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5 Quality Maintenence

5 Quality Maintenence

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06/25/2015

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24

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

25

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

26

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

3M condition analysis. Please follow following guidelines.

1

Based on QD matrix identify where the defect is generated

2

Draw a C & E diagram for the defect for each process/sub-process,

3

Identify inputs for each M (Man, Method, Machine and Material

4

Check each input whether Standard exists or not. If not then make a standard.

5

All standards are to be followed during Process.

6

If a standard is difficult to follow or if they are loose then standards are to be revised.

Status of Standard

Symbol

1Loose Standard
2No Standard
3As per standard and followed
4Difficult to follow
5Not followed

27

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

28

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

29

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

QM Master plan

Master Plan for quality maintenance is planning of various

activities in this pillar with respect to the time frame in

months and years. According to the stage of TPM

implementation it can start at various levels. In the

beginning it will start with data collection on defects to

improving conditions to sustaining zero defect conditions.

30

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

Brakes India (Sholinghur)

31

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

TPM MASTER PLAN QM SUB COMMITTEE

32

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

ActivityPalnned

Actual Plant. A

Actual line A

Actual line B

Actual Slitting

Year

QM-STEPS

Details ofactivity

Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3

9.Consolidation
andconfirmation
of all check
points.

*Usetheresultsofstep8tosummarize
theinspectionitems. *Preparequality
checkpoint list.

10.Preparationof
aquality
component
control tableand
asuranceof
qualitythrough

*Definestandardinnumerical/
observableform.

7.Implementation
of improvements.

8.Reviewof
productioninput
conditions.

*Reviewtheproductioninput conditions
identifiedinstep2. *Checkwhether
productioninput conditionsare
appropriateandcorrect.

5. Usageof P-M
analysistechnique
totrackdown
causesof
problems.

*Investigateusingtechniquessuchas
P-Manalysis andpropose
countermeasures.

6.Assesment of
impact of
proposedcounter
measures
(FMEA2).

*Performpreliminaryevaluationof the
post improvement situation.

3.Preparationof
problemchart

*Clearifyproduction-input conditions
for problemsineachsubprocess.
*Act promptlyagainst problems that
canbetackledonthespot *Carefully
workout countermeasuresfor
complexproblems. *Devise
investigationtechniques andplan

4.Evaluationof
seriousnessof
problems.
(FMEA1)

*Priorities problemsbyassessing
their impact onqualitydefects.

1.Preparationof
QAMatrix:

*Checkqualitycharacteristics.
*Investigatedefect modes and
subprocess wheredefect occures.
*Assessseriousnessof defect mode.

2. Preparationof
Production-Input
conditionanalysis
table

*Checkdeficiencyinproductioninput
conditions for eachdefect modein
eachsub-process. *Checkwhether
standardsexistsandarebeing
followed.

MASTERPLANFORQUALITYMAINTENANCE ACTIVITIES.

2004-2005

2005-2006

2006-2007

2007-2008

33

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

3M analysis

This analysis is a set of conditions with respect to

machine, material and method for obtaining a good

products. It helps in identifying 3M standards and checking

is possible against these standards. Removing this

variability can some times eliminate Quality Defects in the

product.

34

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

Identification of Operating Conditions with respect
to Machine, Material & Method

Defect

Sl.no

Mode

1

Blister

1) Unloading of baked linings

1) Temperature in the

1) Moisture in the material

from Thermal shock oven in

Post curing oven as per

a specified time.

the specification.

2) Variation in resin
properties

2) Variation in Setting of Vent

2) Curing pressure as per

stroke.

the specification.

3) Temperature in the curing
mould as per specification.

2

Soft

1) Even spreading of mix

1) Curing pressure as per

1) Inclined Plate Flow value

in the moulds.

the specification.

of the powder resin as per
specification.

2) Cleaning of mould edges

2) Temperature in the curing

after the application of Liquid

mould as per specification.

2) Curetime of the resin as

emulsion solution in the

per specification.

moulds.

3) Variation in the bulk
density of the mix.

4) Concentration of the liquid
emulsion solution as per
specification.

According to standard

Statndards needed

Standards not properly followed

Method (People)

Machine

Material

3M Relation

35

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

Identification of Operating Conditions with respect
to Machine, Material & Method

Defect

Sl.no

Mode

3

Dent

1) Cleaning of curing moulds

1) Chrome plating of the

1) Concentration of the liquid

after unloading the product.

mould as per specification.

emulsion solution as per
specification.

2) Temperature in the curing
mould as per specification.

4

Crack

1) Setting of Vent stroke as

1) Temperature in the curing

1) Variation in resin

needed to the product.

mould as per specification.

properties

2) Curing pressure as per
the specification.

5

Flash

1) Cleaning of flashes in the

1) Clearance between the

1) Inclined Plate Flow of the

Dent

edges of the box after

mould and the spacers

powder resin as per the

unloading the lining from the

specification

curing moulds.

2) Curing pressure as per
the specification.

6

Thickness1) Weighment of mix as per

1) Curing pressure as per

1) Bulk density of the mix as

Unclear

the specification

the specification

per specification.

2) Flash removal below the

2) Error free weighing scale

bottom mould.

at common weighing.

3) Correct stock removal in
OD grinding.

4) Correct stock removal in
ID grinding.

According to standard
Standards not properly followed

Statndards needed

3M Relation

Method (People)

Machine

Material

36

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

3M CONDITION FOR NO BLISTER BUBBLES

How to
check

Machine

Baffle plate

Both sheet should be seated Hand

Comp.sup.

Daily

without gap

Dipper agitator

Uniform Rotation

Visual

Prodn.sup

Daily

Voltage

240±10 V

VoltmeterProdn.sup

Daily

Track Chain

No jerking

Visual

Prodn.sup

Shift once

PROCESS

Dipper temperature28±2 C

DigitronProd. Sup./operatorHourly

Latex circulation

No repelling of bubbles fromVisual

Prod. Sup./Comp.supWeekly

dipper agitator

Drying

All teat end heaters should

Visual

Prod.Sup.

Daily

be switched off in I drier

Responsibility

Frequency

3M COndition

Required value

What to do

37

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

3M CONDITION FOR NO BLISTER BUBBLES

How to
check

No.1 product weight0.75 - 0.80 Gms.

WeighmentProdn.sup

Hourly

Material(LATEX)

S.I.Value

2.0 - 2.4

S.I.check

Comp.sup/Lab.sup

Daily

Total alkalinity

0.35 - 0.50 %

Titration

Comp.sup/Lab.sup

Daily

Sediments

No sediments

Hand

Comp.sup/Lab.sup

Weekly

3M Condition

Required value

Responsibility

FrequencyWhat to do

38

TPM Club India

Quality Maintenance Pillar

© Confederation of Indian Industry

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