SOLVING AT EVEREADY INDUSTRIES A_CASE STUDY ( PROBLEM Mackground ¢ Motels and Gros plant of Eveready India Lid. commonced operations i 1056 jacture of dry battery, ine calote sheots for pr bused super alloys. components. Manufacturing of calots involves operations 19. casting, rolling and punching: Increasing zinc prices, nag ed to cut down manufacturing cosis. The us, On reduction of defectives. Segregation Nribution coming tion of Proble St dalacts narrowed down the main Nor the hot rolling stage. “Higher Rejection of Zine Coils during Rolling Crebtew team : Gross-functional (QIT) representing the @ Production and Engineering supported by a group 4 hourly rated employees in the concerned areas was put together. Target of 6 monihs was sat for completion Gt the project pution > With a dew to understand the features OC ING ‘problem, a detailed check sheet (Fig. 1) EEECTIVE on [= ex ‘ae [ou oe] ond March "94, and this has been expressed a run chant (Fig 2) indicating an average of about 5.2% after rolling, exceeding O% In 4 out of 12 monihs. A parate chart (Fig 3) Lased on this data, indicates that about 73% of the PLEO LI WES = ANALYSIS ROLLING TIVE PARETO ne-winane 10 92 relections were due to “off gauge" and “machine breakdown” Analysis > Stratification, shown in Fig. 4 indicates the rejection of off gauge was mainly due to thickness going below lower limit of specification as compared to that above higher limit. Further stratificauon, Pre 5 into shift-wise and stack-wise rejections indicatedANALYSIS OFF-GAUGE REJECTION STRATIFIED DATA that large number of coils were rejected at the shitt Starting and the rejection came down during subsequent stack rolling. Fig. 6 (pie-chart) confirms the same observation, The team then draw up a cause-oltect Glagram (Fig. 7) was then drawn up and the foot causes: arrived at using the & Why (Fig. 7a ard 76) technique and the vital causes idantilied ware * — first stack rolling — increase in break-aap = PM schedule not tollowed Corrotiation botwoen the rejection (result) and the tat steteske TOM (eat eShtimed Inrough # seattor diagram (rig. 8) 1g a corralation cootticient -F ‘break gap" was also corroborated through tasting of hypemnesis (Fig. 8) Counter Measures : Based on tha root-cause analysis the countermeasures were planned for implementaten With assigned fesponsibililies follawed 5W- ROLLING REJECTION — JUNE “93 — STACK & SHIFTWISE TH (Fig. 10) and implementation done through POCA appreach (Fig. 11). rs Achievements : An improvement of 70% eS] in reduction’ due to of gauge was achieved aod this in actual terms came dawn to Biave'trom the earlier 8% (Fig. 12). The, cost saving achieved was Rat lakh por Standardisation a. The correlation parameters for test Stack rolling have been communicated to GA inspection group and operatives : at Rough Holling Mullin the form of a b. Periodical checking Gwice in a month) of brake cal gap is done. ©. PM calender has been made and religiously tollowed, Reflection + The improvement action Participation of shop floor stall A list of unattended targets has been made through POGA cycle to be taken Up next. DOE will be required to resolve 7 Some to the unrescived problems, The case study hightignted the power tis-3_] of Systomatic problem solving matnods fora team crossing functions and levelsDefectives Stackwise METALS & ORES - CALCUTTA ANALYSIS. 5S - WHY Probion Higher Rejection due to Of-Gauge wry 7 Gouge could not be ceptroitea. | ANALYSIS i { wny 2 Increase in the brake gap of the screw CAUSE & EFFECT DIAGRAM MACHINE po enain™ ROUT RETURN ae oven SE aap _— se EPL a EATS" PERHGheaL RAMOR— Cheon tee = ne ean eiiatne SEAR INina sonomeren gangn, oy ee PRSrst, in oe BAR ee werwigee : oe Biae encer a ser 7SCATTER DIAGRAM Metals & Ores Calcutta (Test or Hypoinesis) ALTERNATE HYPOTHESIS - H, CRITICAL VALUE CONCLUSION NULL HYPOTHESIS: ALTERNATE HYPOTHESIS, DECISION ~ 8 = 715 at om. etgnilicshew Invetwnh 10 degrees of treedam, Null hypothesis can not be rejected Null hypothesis Is rejected at 5% significance level SS eee emul ernie oes onibateene =COUNTERMEASURES. CHECK ROLLING DEFECTIVE OFF-GAUGE ~ — o e Pa 5 e 2 iS N 29 1994-95 MONTH s