BY GRINDING e)FAIRING BY HEATING AND COOLING FOR STRAIGHTENING THE ANGLES. 1. REMOVE WELDING BURRS FROM ANGLES. b) CHECK THE STRAIGHTNESS OF AL. b) REMOVE WELD METAL FROM AL. 3. 2.0 a.GRSE STEP –7(A) DISHARI-S DATA ANALYSIS ON THE ROOT CAUSE ACTIVITY-WISE DATA COLLECTION & STRATIFICATION FOR STRONG BACKING ALUMINUM PANEL STRATIFICATION OF ACTIVITIES IN TO 5. PANELS C) LIGHT HAMMERING BY WOODEN MALLET FOR NECESSARY FAIRING AS REQUIRED. SEGREGATION THE REJECTED ANGLES .) MARKING b) CUTTING c) DEBARRING d) BUFFING OF 4 NOS.0 3. SUB .FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING. ANGLES) AFTER COMPLETION OF ERECTION OF WHEEL HOUSE AT BRIDGE DECK OF SHIP USING METAL FORK.MAIN ACTIVITIES SL NO. ANGLES BY GRINDING. a) TACKING/FITTING OF ALUMINIUM ANGLES ON 4. a) CARRY THE AL. PANEL FOR STRONG BACKING THE PANELS. PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS . a) CHECK THE STRAIGHTNESS OF ANGLES. REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS. OF PANEL.0 SLIDE 58 . ANGLES TO SHOP FROM SITE & SHIP . a) REMOVE ALL THE STRONG BACKS (AL.5 9. b) REMOVE ALL THE STRONG BACKS (AL. 2. 5. ANGLES) AFTER COMPLETION OF ERECTION OF WHEEL HOUSE BLOCK AT SITE USING METAL FORK. b) SEGREGATE THE DEFORMED ANGLES.SIDES OF AL.ACTIVITIES MAIN ACTIVITY MAN HOUR CONSUMED PER PANEL 2. 75 X 50 X 6 MM AS PER REQUIRED LENGTH FOR ONE NO. 1.5 4. TACKING/ FITTING OF STRONG BACK ON ALUMINIUM PANEL.

5 16.0 11 8 92 100 SLIDE 59 .0 14.0 50 50 B C 3.0 1.0 9. TACKING/FITTING OF STRONG BACK ON ALUMINIUM PANEL REMOVE WELD METAL FROM ANGLES 9.5 17 14 67 81 D E PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS.5 18.5 12.GRSE STEP –7(B) DISHARI-S DATA ANALYSIS ON THE ROOT CAUSE WITH THE HELP OF AVAILABLE DATA FROM DATA ANALYSIS PARETO ANALYSIS WERE DONE AND SUBSEQUENTLY PARETO DIAGRAM WERE DRAWN PARETO ANALYSIS SL NO MAIN ACTIVITIES MAN MIN. REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS 2.0 2. CONSUMED INDVL CUMM PERCENTAGE INDVL CUMM A SEGREGATION THE REJECTED ANGLES & FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING.

GRSE DISHARI-S DATA ANALYSIS ON THE ROOT CAUSE PARETO DIAGRAM 100 15 FREQUENCY 100 92 81 67 80 60 40 PERCENTAGE SLIDE 60 10 50 5 20 0 A B C D E 0 PROBLEM IT IS OBSERVED FROM PARETO DIAGRAM THERE IS 50% INVOLVEMENT OF INEFFECTIVE TIME FOR FAIRING OF AL ANGLE .

ANGLES(75 X 50 X 6mm) REQUIRED REUSED AFTER REJECTED AL. PANELS FOR TRANSPORTA TION & ERECTION OF WHEEL HOUSE. DESCRIPTION OF WORK TOTAL LENGTH IN METER OF AL. ANGLE FOR STRAIGHTENING DUE TO NOT USEABLE STRONG BY FAIRING DUE TO DEFORMATIO BACKING N AFTER HIGH THE PANEL REMOVING DISTORTION AFTER STRAIGHTENIN G BY FAIRING WJ FAC 2063 WJ FAC /2064 IPV/2075 APV/2076 STRONG BACKING OF AL. SHIP/ CONST.GRSE DISHARI-S DATA ANALYSIS ON THE ROOT CAUSE DATA RELATED TO RE-USE. PANEL. AVERAGE PER SHIP 138 137 126 125 132 70 66 60 65 65 21 25 18 20 21 (16%) 47 46 48 40 46 (35%) SLIDE 61 . NO. DEFORMED & HIGHLY DISTORTED AL. ANGLE AFTER ITS REMOVAL FROM AL.

GRSE DISHARI-S DATA ANALYSIS ON THE ROOT CAUSE PIE CHART SHOWS % OF REUSE & REJECTED AL. ANGLES. 16% DUE TO DEFORMATION AFTER REMOVING STRONG BACK & 35% IS NOT RE-USEABLE DUE TO HIGH DISTORTION AFTER FAIRING SLIDE 62 .E. 35% 16% 49% RE-USE DEFORMED HIGHLY DISTORTED IT IS OBSERVED FROM PIE CHART THERE IS 51% REJECTION OF AL ANGLE I.

87 16 42 HIGH (2ND HIGHEST) LOWER THAN ALUMINIUM IT IS OBSERVED FROM THE TABLE THAT IRON IS MUCH MORE HEAVIER. (BHN) MALLEABILITY ALUMINIUM IRON 2.7 7. ANGLES FOR STRONG BACKING THE AL PANELS” SLIDE 63 . HARDER & LESS MALLEABLE THAT ALUMINIUM “FINALLY CONCLUDED FROM THE PHYSICAL PROPERTIES OF METAL THAT THE ROOT CAUSE BEHIND THE PROBLEM ARE THE PREVAILING PRACTICE OF USING SOFT./cm2 ) MELTING POINT (DEGREE CENTIGRADE) 659.GRSE DATA ANALYSIS ON THE ROOT CAUSE DISHARI-S CONCLUSION OF ROOT CAUSE ANALYSIS PHYSICAL PROPERTIES OF METAL METAL DENSITY (gm. HIGHLY MALLEABLE & LIGHT IN WEIGHT AL.7 1535 HARDNESS NO.

QC MEMBERS DECIDED TO DEVELOP THE SOLUTION OF THE PROBLEMS. SLIDE 64 . BASED ON ADVANTAGES & DISADVANTAGES OF BOTH THE SYSTEM QC MEMBERS CONCLUDED THAT THE SECOND METHOD IS THE MOST EFFECTIVE FOR THE SOLUTION OF THE PROBLEM.GRSE STEP –8(A) DISHARI-S DEVELOPMENT OF SOLUTION AFTER FINDING OUT THE ROOT CAUSE OF PROBLEM BASED ON DATA ANALYSIS. DURING BRAINSTORMING SESSION. MEMBERS SUGGESTED TWO ALTERNATIVE METHODS FOR THE SOLUTION OF THE PROBLEM.

GRSE A. MS/AL TRANSITION JOINT IS COSTLY AND BROUGHT OUT ITEM. ANGLES BY FAIRING WORK WILL REDUCED TO ZERO. 2 . 3. HIGH INEFFECTIVE TIME FOR REMOVAL OF WELD MATERIAL & STRAIGHTENING THE AL. NO DISTORTION OF MS FLAT BARS . LUGS. 2. USE MS/AL. METHOD ACTIVITY ALTERNATIVE METHOD FOR DEVELOPMENT OF SOLUTION ADVANTAGE 1. ANGLE FOR STRONG BACKING THE AL. ANGLE FOR STRONG BACKING THE AL. NOT ACCEPTABLE B. 2. TACKING/FITTING THE AL. ANGLES BY FAIRING WORK WILL REDUCED TO ZERO. DISADVANTAGE PROPER PRESERVATION OF MS FLAT BARS &AL. USE ALUMINIUM LUGS. 2. LUGS WITH AL. 1ST. 6. 4. 3. THERE IS A CHANCE OF FAILURE AT PASTED JOINT OF MS/AL TRANSITION JOINT . NO WASTAGE OF COSTLY MATERIAL. DRILL HOLES(6mm) ON MS FLAT BARS & AL.PANEL 1. MS PORTION OF MS/AL TRANSITION JOINT TO BE TACKED WITH MS FLAT BAR AND ALUMINIUM PORTION TO BE TACKED WITH AL. PANELS. NO WASTAGE OF COSTLY MATERIAL 3 . USE MS FLAT BARS IN PLACE OF AL. ADVANTAGE 1 . 2ND. AFTER ERECTION OF PANELS REMOVE TACK WELD BY FORK. LUGS IS REQUIRED FOR REUSE IN THE NEXT SHOP. PANELS FOR STRONG BACKING. 5.HIGH INEFFECTIVE TIME FOR REMOVAL OF WELD MATERIAL & STRAIGHTENING THE AL. NO DISTORTION OF MS FLAT BARS 2. 7. PANELS. TRANSITION JOINT (BI METALLIC) 3. METHOD ACTIVITY 1. GRIND THE LUG TI REMOVE WELD MATERIAL. REMARKS ACCEPTABLE SLIDE 65 . USE MS FLAT BARS IN PLACE OF AL. DISADVANTAGE DISHARI-S REMARKS 1. DISMANTLED LUGS BY REMOVING THE BOLTS. FITTING THE LUGS WITH MS FLAT BARS BY BOLTING.

