Company

Logo

Project Name

1
 Company
Introduction Logo

Organization Name:

Deptt.:

Theme:

Need:

Team Facilitator :

Team Leader :

Team Members :

Start Date Of Project End Date of Project

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 Company
Project Theme vs Methodology Logo

Project Theme Methodology

Quality DMAIC

Productivity DMAIC/PDCA

HR PDCA

Maintenance PDCA

DMAIC: Define Measure Analyze Improve and Control

PDCA: Plan Do Act Check
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 Company
Methodology vs Steps Logo

Theme Quality Tool 1 Tool 2 Tool 3 Tool 4

Methodology DMAIC
1 Define Scoping tree Historical Pareto Analysis Cost estimation
trend
2 Measure SIPOC PFD Input-Output Process
Diagram Analysis Sheets Capability study
With VA and MSA
and NVA
3 Analyze Cause and Cause and Cause validation
Effect effect and FMEA
Diagram Matrix
4 Improve Implementation of countermeasure and trials

5 Control Effectiveness Process Operation Review of

Check Capability standards FMEA, Control
study updation plan and WI
4
 Company
Methodology vs Steps Logo

Theme Productivity Tool 1 Tool 2 Tool 3 Tool 4

Methodology DMAIC
1 Define Historical Scoping Target Setting Cost Saving
Trend tree estimation
2 Measure PFD Analysis Cycle time Operator SWCS
With VA and study/setu utilization study
NVA p
changeov
ers study
3 Analyze 4M Analysis Kaizens Lay outing/
Automation/

4 Improve Implementation of countermeasure and trials

5 Control Effectiveness Process Operation Review of

Check Capability standards FMEA, Control
study updation plan and WI5
 Company
Methodology vs Steps Logo

Theme HR Tool 1 Tool 2 Tool 3 Tool 4

Methodology PDCA
1 Plan TEI check Prioritizing Activity Plan and Cost Saving
sheet areas Target Setting estimation
2 Do Current Gaps in Measure KPI’s Act on decided
system current related to areas(Kaizens)
system current system

3 Check Check KPI’s are showing a positive trend (Effectiveness)

4 Act Change Set Measure

methodology Standards Achievement
where there and freeze
is no positive WI’s
trend 6
 Methodology vs Steps Company
Logo

Theme Maintenance Tool 1 Tool 2 Tool 3 Tool 4

Methodology PDCA
1 Plan Scoping Tree Prioritizing Activity Plan and Cost Saving
and pareto areas Target Setting estimation
Analysis
2 Do Cause and Cause Act on root
Effect validation/ cause (Kaizens)
Analysis C-E Matrix

3 Check Check KPI’s are showing a positive trend

4 Act Change Set Measure

methodolog Standards Achievement
y where and freeze and Cost saving
there is no WI’s
positive
trend 7
 Company
Logo

Content- Quality

1 • Identification of Problem

2 • Reason For Selection

3 • Define Phase

4 • Measure Phase

5 • Analyze phase

6 • Improve Phase

7 • Control phase

8 • Future Action plan

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 Company
Logo

Content-Productivity

1 • Identification of Problem

2 • Reason For Selection

3 • Define Phase

4 • Measure Phase

5 • Analyze phase

6 • Improve Phase

7 • Control phase

8 • Future Action plan

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 Company
Logo

Content-HR

1 • Identification of Problem

2 • Reason For Selection

3 • Planning phase

4 • Doing Phase

5 • Checking Phase

6 • Acting Phase

7 • Results

8 • Future Action plan

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 Company
Logo

Content-Maintenance

1 • Identification of Problem

2 • Reason For Selection

3 • Planning phase

4 • Doing Phase

5 • Checking Phase

6 • Acting Phase

7 • Results

8 • Future Action plan

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 Scoping Tree- Example Company
Logo

High Rejection PPM

Pressure Die Cast Shop

CAP-WTR-THERMO-C CW-THERMOSTAT-C CC-THERMOSTAT-C

CCTHERMO-MARUTI-C CCP-SENSOR-C

Non Filling Blow Hole Leakage Chip off Others

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 Company
Historical Trend of Non-filling in CCP Sensor- Example Logo

Last 6 Month PPM Trend for Non Filling

120000

100000 100502

80000
PPM

63429
60000

48099 47981
40000 41795
34875

20000

0
Apr'16 May'16 June'16 July'16 Aug'16 Sep'16

Time Period

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 Company
Defect wise Pareto- Example Logo

Selected for
Project

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 Company
Logo

Cost saving estimation - Example

• Avg. Monthly Production = 8922 (Apr-16 to Sep-16)
• Avg. Monthly Rejection = 2350 Nos.( for 3 selected defects )

As per our Target Rej reduction.

• Non Filling :- (69385-20682) = 48704 PPM

• Blow Hole :- (42644-16608) = 26036 PPM
• Leakage :- (46372-874) = 45498 PPM

Total Actual Rejection Savings = (120238*8922/1000000)

= 1073 Nos / Month

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 Company
SIPOC- Example Logo

Suppliers Inputs Process Outputs Customers Requirements

•Raw Material •Maruti Suzuki •Fitment as per
 JAY MATA DI • Die Casting •Final Machined
•Manpower India Ltd Mating part (Case)
 CHEM TREND • Fettling part after casting
• Raw Material • Appearance as per
 WAKER • Shot
Melting Machine limit sample
 SARU METAL Blasting
 CENTURY •Power • CNC
 JSB •Dies Machining
•Machine Tools
•Shot blasting
Machine
•Consumables
•Root card
•Packing material
-Bins
-Plastic Separator
- Tape
- Identification slip

Start End
RM High
Inspection Melting Pressure Shot Packing
Receiving Inspection Machinin Inspection
Die casting Blasting
g

Inference:- There are 9 steps in This Process

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 Company
Process Flow Diagram- Example Logo

START END

Storage of Raw
100 % final
material
Inference of PFD inspection

Total steps: 11 nos.