an action plan showing time bound and responsibility shared by the member as shown below :ACTION PLAN FOR DEVELOPING SOLUTION (TIME BOUND & RESPONSIBILITY SHARED) ROOT CAUSE ACTION PLAN FOR DEVELOPMENT OF SOLUTION TARGET DATE FOR COMPLETION 01-04-11 To 07-04-11 RESPONSIBILITY THE PREVAILING PRACTICE OF USING SOFT. RESULT:THERE IS 50% WASTAGE OF COSTLY MATERIAL(AL. MR. PANELS FOR STRONG BACKING.ROY MR. 3) DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. 9) STRAIGHTENING THE MS FLAT BARS BY FAIRING WORK AS REQUIRED.GHOSH 08-04-11 To 13-04-11 MR. 4) FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT. S.POLLEY MR. 7) DISMANTLE AL. 5) TACKING/FITTING AL. LUGS BY GRINDING. ANGLE) AFTER REMOVAL OF ALUMINIUM STRONG BACK FROM PANELS 1) PREPARE A SKETCH WITH BILL OF MATERIAL INCL . BACHAR SLIDE 66 . GHOSH MR. H. S.K.e. LUGS WITH AL.GRSE A C P D STEP –8(B) DISHARI-S ACTION PLAN FOR DEVELOPMENT OF SOLUTION While developing the solution of the problem in line with second method of solution. LUGS. 8) REMOVE WELDING BARS FROM AL. CHAKRABORTY MR. 6) REMOVE STRONG BACK AFTER ERECTION OF PANELS. ANGLES FOR STRONG BACKING THE AL PANELS. A. LUGS BY REMOVING BOLTS & NUT FROM FLAT BAR. S.SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG . A. HIGHLY MALLEABLE & LIGHT IN WEIGHT AL. 2) COLLECT CUT PIECE MATERIAL AS REQUIRED. QC members used the Counter Measure Metric technique i.

FITTING LUGS WITH MS FLAT BAR BY BOLT. REMOVE STRONG BACK AFTER ERECTION OF PANELS. SLIDE 67 2. 7. . DISHARI-S P D DEVELOPMENT OF SOLUTION ACCORDING TO OUR ACTION PLAN EXECUTION OF ACTION PLAN ACCORDING TO OUR ACTION PLAN WE PREPARE A SKETCH WITH BILL OF MATERIAL INCL. REMOVE WELD BARS FROM AL. LUGS WITH AL. LUGS. LUGS BY GRINDING STRAIGHTENING THE AL. 6. 9. LUGS BY REMOVING BOLTS FROM FLAT BAR. 5. ANGLES BY FAIRING WORK. 4. 3. PANELS FOR STRONG BACKING. COLLECT CUT PIECE MATERIAL AS REQUIRED.GRSE A C 1. TACKING/FITTING AL. 8. DISMANTLE AL. DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG.

GRSE DEVELOPMENT OF SOLUTION EXECUTION OF ACTION PLAN MS FLAT BAR AND ALUMINIUM LUG DISHARI-S ACCORDING TO OUR ACTION PLAN-1. 3400 x 100 x 10. 2. APPROVED BY : SHRI D K SINHA . 12 100 100 DRAWN BY : DISHARI-S. WE PREPARE A SKETCH WITH BILL OF MATERIAL INCL. 2000 x 100 x 10.NO 1. 2100 x 100 x 10. M(HOF) SLIDE 68 . 3. 2400 x 100 x 10 50 x 50 x 6 30 x 8 QTY. 4800 x 100 x 10. NAME OF THE ITEM MS FLAT BAR ALUMINIUM LUG BOLT & NUT SIZE 8000 x 100 x 10. SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG BILL OF MATERIAL FOR FIXTURE SL.

GRSE DEVELOPMENT & SOLUTION DISHARI-S FLOW DIAGRAM FOR STRONG BACKING AL PANEL BY MS FLAT BAR START COLLECT CUT PIECE MATERIAL AS REQUIRED DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. PANELS FOR STRONG BACKING. LUGS. REMOVE WELDING BURRS FROM ALUMINIUM LUGS BY GRINDING & STRAIGHTENING THE MS FLAT BARS BY FAIRING CHECK NOT OK OK FINISH SLIDE 69 . FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT. LUGS WITH AL. REMOVE STRONG BACK AFTER ERECTION OF PANELS. TACKING/FITTING AL.

LUG SLIDE 70 .GRSE DISHARI-S DEVELOPMENT OF SOLUTION DRILL HOLES ON MS FLAT BAR DRILL HOLES ON AL.

GRSE DEVELOPMENT OF SOLUTION DISHARI-S AL. TACKING/FITTING AL. SLIDE 71 . LUGS ALONG WITH MS FLAT BAR FOR STRONG BACKING. LUGS IS FITTED WITH MS FLAT BAR BY BOLT & NUT.

SLIDE 72 .GRSE DISHARI-S DEVELOPMENT OF SOLUTION REMOVE STRONG BACK AFTER ERECTION OF PANELS.

GRSE DEVELOPMENT OF SOLUTION DISHARI-S STRAIGHTENING THE MS FLAT BAR BY FAIRING REMOVE WELDING BURRS FROM AL. LUGS BY GRINDING. SLIDE 73 .

TACKING/FITTING AL. PANELS FOR STRONG BACKING. REMOVE WELDING BURRS FROM ALUMINIUM LUGS BY GRINDING & STRAIGHTENING THE MS FLAT BARS BY FAIRING CHECK NOT OK OK FINISH SLIDE 74 . REMOVE STRONG BACK AFTER ERECTION OF PANELS. LUGS.GRSE DEVELOPMENT & SOLUTION DISHARI-S FLOW DIAGRAM FOR STRONG BACKING AL PANEL BY MS FLAT BAR START COLLECT CUT PIECE MATERIAL AS REQUIRED DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. LUGS WITH AL. FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT.

GRSE A C P D APPROVAL BY THE MANAGEMENT DISHARI-S DEVELOPMENT & SOLUTION AFTER COMPLETION OF OUR NEWLY DEVELOPED METHOD FOR STRONG BACKING THE FABRICATED AL. WE HAVE EXHIBITED THE SAME FOR MANAGEMENT APPROVAL ON 11.04.11 MANAGEMENT IS PLEASED TO ADVISE YOU TO GO AHEAD WITH THE IMPLEMENTATION OF THE NEWLY DEVELOPED SYSTEM FOR STRONG BACKING THE FABRICATED AL. PANELS. PANELS. SLIDE 75 .

GRSE DISHARI-S DEVELOPMENT & SOLUTION A C P D APPROVAL BY THE MANAGEMENT SLIDE 76 .

GRSE STEP– 9(A) DISHARI-S FORESEEING PROBABLE RESISTANCE PLAN THROUGH BRAINSTORMING NORMALLY. THERE MAY BE RESISTANCE TO THAT CHANGE AND OUR FELLOW WORKMEN MAY NOT EASILY ACCEPT SUCH A CHANGE. WE MADE BRAIN STORMING FOR OVER COMING THE RESISTANCE WHICH MAY COME FROM OUR NON MEMBERS & UNION REPRESENTATIVE DURING IMPLEMENTATION OF OUR PROJECT. SLIDE 77 . IF WE TRY A DRASTIC CHANGE IN OUR EXISTING METHOD OF WORKING.

MANPOWER MAY BE REDUCED AFTER IMPLEMENTATION OF OUR IMPROVED METHOD SLIDE 78 2. 3 UNION REPRESENTATIVES FELLOW WORKMEN (PROSPECTIVE MEMBERS) 4 5 .GRSE STEP– 9(B) DISHARI-S FORESEEING PROBABLE RESISTANCE DO ACCORDING TO OUR PLAN. LOSS OF PRODUCTION DURING TRIAL RUN & IMPLEMENTATION OF PROJECT. INVOLVEMENT OF HUES MAN POWER AS WELL AS HIGH PROJECT COST. ANY IDEA FOR BETTERMENT TO BE GIVEN BY OUR HIGHER AUTHORITIES.04. WE MADE A LIVE PRESENTATION ON 19.AS A RESULT THERE WILL BE TREMENDOUS PRESSURE ON US TO MAINTAIN THE DELIVERY SCHEDULED OF PRODUCTION.2011 IN PRESENCE OF THEM. DURING PRESENTATION MAJORITY OF THEM IN CONSENSUS WITH US :- SL. 1 RESISTANT PRODUCTION SUPERVISOR TYPE OF RESISTANCES PRODUCTION SUPERVISOR WERE NOT AGREED TO SPARE THE TIME FOR STOPPAGE OF WORK DURING EXPERIMENTAL WORK.

GRSE STEP– 9(C) DISHARI-S FORESEEING PROBABLE RESISTANCE CHECK & ACT WE OVERCOME THE VARIOUS RESISTANCE RAISED BY THE MINORITY OF THEM BY CONVINCING ABOUT THE BENEFIT OF OUR PROJECT PROBABLE RESISTANCE & IT‟S REMEDY RESISTANCE FACED DURING LIVE PRESENTATION OF OUR PROJECT 1. INVOLVEMENT OF HUES MAN POWER AS WELL AS HIGH PROJECT COST. RESULTING NEW DOOR WOULD BE OPEN FOR GETTING FRESH ORDER FROM OUR CUSTOMER. MANPOWER MAY BE REDUCED AFTER IMPLEMENTATION OF OUR IMPROVED METHOD . LOSS OF PRODUCTION DURING TRIAL RUN & IMPLEMENTATION OF PROJECT. 2) THEIR SUGGESTION & VIEWS TO BE NOTED DOWN AND WOULD BE TAKEN INTO CONSIDERATION WHEREVER APPLICABLE BEFORE IMPLEMENTATION OF OUR PROJECT. THEY WERE ULTIMATELY CONVINCED. 5) CONVINCE THEM THAT QC IS A PLATFORM WHERE WE THE GRASS ROOT LEVEL WORKFORCE CAN EXPLORE OUR GROUP INNOVATIVE IDEAS FOR BETTERMENT OF PRODUCTION & QUALITY A) NONMEMBER B) UNION REP. 4. 3) EXPLAINED THEM THAT THE PROJECT COST IS ONE TIME INVESTMENT AND THE PAY BACK PERIOD IS VERY MINIMUM. ANY IDEA FOR BETTERMENT TO BE GIVEN BY OUR HIGHER AUTHORITY. RESISTANT COUNTER MEASURE FOR OVERCOMING RESISTANCE 1) DISCUSSED WITH THE NON-MEMBER & UNION REPRESENTATIVE ABOUT THE BENEFITS AFTER IMPLEMENTATION OF OUR NEW PROJECT. 2. SLIDE 79 . 5. 4) WE CAN SATISFY OUR CUSTOMER BY MEETING THE PRODUCTION TARGET IN TIME. PRODUCTION SUPERVISOR WERE NOT AGREED TO SPARE THE TIME FOR STOPPAGE OF WORK DURING EXPERIMENTAL WORK. SINCE THERE MAY BE TEMPORARY DELAY IN DELIVERY OF FINISHED PRODUCT.AS A RESULT THERE WILL BE TREMENDOUS PRESSURE ON US TO MAINTAIN THE DELIVERY SCHEDULED OF PRODUCTION 3.

GRSE STEP –10(B) DISHARI-S TRIAL IMPLEMENTATION & CHECKING PERFORMANCE DO WE CARRIED OUT STRONG BACKING ONE NO ALUMINIUM PANEL(5006 X 2400) BY TACKING/FITTING AL.11 TO 27. QTY LIST OF MATERIAL INSPECTION BY HOD. WE REMOVED THE STRONG BACK.FROM 21.04. 04. LUGS BOLTED WITH MS FLAT BARS ON TRIAL BASIS FROM 21.04. NO.04.11 TO 27. 11 DESCRIPTION SIZE & DRAWING NO. A C P D PERFORMANCE RESULT DURING TRIAL RUN TRIAL PERIOD .11 AFTER ERECTION OF PANEL. 2072796/115201 3 a) MS FLAT BAR b) ALUMINIUM LUG c) BOLT & NUT YES NIL NOTE : PP&C DEPARTMENT RECOMMENDED US TO REDUCE THE SIZE OF AL LUG FROM 50 X 50 X 6MM TO 40 x 40 x 6 MM TO REDUCE DISTORTION SLIDE 80 . CONDITION OF STRONG BACK AFTER REMOVAL FROM PANEL RE USABLE NOT RE-USEABLE STRONG BACKING OF ALUMINIUM PANEL 5006 x 2400 x4 mm DRG. THE PERFORMANCE & QUALITY OF FINISH PRODUCT WAS CHECKED BY COMPETENT AUTHORITY & FOUND HIGHLY SATISFACTORY.

GRSE STEP –10(B) DISHARI-S TRIAL IMPLEMENTATION & CHECKING PERFORMANCE CHECK A REVISED SIZE OF AL LUG AS RECOMMENDED BY PP&C DEPARTMENT P D C SLIDE 81 .

0 2.0 SLIDE 82 . ANGLES ( STRONG BACK) ON AL PANEL TACKING/FTG OF AL.5 M NIL 6 7 8 REMOVE WELD METAL FROM AL.5 2. PANELS MAN HOUR CONSUMED / PANEL BEFORE QC 1 2 3 PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS FITTING AL.0 1.GRSE STEP –10(C) DISHARI-S TRIAL IMPLEMENTATION & CHECKING PERFORMANCE CHECK A C SL NO P D ACTIVITY WISE DATA FOR STRONG BACKING OF AL PANEL WERE COLLECTED DURING TRIAL IMPLEMENTATION BY DIRECT OBSERVATION & WAS COMPARED WITH OBSERVED DATA BEFORE QC COMPARATIVE STUDY OF ACTIVITY WISE MAN HOUR CONSUMED /PANEL FOR STRING BACKING ALUMINIUM PANELS BEFORE & AFTER QC AS INDICATED BELOW:MAIN ACTIVITIES FOR STRONG BACKING AL. LUGS WITH MS FLAT BARS ( STRONG BACK) ON AL PANEL 4 5 REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS. REMOVE WELD METALS FROM ANGLES BY GRINDING.5 1.0 1. STRAIGHTENING THE MS FLAT BARS TOTAL 9.0 3.0 18.0 7. FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING. AFTER QC WASTAGE OF AL ANGLE / PANEL BEFORE QC AFTER QC 2.0 1.0 4. LUGS WITH MS FLAT BARS TACKING/FTG OF AL.0 9. LUGS BY GRINDING SEGREGATION THE REJECTED ANGLES .

5 TOTAL MAN HOUR CONSUMED / PANEL IMPROVEMENT AFTER QC. SPENT BEFORE & AFTER QC 18. CONSUMED BEFORE QC AFTER QC DURING TRIAL RUN. TO 9. 2. (BASED ON LINE & BELT GRAPH) 1.0 MAN HOURS. WE PREPARED A LINE AND BELT GRAPH TO SHOW THE IMPROVEMENT AFTER QC AS INDICATED BELOW :ACTIVITIES WISE COMPARATIVE MAN-DAYS.0 6 4 2 0 BEFORE QC AFTER QC 7.0 MAN HOURS. TOTAL PRODUCTION TIME IS REDUCED FROM 18. 9.0 LINE & BAR DIAGRAM 8 LENGTH IN Mtr.GRSE DISHARI-S TRIAL IMPLEMENTATION & CHECKING PERFORMANCE 59 CHECK STEP –10(D) WITH THE HELP OF ACTIVITY WISE MAN HOURS. (54%) SLIDE 83 . WASTAGE OF AL ANGLE / PANEL WASTAGE OF COSTLY AL ANGLE HAS COME DOWN TO ZERO LEVEL.

QC MEMBERS DECIDED TO GO FOR REGULAR IMPLEMENTATION OF THE NEWLY DEVELOPED METHOD FOR STRONG BACKING ALL THE ALUMINIUM PANELS BY TACKING/FITTING AL.GRSE STEP –11 (A) REGULAR IMPLEMENTATION PLAN A C P D DISHARI-S AFTER ACHIEVING HIGHLY SATISFACTORY RESULTS DURING TRIAL RUN.FOR AUDITED & NECESSARY CERTIFICATION.   FIND OUT TANGIBLE & INTANGIBLE BENEFITS DURING OUR QC PROGRESS. AND THE LUGS ARE BOLTED WITH MS FLAT BARS. THE SAME WILL BE SENT TO IE&P DEPT. DURING REGULAR IMPLEMENTATION QC MEMBER PLANNED TO FOLLOW THE FOLLOWING STEPS :  AFTER COMPLETION OF TRIAL RUN WE WILL REVIEWED EVERY ACTIVITIES & UPDATED THE SAME & A REVISED MILE STONE CHART WILL BE PREPARED FOR THE BALANCE ACTIVITIES LIKE REGULAR IMPLEMENTATION & FOLLOW UP ACTION ACTIVITY WISE DATA WILL BE COLLECTED FOR STRONG BACKING AL. SLIDE 84 . LUGS WITH PANELS. PANELS BY NEWLY DEVELOPED METHOD AFTER IT‟S REGULAR IMPLEMENTATION (AFTER QC) AND THE SAME WILL BE COMPARED WITH THE DATA BEFORE QC TO OBSERVE THE IMPROVEMENT ACHIEVED AFTER QC.