Inspecti NVA steps: 05 nos.
on of (All are Muda type1)
raw VA steps : 06 nos. Machining
process

materia
l

Transfer
of metal Transfer of
to metal to
Melting of HPDC Die Casting 100% casting
Central metal M/C Process Fettling Shot Blasting
insp.

melting holding
Furnace furnace
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 Company
Input-Output Sheet- example Logo

Process Output Feature Process Input

VA Test(s)/
Process Step SOP Equipment Output Feature Specification Msa Capability Input(x) C/N Feature Specification
/NVA Analysis
Die Properly As per TRM

Operator
Die Pm NVA Manual N/A C Skill level Min Level 2 OK
pm check sheet
safety door
NVA Manual Mould start closing speed medium speed N/A C Die coat As per WI 016-712 OK
closing
VA CP Die casting full shot visual ok as per ops N/A C Machine Name 250 Ton OK
Die casting appearance C origin position 346±5 mm 346
shot weight C v1 speed 0.22±0.05 m/s 0.25
C v2 speed 3±0.5 m/s 3.04
C s1 position 260±5 mm 260

C s2 position 295±5 mm 295

C intensification pressure 200±10 kg/cm2 200

Machine
intensification pressure
C 5±1 sec 6
hold time (in sec)
Accumulator
C 95±10 kg/cm2 95
pressure (kg/cm2)
C Metal Temperature 660±10 °C 670
C Die open time 10±2 sec 8
C Plunger return time 10±5 sec 8
C Ejection delay time 1.5±1.0 sec 0.5
C Ejection return time 1.5±1.0 sec 1
C Biscuit thickness 20±5 mm 17
C Die temp fix 170±50 °C 171
C Die temp moving 170±50 °C 170
C RM Grade ADC 12 ADC 12

Raw Material
C Metal Melting temp 700 °C
C Spectro sample As per Spectro OK
N2 degassing for
N vacuum sample
as per WI ok
c Size As per model OK
VA :- Value added Die /Mould C Die life 1.25 Lac OK
NVA :- NON value added N Oily OK
C :- Controlled
N :- Non Controlled N Dusty OK

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 Company
Process Capability study - example Logo

D
M A
I
C
Inference: Low Cp because of high
process spread, low Cpk because of
shift of mean towards LSL.
 Company
Cause & Effect Analysis - Example Logo

1-MAN 3-MACHINE & Die

Sprue bush leak N2 Gas Leak

Fatigue

D
Die Leak
Slide Wrong Machine
overheat

M A
Selection
Skill
Non
Filling

I
Silicon Percentage Hydraulic Biscuit thickness
High Pressure low Less or High

C
Gas impurity Low Die Chill Vent Jam
in molten temperature No Over flow or vent at Last
metal Low casting fill Point
pressure
Low metal temp
Casting Pre filling

2-MATERIAL 4-METHOD

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 Company
Cause Validation sheet- Example Logo

Potential Cause For

So No Validation Detail Control Judgment
Occurrence
1 Fatigue of M/C operator Run the machine myself for 1 hrs. By Gemba Ok

2 Skill As per present skill matrix Gemba on machine Ok

3 Sprue-bush water leak As per die check sheet and visually Die check sheet and Gemba Ok
Die check sheet and Gemba
4 Die water leak Die check sheet and visually Ok
In slide punch cooling not available As per ops slide temp ok after

D
5 Slide over heat Ok
spray
6 N2 gas leak Checked and found 70 kg /cm2 As per ops found ok Ok

M A
Wrong machine selection
7 Die run on Hpdc 250 ton As per control plan ok Ok
Silicon percentage high As per chemical composition
8 Found ok Ok
report
Gas impurity in molten metal Found no gas type impurity in molten
9 After degassing vacuum sample Ok

I
metal

10 Hydraulic pressure low Hydraulic pressure found 145 kg/cm2 As per ops Ok

C
Actual see the die temperature by lesser
11 Die temp. Low As per ops Ok
gun
12 Casting pressure low Casting pressure found 845 kg/cm2 As per ops Ok
Biscuit thickness variation in part ± 5 mm
13 Biscuit thickness low or high As per ops Ok

No overflow or vent at Last fill On machine A oil shot taken found last fill
14 Gemba and fill test Ng
point point.
15 Metal temp. Low Metal temp. Found 665 °C As per ops Ok
16 Casting prefill Check practical and found ok By Gemba Ok

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 Kaizen For Filling Pattern- Kaizen sheet Company
Logo
Example
Company: Result: Reduce Blow
Deptt.: Hpdc
hole and Leakage Month of Report Nov’16
Production
rejection
Subject :- To reduce Blow hole and Leakage rejection Part No.: CCP Sensor Process: Die Casting

Before After Productivity

Quality

D
Cost

M A
Delivery

Safety

Morale

I
5S

C
Others
COMMENTS : COMMENTS: Cost 6.8 lac
In this pattern, filling is opposite from In this pattern, filling is done from side saving/Year Approx.
tube area . wards to tube area.
Date of Imple. 25/11/2016

Benefits: Suggested by Santosh, Jagdish

Reduction in blow hole in rejection Approved by Baljeet singh

 Company
KPI Minitoring Example Logo

DPPM Trend of Dia 77 Over Size / under Size

D
M
A
I
C
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