S. GHOSH. ROY. K. A. TANGIBLE GAIN & INTANGIBLE GAIN. K.O. SHOP (FOJ) PROJECT: ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM QC STEP 3 TO 10 11 ACTIVITIES 1 2 3 4 5 TIME SCHEDULE IN WEEKS 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 FROM DEFINING THE PROBLEM TO TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION A) PREPARE A MILE STONE CHART FROM REGULAR IMPLEMENTATION TO FOLLOW-UP ACTION & REVIEW B) DATA COLLECTION & COMPARISON OF IMPROVEMENT (BEFORE & AFTER QC). O.10 FOR THE BALANCE ACTIVITIES LIKE REGULAR IMPLEMENTATION & FOLLOW UP ACTION. COMP-:01-06-11 QC MEMBERS: S. 12 FOLLOW-UP ACTION & REVIEW PLANNED ACTUAL SLIDE 85 .05.: 24-01-11 D. D.GRSE A C P D STEP –11(B) DISHARI-S REGULAR IMPLEMENTATION DO REVISED MILESTONE CHART AFTER TRIAL IMPLEMENTATION AFTER COMPLETION OF TRIAL RUN WE HAVE REVIEWED EVERY ACTIVITIES & UPDATED THE SAME & A REVISED MILE STONE CHART IS PREPARED ON 26. POLLEY. START. H.BACHAR QC TEAM : DISHARI ( S ) / STRUC.

0 1. FITTING AL. LUGS WITH MS FLAT BARS TACKING/FITTING OF AL. STRAIGHTENING THE MS FLAT BARS TOTAL 1.PANELS PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS .GRSE A C P D STEP –11(C) DISHARI-S REGULAR IMPLEMENTATION DO DATA COLLECTION & COMPARISON WITH THE CORRESPONDING DATA BEFORE QC AFTER REGULAR IMPLEMENTATION COMPARATIVE STUDY OF ACTIVITIES BEFORE & AFTER QC IS EXHIBITED HERE IN A TABLE AS INDICATED BELOW : SL.5 4. 1 2 3 MAN HOUR CONSUMED /PANEL MAIN ACTIVITIES FOR STRONG BACKING AL.0 SLIDE 86 .0 AFTER QC 1.0 1.06% PRODUCTION TIME IS SAVED DUE AVOIDANCE OF SEGREGATION THE REJECTED ALUMINIUM ANGLES . FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING. LUGS WITH MS FLAT BARS (STRONG BACK) ON ALUMINIUM PANEL BEFORE QC 2.5 9.0 9.0 3. FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING REMARKS 4 5 6 7 8 REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS.0 1. REMOVE WELD METAL FROM AL.0 18. REMOVE WELD METALS FROM ANGLES BY GRINDING. NO.5 52. ANGLES ( STRONG BACK) ON ALUMINIUM PANEL TACKING/FITTING OF AL. LUGS BY GRINDING SEGREGATION THE REJECTED ANGLES .5 2.

DESCRIPTION OF WORK REQUIRED AVERAGE LENGTH (75 X 50 X 6mm) PER SHIP FOR STRONG BACKING THE PANEL REJECTION OF AL. FLAT BARS PER SHIP BEFORE QC A C P D COMPARATIVE STUDY OF REQUIREMENT AS WELL AS REJECTION OF AL. FLAT BARS PER SHIP AFTER QC . . ANGLE AFTER QC. ANGLE PER SHIP BEFORE QC AND REQUIREMENT AS WELL AS REJECTION OF MS.8%) 132 0 SLIDE 87 .( STRONG BACKING BY MS FLAT BAR BOLTED WITH AL.( STRONG BACKING BY ALUMINIUM ANGLES) SHIP/CONST.2% OF TOTAL REQUIRED LENGTH ) AFTER QC. ANGLE PER SHIP BEFORE QC AND REQUIREMENT AS WELL AS REJECTION OF MS. NO. 132 67 (50. REMARKS WJ FAC/2062 WJ FAC/2063 IPV/2074 APV/2075 STRONG BACKING OF AL. CLIT) REQUIRED AVERAGE LENGTH (100X 10 mm) PER SHIP FOR STRONG BACKING THE PANEL REJECTION OF MS FLAT BARS SAVINGS OF 67 METER ALUMINIUM ANGLE PER SHIH (49. PANELS FOR TRANSPORTATION & ERECTION OF WHEEL HOUSE. BEFORE QC.GRSE REGULAR IMPLEMENTATION DO DISHARI-S FURTHER DATA WERE COLLECTED FOR REQUIREMENT AS WELL AS REJECTION OF AL.

& AFTER QC A C P D SLIDE 88 .GRSE REGULAR IMPLEMENTATION CHECK DISHARI-S AUDITED /CERTIFICATION OF VARIOUS DATA FOR FABRICATION OF ALUMINUM BEAMS & GIRDERS BEFORE QC.

AFTER QC (%) COMPARISON OF IMPROVEMENT BEFORE QC & AFTER QC DURING REGULAR IMPLEMENTATION LINE & BAR DIAGRAM 30 PRODUCTION TIME DESCRIPTION OF WORK 25 20 15 10 5 0 27 13.0 AFTER QC SAVING OF PRODUCTION TIME. PANELS 27.5 50% BEFORE QC AFTER QC SLIDE 89 .) FOR STRONG BACKING THE 12 NOS. REDUCTION IN PRODUCTION TIME( INEFFECTIVE TIME) PRODUCTION TIME (MAN-DAYS.5 13. OF PANELS OF EACH WHEEL HOUSE BEFORE QC STRONG BACKING OF AL.GRSE STEP –11(E) DISHARI-S REGULAR IMPLEMENTATION CHECK A C P D 1.

PER SHIP BEFORE QC (STRONG BACKING BY ALUMINIUM ANGLES) AFTER QC ( STRONG BACKING BY MS FLAT BAR BOLTED WITH AL. PANELS 132 MTR.GRSE DISHARI-S REGULAR IMPLEMENTATION COMPARISON OF IMPROVEMENT BEFORE QC & AFTER QC DURING REGULAR IMPLEMENTATION 2. NIL 50.8% BEFORE QC AFTER QC IT IS OBSERVED FROM THE LINE & BAR DIAGRAM THAT :  REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP = 50% = 50. SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP DESCRIPT ION OF WORK TOTAL LENGTH OF MATERIAL FOR STRONG BACKING AL. LINE & BAR DIAGRAM 80 60 40 REQUIRED WASTAGE 67 20 0 STRONG BACKING OF AL. AFTER QC (%) LENGTH IN Mtr. 132 MTR. LUG) REQUIRED WASTAGE SAVING OF COSTLY AL ANGLES. PANEL. 67 MTR.8% SLIDE 90  .

34 LAKHS = 50.8%  TOTAL COST SAVING PER YEAR = 3.78 LAKHS  THE MAN HOURS SAVED IS USED FOR FABRICATION OF VARIOUS SEATS FOR EQUIPMENTS OF SHIP WHICH WERE PREVIOUSLY OUTSOURCED SLIDE 91 .44 LAKHS 1.GRSE STEP –11(G) DISHARI-S REGULAR IMPLEMENTATION TANGIBLE GAIN  REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) = 50%   SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP COST SAVING PER YEAR a) b) LABOUR COST SAVING MATERIAL COST SAVING = = 2.

000/-.GRSE DISHARI-S REGULAR IMPLEMENTATION PROJECT COST 1. SLIDE 92 . WHICH IS ONE TIME. 2. COST OF CUT PIECE MATERIAL IS NOT CONSIDERED. LABOUR COST FOR MAKING ALUMINIUM LUGS AND DRILLING HOLES ON MS FLAT BARS IS APPROX RS 20.

GRSE DISHARI-S REGULAR IMPLEMENTATION INTANGIBLE BENEFITS           RATIONAL THINKING FOR PROBLEM SOLUTION THE JOB WAS COMPLETED TO THE SATISFACTION OF ALL CONCERN JOB SATISFACTION ON ITS ACHIEVEMENT INCREASED EMPATHICALLY RELATIONSHIP INCREASED WORK COMMITMENT INCREASED QC KNOWLEDGE SELF DEVELOPMENT & MUTUAL DEVELOPMENT SELF REALISATION IN COMPLICATED TECHNOLOGY INCREASED GROUP HARMONY CARING AMONG THE WORKGROUP  INCREASED TEAM SPIRIT SLIDE 93 .

WE CONDUCTED FOLLOW-UP ACTION & REVIEW OF OUR NEWLY DEVELOPED PROJECT AS INDICATED HERE :- CHECK SHEET CHECK POINT ACTION PLAN FOR RECURRENCE PREVENTION REVIEW PERIOD RESULT 1. ANGLES.GRSE A C SL 1 STEP –12 DISHARI-S P D FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION TO ENSURE THAT THE SOLUTIONS ARE ADOPTED & MAINTAINED.CONSUMED ON DAILY BASIS & SUMMARIZED ON MONTHLY BASIS . ALWAYS KEEP CLOSE CONTACT THE ALUMINIUM WITH THE GROUP OF PANELS BY MS OPERATIVES WHO ARE FLAT BARS DEPLOYED FOR STRONG INSTEAD OF BACKING THE ALUMINIUM ALUMINIUM PANELS BEFORE IT‟S ERECTION. PANELS AND MAN HR. ANGLES TO AVOID & CONVEYED THEM TO FOLLOW WASTAGE OF AL. 50% WASTAGE OF COSTLY ALUMINIUM ANGLES USED FOR STRONG BACKING THE ALUMINIUM PANELS BEFORE IT‟S ERECTION HAS COME TO ZERO LEVEL BY REPLACING MS FLAT BARS IN PLACE OF AL. MAINTAIN THE DELIVERY SCHEDULE OF FINISHED PRODUCT IN TIME. MAINTAINING A PROGRESS REVIEW CHART FOR MONITORING THE MONTHLY WASTAGE OF MATERIAL USED FOR STRONG BACKING THE AL. STRONG BACKING 1. THE IMPROVED METHOD. FINISHED PRODUCTS ARE DELIVERED IN TIME. ANGLES. 2 SLIDE 94 . 3. 2.

0 NOT USED BECAUSE MS CAN NOT BE FITTED WITH ALUMINIUM BY TACKING REPLACED BY MS FLAT BARS SLIDE 95 .0 13. FAIRING 27. CONSUMED FOR STRONG BACKING THE ALUMINIUM PANELS AS WELL AS THE WASTAGE OF COSTLY ALUMINIUM ANGLES.0 14. SHIP WISE PROGRESS REVIEW CHART FOR MAN HRS. ALUMINIUM ANGLES/MS FLAT BARS (LENGTH IN METER) USED FOR STRONG BACKING THE PANEL ALUMINIUM ANGLES USED 2063 (WJ-FAC) 2064 (WJ-FAC) 2065 (WJ-FAC) 2075 (IPV) 2076 (IPV) 136 138 137 WASTAGE 69 70 66 125 126 0 0 MS FLAT BAR USED WASTAGE TOTAL MANDAYS CONSUMED/SHIP FOR STRONG BACKING THE ALUMINIUM PANELS AND REMOVAL INCL.0 26.0 28. NO.GRSE STEP –12 (A) DISHARI-S FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION A P C D WE ARE MAINTAINING A PROGRESS REVIEW CHART FOR MONITORING THE MONTHLY MAN HRS. CONSUMED FOR STRONG BACKING AND WASTAGE OF COSTLY ALUMINIUM ANGLES CONST.

0 MANDAYS /SHIP TO 13. ANGLE = NIL 13 0 0 2076 14 0 2063 2064 2065 2075 STRONG BACK USED (Mtr. REMOVAL & FAIRING FOR STRAIGHTENING THE AL ANGLE/MS FLAT BARS CAME DOWN FROM 27.) MANDAYS) WASTAGE OF COSTLY ALUMINIUM ANGLE (USED AS STRONG BACKING THE AL. SLIDE 96 .5 MANDAYS LEVEL AFTER QC.) OBSERVATION :  STRONG BACK REJECTED(Mtr. PANELS) CAME DOWN FROM 68 Mtr. /SHIP WASTAGE OF COSTLY AL. CONSUMED FOR STRONG BACKING AND WASTAGE OF COSTLY ALUMINIUM ANGLES BEFORE QC 140 120 100 80 60 40 20 27 28 26 69 70 66 136 138 137 125 AFTER QC 126 WASTAGE OF COSTLY AL .ANGLE = 68 Mtr. /SHIP TO ZERO LEVEL AFTER QC. THE MANDAYS SPENT FOR STRONG BACKING INCL.GRSE DISHARI-S FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION SHIP WISE PROGRESS REVIEW CHART FOR MAN HRS.

AFT. STANDARDISATION OF VARIOUS SIZES MS FLAT BARS AND ALUMINIUM LUGS DESCRIPTION OF ITEMS SIDE BHD. BHS. PARTITION BHD. NO. AS A FOLLOW UP ACTION WE HAVE STANDARDIZED MS FLAT BARS & AL.(S) SIDE BHD. LUGS TO BE USED FOR STRONG BACKING THE VARIOUS SIZES AL.PANELS FOR FABRICATION & ERECTION OF WHEEL HOUSE OF WJFAC/IPV CLASS OF SHIPS. BHD. PARTITION BHD. 1 2 3 4 5 6 7 8 9 10 FOLLOW UP ACTION/REVIEW & DISHARI-S RECURRENCE PREVENTION STEP –12(B) STANDARDISATION P D AFTER SUCCESSFUL REGULAR IMPLEMENTATION OF OUR PROJECT & SUBSEQUENT DISCUSSION WITH PLANNING DEPT. ALUMINIUM PANELS SIZE IN mm QTY MS FLAT BAR SIZE IN mm QTY ALUMINIUM LUG SIZE IN mm QTY 8300 X 2400 5250 X 2400 3800 X2400 5006 X 2600 2500 X 2400 1400 X 2400 2500 X 2400 1450 X 2400 940 X 2400 1560 X 2400 2 1 1 1 1 2 1 1 1 1 8000 x 100 x 10 2000 x 100 x 10 4800 x 100 x 10 2000 x 100 x 10 3400 x 100 x 10 2000 x 100 x 10 4600 x 100 x 10 2000 x 100 x 10 2100 x 100 x 10 2000 x 100 x 10 1000 x 100 x 10 2000 x 100 x 10 2100 x 100 x 10 2000 x 100 x 10 1100 x 100 x 10 2000 x 100 x 10 500 x 100 x 10 2000 x 100 x 10 1100 x 100 x 10 2000 x 100 x 10 4 4 2 2 2 2 2 2 2 2 4 4 2 2 2 2 2 2 2 2 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 80 40 48 20 34 20 44 20 20 20 20 40 20 20 10 20 05 20 10 20 SLIDE 97 . PARTITION BHD. PARTITION BHD. PARTITION BHD.GRSE A C SL.(S&P) SIDE BHD.(P) FORD.

GRSE STEP –12 (C) DISHARI-S FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION COMPARATIVE MILESTONE CHART ACTIVITY WISE REVIEW & UPDATE AND COMPARE THE ACTUAL TIME TAKEN WITH THE ESTIMATED TIME QC TEAM : DISHARI ( S ) / STRUC.06.01. S BACHAR TIME SCHEDULE IN WEEKS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 DEFINING & ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES AND DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE & TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION 5 6&7 8 9 & 10 11 12 FOLLOW-UP ACTION & REVIEW PLANNED – 20 WEEKS ACTUAL– 24WEEKS SLIDE 98 . GHOSH.11 QC MEMBERS: S. O COMP. SHOP (FOJ) PROJECT: ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM QC STEP 3 &4 ACTIVITIES 1 2 3 4 5 6 7 8 D.11 D. H. POLLEY. ROY. K.: 22. K. TART.:06.A. O.

DURING REGULAR IMPLEMENTATION ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION DURING PREPARATION OF PROGRESS REVIEW CHART 12 FOLLOW-UP ACTION & REVIEW 1-WEEK 2-WEEK + 1-WEEK SLIDE 99 . OF MEETING) + 1-WEEK ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION DURING DATA ANALYSIS. DEPT.GRSE FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION DISHARI-S COMPARISON BETWEEN ACTUAL TIME TAKEN WITH THE ESTIMATED TIME AS PER MILS STONE CHART WITH REASONS OF VARIATION QC STEP ACTIVITY TIME ESTIMATED ( IN NO. OF MEETING) 4-WEEKS 2-WEEKS 3-WEEKS ACTUAL TIME TAKEN (IN NO. REASON 3&4 5 6&7 DEFINING & ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES AND DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE & TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION 8 9 & 10 4-WEEKS 4-WEEKS 4-WEEKS 4-WEEKS - 11 2-WEEK 4-WEEKS + 2-WEEK ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION FOR AUDIT &CERTIFICATION OF GAINS FROM IE&P. OF MEETING) 4-WEEKS 2-WEEKS 4-WEEKS ADDITIONAL TIME TAKEN (IN NO.

GRSE STEP –12 (D) DISHARI-S FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION EFFECTIVENESS OF THE REMEDY ON IMPLEMENTATION OF OUR NEWLY DEVELOPED METHOD COMPARATIVE PARETO DIAGRAM IS USED TO CHECK THE EFFECTIVENESS OF THE REMEDY ON IT‟S IMPLEMENTATION COMPARATIVE PARETO DIAGRAM BEFORE QC CUMULATIVE % LINE AFTER QC SOLVED PROBLEM “A” CUMULATIVE % LINE IT IS OBSERVED FROM THE COMPARATIVE DIAGRAM THAT AFTER TAKING PROPER REMEDIAL MEASURE THE PROBLEM A IS SOLVED SLIDE 100 .

STRATIFICATION. STEPS PROBLEM IDENTIFICATION PROBLEM SELECTION DISHARI-S TOOL & TECHNIQUE USED BRAINSTORMING. PROGRESS REVIEW CHART.GRSE SL. DATA COLLECTION. PARETO DIAGRAM. DATA COLLECTION. DATA COLLECTION . DATA COLLECTION . STRATIFICATION . 1 2 12-QC. WHY. ECT. 5W-1H TECHNIQUE. BAR-DIAGRAM. BRAINSTORMING. LINE & BELT GRAPH . VALIDATION OF PROBABLE CAUSES. BRAINSTORMING. DATA COLLECTION. CAUSE & EFFECT DIAGRAM. DATA COLLECTION. A-B-C ANALYSIS. 5W-1H TECHNIQUE. PIE CHART.BAR DIAGRAM.OPTION CHART & PARETO CHART. BAR DIAGRAM. FLOW DIAGRAM 4-W & 1-H TECHNIQUE. LINE & BAR DIAGRAM. 5W-1H TECHNIQUE. QUALITY CIRCLE TOOL & TECHNIQUE USED 3 4 DEFINE THE PROBLEM ANALYSIS THE PROBLEM 5 6 7 8 9 10 11 12 IDENTIFICATION THE PROBABLE CAUSES OF THE PROBLEM IDENTIFICATION THE ROOT CAUSES OF THE PROBLEM DATA ANALYSIS FOR ROOT CAUSE DEVELOPING SOLUTION FORESEEING PROBABLE RESISTANCE TRIAL IMPLEMENTATION & CHECK PERFORMANCE REGULAR IMPLEMENTATION FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION SLIDE 101 . BRAINSTORMING.WHY ANALYSIS. LINE & BAR DIAGRAM. RUN CHART.

GRSE DISHARI-S PRODUCTION LOSS DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE WE MADE A MILESTONE CHART OF 18 WEEKS TO COMPLETE OUR FUTURE PROJECT. SLIDE 102 .

GHOSH. POLLEY. S BACHAR TIME SCHEDULE IN WEEKS 1 PLAN 3 4 5 DO DEFINING THE PROBLEM ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6 7 8 9 CHECK 10 11 ACT 12 TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION FOLLOW-UP ACTION & REVIEW SLIDE 103 .07. A.2011 DURING COMPLETION DATE –09. K. S.11. K.2011 QC MEMBERS: S. NIZAMUDDIN. SHOP (FOJ ) PROJECT:PRODUCTION LOSS ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE QC STEP ACTIVITIES STARTING DATE --.07.GRSE DISHARI-S MILESTONE CHART FOR FUTURE PROJECT  WE MADE A MILESTONE CHART OF 18 WEEKS TO COMPLETE THE PROJECT  MILESTONE CHART IS HANDED OVER TO OUR CO-ORDINATOR FOR REGISTRATION OF THE PROJECT QC TEAM : DISHARI ( S ) / STRUC. CHAKRABORTY. H. ROY.

G. All The Non-Members Of Our Shop. SLIDE 104 .GRSE DISHARI-S We extend our gratitude and thanks to the following agencies for their wholehearted co-operation & support for the completion of our project. 3. Our Management. 1. S. R. IE &P Department 4. E. 2. Trade Union.

PROBLEM:-ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM.  WASTAGE OF ABOUT 50% COSTLY ALUMINIUM ANGLE DUE TO DEFORMATION AND / OR DISTORTION AFTER IT‟S REMOVAL. ANGLES BY FAIRING SLIDE 105 . ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS.) DISTORTED ANGLES TACKING/FITTING OF AL. IMPACT OF THE PROBLEM : ADDITIONAL TIME (INEFFECTIVE TIME) IS ADDED TO PRODUCTION TIME TO REMOVE THE DISTORTION.  DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB. STRAIGHTENING THE AL.GRSE CASE STUDY AT A GLANCE DEFORMED ANGLES DISHARI-S STRONG BACKING THE ALUMINIUM PANELS ( BEFORE QC.

GRSE CASE STUDY AT A GLANCE STRONG BACKING THE ALUMINIUM PANELS ( AFTER QC.) DISHARI-S AL. STRAIGHTENING THE MS FLAT BAR BY HAMMERING SOLUTION OF THE PROBLEM:.44 LAKHS.8%  COST SAVING PER YEAR a) LABOUR COST SAVING = 2. b) MATERIAL COST SAVING =1. LUGS BY GRINDING. TACKING/FITTING AL. LUGS ALONG WITH MS FLAT BAR FOR STRONG BACKING.34 LAKHS SLIDE 106 .STRONG BACKING THE ALUMINIUM PANELS BY MS FLAT BARS BENEFIT: REDUCTION IN PRODUCTION TIME (INEFFECTIVE TIME) = 50%  SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP = 50. LUGS IS FITTED WITH MS FLAT BAR BY BOLT & NUT REMOVE WELDING BURRS FROM AL.

GRSE DISHARI-S OUR THEME SONG ON QC “QUALITY CONCEPT FOR SUSTAINABLE DEVELOPMENT” “SOLVE THE PROBLEMS IN SMALL GROUPS.S SLIDE 107 . COME ON BROTHER. DO NOT BE SHY TORCH-BEARER OF NEW INDIA FLY THE BANNER FOR QC HIGH” DISHARI .

3) DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB DUE TO INVOLVEMENT OF ADDITIONAL WORK 1) OPERATOR.44 L b) MATERIAL COST SAVING =1.22.34 L PROBABLE MAIN CAUSES OF THE PROBLEM ROOT CAUSE OF THE PROBLEM SOLUTION OF THE PROBLEM BENEFIT PROJECT DURATION DATE OF STARTING . 1) REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) = 50% 2) SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP = 50. ANGLES FOR STRONG BACKING THE AL PANELS.06. 2) TACKING/FITTING AL. 5) ERECTION PROCEDURE. PANELS FOR STRONG BACKING.GRSE DISHARI-S CASE STUDY AT A GLANCE TITLE OF CASE STUDY (PROBLEM) IMPACT OF THE PROBLEM ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM 1) HIGH IN-EFFECTIVE TIME 2) 50% WASTAGE OF COSTLY ALUMINIUM ANGLES WHICH IS USED FOR STRONG BACKING THE ALUMINIUM PANEL. HIGHLY MALLEABLE AND LIGHT IN WEIGHT AL. 06. PANELS. LUGS WITH AL. 3) TACKING/FITTING PROCEDURE OF STRONG BACK. 4) TRANSPORTATION OF AL.11 DATE OF COMPLETION . 1) FITTING LUGS WITH MS FLAT BAR BY BOLT & NUT. THE ROOT CAUSE BEHIND THE PROBLEM ARE THE PREVAILING PRACTICE OF USING SOFT.8% 3) COST SAVING PER YEAR = a) LABOUR COST SAVING = 2.11 SLIDE 108 . 01. 2) MATERIAL USED FOR STRONG BACK.

GRSE DISHARI-S SLIDE 109 .

GRSE DISHARI-S QUESTION & SUGGESTION PLEASE .

0 RS 194  2.4 M “A” PANEL 18.61 LAKHS a) YEARLY LABOUR COST SAVING FOR 4-NOS.90 (190 % OH) = RS 10126. 5063.GRSE REGULAR IMPLEMENTATION DISHARI-S TANGIBLE GAIN (COST BENEFIT ) MAN HRS.0 LABOUR COST / BEAM &GIRDER BEFORE QC 18.80 AFTER QC 9. X 4 no.40 LABOUR COST SAVINGS /BEAM &GIRDER DESCRIPTION OF WORK FABRICATION OF 8 M  2.0 RS 194  2.WJFAC/IPV VESSEL =Rs. SPENT /BEAM &GIRDER BEFORE QC AFTER QC 9.90 (190% OH) = RS 5063.500 x 67 Mtr. WJFAC/ IPV VESSEL = Rs.40 NO OF PANELS FOR EACH WJFAC & IPV VESSEL = 12 TOTAL LABOUR COST SAVING FOR EACH WJFAC/ FPV VESSEL := Rs. 1. 0. 2. vessels =Rs.40 X 12 NOS =Rs.0 RS 5063.44 LAKHS (APPROX) YEARLY MATERIAL COST SAVING FOR 4-NO.34 LAKHS .

SLIDE 11 1 REWORK 4 5 6 7 8 . NO. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING.GRSE STEP –1( A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. PRESS BENDING MACHINE. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC. REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. 1 2 WORK RELATED PROBLEMS IN THE AREA OF REWORK REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. NO. EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL. MAJOR PROBLEM AREA SL. 3 PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.

SPECIALLY DURING RAINY SEASON. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS. 9 WORK RELATED PROBLEMS IN THE AREA OF REWORK 1 REWORK EXCESSIVE DISTORTION DURING FABRICATION OF AL. SLIDE 12 4 . 2 PRODUCTION LOSS PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. 1 2 3 PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIP‟S SUPERSTRUCTURE WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS 10 SL NO MAJOR PROBLEM AREA SL. NO. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE.GRSE STEP –1(A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. NO.

WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. NO. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM SLIDE 13 . GASKET CUTTING FOR PLUMBING WORK. 5 WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG. PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS. 2 6 7 8 9 10 11 PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH. UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS. PRODUCTION LOSS DUE TO UNEVEN LEVEL OF BLACK SMITH FLOOR.GRSE DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA PRODUCTION LOSS SL.

DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. HUGE AMOUNT OF UNUSED / OBSOLETE TOOLS / MACHINE / MATERIALS OF TOOL STORE ARE KEPT IN A UN SYSTEMATIC WAY. PROBLEM DUE TO NON AVAILABILITY OF PROPER STORE FOR KEEPING PERSONAL BELONGINGS OF OPERATIVE AT GATE . NO 1 2 3 3 HOUSE KEEPING/ SPACE WORK RELATED PROBLEMS IN THE AREA OF HOUSE KEEPING / SPACE DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE.GRSE STEP –1( A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. PERSONAL/ OUTSIDERS. KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE. SLIDE 14 4 5 6 7 8 .NO 2. IMPROPER STORING ARRANGEMENT CAUSES PROBLEM FOR IDENTIFICATION OF REUSABLE MATERIAL.

INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION. 1 2 4 DISSATISFACTION 3 4 5 6 SLIDE 15 .GRSE DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO 3 MAJOR PROBLEM AREA HOUSE KEEPING/ SPACE SL. COMMUNICATION PROBLEM DUE TO NON AVAILABILITY OF PUBLIC TELEPHONE BOOTH NEAR THE GATE–NO 2. 9 WORK RELATED PROBLEMS IN THE AREA OF HOUSE KEEPING / SPACE NO SHOP‟S NAMEPLATE ON TOP OF MAIN ENTRANCE GATE FOR IDENTIFICATION OF SHOP. WORK RELATED PROBLEMS IN THE AREA OF DISSATISFACTION INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR. NO. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. ESPECIALLY WHERE PRECISION WORK TAKE PLACE. SL NO MAJOR PROBLEM AREA SL. 10 PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF TIG /MIG & PLASMA WELDING MACHINE OF DIFFERENT MAKE. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. NO. INADEQUATE LIGHT & FAN IN DRESS CHANGING ROOM.

M. 1 2 5 FACILITY 3 4 SL NO MAJOR PROBLEM AREA SL. OXYGEN AND D.A. IN SITU PREPARATION OF „C‟-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. BUS STAND SHED OUTSIDE THE GATE NO-2 ARE BROKEN FOR A LONG TIME. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH. 1 2 3 WORK RELATED PROBLEMS IN THE AREA OF FACILITY EXISTING SHOP FLOOR CONDITION CAUSES PROBLEM OF FABRICATION OF HEAVY STRUCTURE. WORK RELATED PROBLEMS IN THE AREA OF DELAY A. INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION. NO. 6 DELAY SLIDE 16 .C. NO. PROBLEM OF WORKING OUTSIDE SHOP FLOOR (OPEN AIR) FOR FABRICATION & ERECTION SPECIALLY DURING SUMMER & RAINY SEASON. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL.GRSE DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. REGULATORS.

FREQUENT DISLOCATION OF ASBESTOS SHED OF SHOP DURING HEAVY STORM CAUSING SAFETY HAZARDS & WASTAGE OF MATERIALS DUE TO RAIN. BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPING OF DAMAGE CABLE. FREQUENT DAMAGE OF HEAD SCREEN FOR WELDING CAUSES WASTAGE. WELDING HOLDER CAUSING LOSS OF PRODUCTION AS WELL AS SAFETY HAZARD.. 6 7 8 SLIDE 17 . ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM. INSIDE SHOP FLOOR .GRSE DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SLN O MAJOR PROBLEM AREA SL NO 1 2 7 ACCIDENTAL HAZARD / SAFETY HAZARD 3 4 5 WORK RELATED PROBLEMS IN THE AREA OF ACCIDENTAL HAZARD / SAFETY HAZARD CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING.

“D” SHACKLES ETC. VERTICAL CLAMPS. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER. GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD.GRSE STEP –1( A) DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. WHICH ARE USED WITHOUT LOAD TESTING. NON AVAILABILITY OF ALARM BELL IN EOT CRANE MAY CAUSES ACCIDENTAL HAZARD. SLIDE 18 7 ACCIDENTAL HAZARD / SAFETY HAZARD 11 12 13 14 . CHANCES OF SAFETY HAZARD FROM VARIOUS LIFTING TACKLES LIKE WIRE SLING. NO. INADEQUATE INSULATION OF MMAW HOLDERS CAUSES ACCIDENTAL HAZARD. 9 10 WORK RELATED PROBLEMS IN THE AREA OF ACCIDENTAL HAZARD / SAFETY HAZARD HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING IT‟S OPERATION CAUSES SAFETY HAZARDS.

FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. 1 2 8 POLLUTION / HEALTH HAZARD 3 4 5 WORK RELATED PROBLEMS IN THE AREA OF POLLUTION / HEALTH HAZARD STAGNANT DRAINAGE WATER CAUSES UNHYGIENIC ENVIRONMENT CONDITION IN SHOP FLOOR. 1 2 WORK RELATED PROBLEMS IN THE AREA OF UTILIZATION IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES. NO. BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. IMPROPER UTILIZATION OF CUT PIECE MATERIAL. SL NO 9 MAJOR PROBLEM AREA UTILIZATION SL. FRONT SPACE OUTSIDE THE ENTRANCE GATE OF SHOP REMAINS UN CLEANED. FLOODING OF DRESS CHANGING LOBBY ATTACHED TO SHOP DURING RAINY SEASON CAUSING LOSS OF PRODUCTION & UNHYGIENIC ATMOSPHERE. DRILLS. SLIDE 19 . NO.GRSE DISHARI-S IDENTIFICATION OF PROBLEM IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING) SL NO MAJOR PROBLEM AREA SL. TAPS ETC.

GRSE

DISHARI-S

IDENTIFICATION OF PROBLEM
IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING)
SLN O MAJOR PROBLEM AREA SL. NO. WORK RELATED PROBLEMS IN THE AREA OF UTILIZATION

9

UTILIZATION

3
4

UNDER UTILIZATION OF HUGE QUANTITY OF SCRAP MATERIALS LIKE PLATES, ANGLE, CHANNEL ETC.
UN UTILIZATION OF BROKEN /OVER USED DRILL BITS & TAPS.

SLN O

MAJOR PROBLEM AREA

SL. NO. 1 2

WORK RELATED PROBLEMS IN THE AREA OF WASTAGE / DAMAGE DAMAGE OF WELDING TRANSFORMER, RECTIFIER MACHINES ETC. FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS. FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. DAMAGE OF ELECTRODE CARTOONS DUE TO STORING OUTSIDE FLOOR OF THE SHOP. DAMAGE OF COLUMN POST FROM CONTROLLING DRINKING WATER WASTAGE IN FRONT OF THE DEPARTMENT.

10

WASTAGE/ DAMAGE

3 4 5

6

WASTAGE OF END PORTION OF FILLER ROD USED IN TIG WELDING. SLIDE 20

GRSE

DISHARI-S

IDENTIFICATION OF PROBLEM
74 PROBLEMS IN 10- MAJOR WORK RELATED PROBLEM AREA OF “A”,“B”, “C” & “A/K” CATEGORIES (THROUGH BRAINSTORMING)
SL 1 2 PROBLEMS CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING. INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR, ESPECIALLY WHERE PRECISION WORK TAKE PLACE. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. A.M.C. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH, OXYGEN AND D.A. REGULATORS. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES, DRILLS, TAPS ETC. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. PROBLEM AREA ACCIDENTAL HAZARD / SAFETY DISSATISFACTION RATINGS A B

3 4

PRODUCTION LOSS RE WORK

A C

5

DELAY

A

6 7 8

PRODUCTION LOSS UTILIZATION DELAY

A C A

SLIDE 22

GRSE

DISHARI-S

IDENTIFICATION OF PROBLEM
SL 9 10 11 12 13 14 15 16 PROBLEMS IMPROPER UTILIZATION OF CUT PIECE MATERIAL. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC. REWORK & FAILURE OF WELDING JOINTS FROM IMPROPER PLATE PREPARATION. WELDING HOLDER CAUSING LOSS OF PRODUCTION AS WELL AS SAFETY HAZARD. DAMAGE OF WELDING TRANSFORMER, RECTIFIER MACHINES ETC. BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPING OF DAMAGE CABLE. STAGNANT DRAINAGE WATER CAUSES UNHYGIENIC ENVIRONMENT CONDITION IN SHOP FLOOR. FLOODING OF DRESS CHANGING LOBBY ATTACHED TO SHOP DURING RAINY SEASON CAUSING LOSS OF PRODUCTION & UNHYGIENIC ATMOSPHERE. EXISTING SHOP FLOOR CONDITION CAUSES PROBLEM OF FABRICATION OF HEAVY STRUCTURE. PROBLEM OF WORKING OUTSIDE SHOP FLOOR (OPEN AIR) FOR FABRICATION & ERECTION SPECIALLY DURING SUMMER & RAINY SEASON. PROBLEM AREA UTILIZATION RE WORK RE WORK ACCIDENTAL HAZARD / SAFETY DAMAGE ACCIDENTAL HAZARD / SAFETY HEALTH HAZARD HEALTH HAZARD RATINGS A A/K A C B A/K B B

17 18

FACILITY FACILITY

C C

SLIDE 23

BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED. CRANE GIRDER OF EOT CRANE OF SHOP CAUSES SOUND POLLUTION & VIBRATION RESULTING FUSE OF FOCUSING BULBS.GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 19 20 21 22 23 24 25 PROBLEMS UNDER UTILIZATION OF HUGE QUANTITY OF SCRAP MATERIALS LIKE PLATES. KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME. PERSONAL/ OUTSIDERS. INADEQUATE LIGHT & FAN IN DRESS CHANGING ROOM. DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. ANGLE. BUS STAND SHED OUTSIDE THE GATE NO-2 ARE BROKEN FOR A LONG TIME. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE. SPECIALLY DURING RAINY SEASON. PROBLEM AREA UTILIZATION HOUSE KEEPING ACCIDENTAL HAZARD/ SAFETY FACILITY HEALTH HAZARD DISSATISFACTION POLLUTION RATINGS C A/K A C A A/K B 26 27 28 HOUSE KEEPING PRODUCTION LOSS DISSATISFACTION A A C SLIDE 24 . CHANNEL ETC.

DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG. EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK.GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 29 30 PROBLEMS FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE. ACCIDENTAL HAZARD/ SAFETY HOUSE KEEPING C A SLIDE 25 . ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. PROBLEM AREA DAMAGE ACCIDENTAL HAZARD/ SAFETY DAMAGE PRODUCTION LOSS PRODUCTION LOSS DISSATISFACTION RE WORK HOUSE KEEPING RATINGS A A 31 32 33 34 35 36 B B A A/K A A 37 38 FREQUENT DAMAGE OF HEAD SCREEN FOR WELDING CAUSES WASTAGE. FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. INSIDE SHOP FLOOR .

PRODUCTION LOSS DUE TO UNEVEN LEVEL OF BLACK SMITH FLOOR. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM. COMMUNICATION PROBLEM DUE TO NON AVAILABILITY OF PUBLIC TELEPHONE BOOTH NEAR THE GATE–NO 2. GASKET CUTTING FOR PLUMBING WORK. FREQUENT DISLOCATION OF ASBESTOS SHED OF SHOP DURING HEAVY STORM CAUSING SAFETY HAZARDS & WASTAGE OF MATERIALS DUE TO RAIN. DAMAGE OF ELECTRODE CARTOONS DUE TO STORING OUTSIDE FLOOR OF THE SHOP. IMPROPER STORING ARRANGEMENT CAUSES PROBLEM FOR IDENTIFICATION OF REUSABLE MATERIAL. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION.GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 39 PROBLEMS WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. DAMAGE OF COLUMN POST FROM CONTROLLING DRINKING WATER WASTAGE IN FRONT OF THE DEPARTMENT. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. PROBLEM AREA PRODUCTION LOSS RATINGS A 40 41 42 43 44 RE WORK DAMAGE HOUSE KEEPING HOUSE KEEPING DAMAGE A C A/K A B 45 46 47 PRODUCTION LOSS SAFETY HAZARD C B A/K ACCIDENTAL HAZARD DISSATISFACTION 48 C SLIDE 26 .

NO SHOP‟S NAMEPLATE ON TOP OF MAIN ENTRANCE GATE FOR IDENTIFICATION OF SHOP. PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH. HIGH VOLTAGE SWITCH BOARDS KEPT IN A ROOM NEAR THE OUTSIDE WORKING FLOOR MAY BE DAMAGED / SHORT – CIRCUITED DUE TO FALLING OF RAIN WATER THROUGH ROOF. HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING IT‟S OPERATION CAUSES SAFETY HAZARDS. HUGE AMOUNT OF UNUSED / OBSOLETE TOOLS / MACHINE / MATERIALS OF TOOL STORE ARE KEPT IN A UN SYSTEMATIC WAY. UN UTILIZATION OF BROKEN /OVER USED DRILL BITS & TAPS. FRONT SPACE OUTSIDE THE ENTRANCE GATE OF SHOP REMAINS UN CLEANED .GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 49 PROBLEMS PROBLEM DUE TO NON AVAILABILITY OF PROPER STORE FOR KEEPING PERSONAL BELONGINGS OF OPERATIVE AT GATE . REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS.NO 2. PROBLEM AREA SPACE RATINGS C 50 51 52 53 PRODUCTION LOSS HEALTH HAZARD SAFETY HAZARD REWORK A C A/K A 54 HOUSE KEEPING C 55 56 HOUSE KEEPING UTILIZATION B B 57 UTILIZATION A SLIDE 27 .

“D” SHACKLES ETC. PRODUCTION LOSS PRODUCTION LOSS ACCIDENTAL HAZARD SAFETY HAZARD A 64 65 66 A B B SLIDE 28 . WHICH ARE USED WITHOUT LOAD TESTING. 59 60 WASTAGE HOUSE KEEPING B A 61 REWORK A 62 ACCIDENTAL HAZARD A 63 PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS. VERTICAL CLAMPS. INADEQUATE INSULATION OF MMAW HOLDERS CAUSES ACCIDENTAL HAZARD.GRSE SL 58 IDENTIFICATION OF PROBLEM PROBLEMS REWORK DISHARI-S RATINGS A PROBLEM AREA REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS. WASTAGE OF END PORTION OF FILLER ROD USED IN TIG WELDING. PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF TIG /MIG & PLASMA WELDING MACHINE OF DIFFERENT MAKE. CHANCES OF SAFETY HAZARD FROM VARIOUS LIFTING TACKLES LIKE WIRE SLING. PRESS BENDING MACHINE. NON AVAILABILITY OF ALARM BELL IN EOT CRANE MAY CAUSES ACCIDENTAL HAZARD. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL.

GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD.GRSE DISHARI-S IDENTIFICATION OF PROBLEM SL 67 PROBLEMS EXCESSIVE DISTORTION DURING FABRICATION OF AL. IN SITU PREPARATION OF „C‟-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER. INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIP‟S SUPERSTRUCTURE. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM PROBLEM AREA REWORK RATINGS A 68 69 DISSATISFACTION ACCIDENTAL HAZARD B B 70 ACCIDENTAL HAZARD A 71 72 73 FACILITY DELAY REWORK B A A 74 PRODUCTION LOSS A SLIDE 29 . INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION.

ALIGN THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD.GRSE DEVELOPMENT OF SOLUTION DISHARI-S LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE . THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK. .

Sign up to vote on this title
UsefulNot useful