Rejection Minimisation using QC

tools.

H. Anne Marina 2012108007

P. Harita 2012108013
G.M. Priyankha 2012108023
Sharmila Deepak 2012108032
Objective:
 To minimise the rejection of the parts using QC tools.
 To improve the productivity of the company
Work done :

 Thorough study of the plant

 Identification of the problem

 Data collection

 Pareto analysis of the defect data

 Identification of key defect

 SLEEVE BLANK
180 100.0%
167

160 90.0%

80.0%
140 135

70.0%
120

60.0%
100 MAJOR DEFECT:
Inner diameter
Defect 50.0%

no. 80 40.0%
66
63
58
60
30.0%
46

40
20.0%
22 21 21
20 16
12 10.0%
10
6 6 6 4 3 3 3 3 2 2 2 1 1
0 0.0%

Reasons
FINDINGS
 Sleeve blank was chosen since it had the maximum
rejections.
 After pareto analysis of the defect data of Sleeve blank, it was
found that the major defects were due to Inner diameter and
CNC unwash.
 CNC unwash is due to operator.
 Reasons for defects due to Inner diameter are further
analysed.
DATA COLLECTION

 For further analysis, inner diameter readings for 32

continuous samples were taken.

 Since, sleeve blank is made of two operations, readings were

taken at the top, middle and bottom.

 Measurements were taken using Air gauge.

 Histogram and run chart were used for analysis

 BOTTOM MIDDLE TOP
II OPERATION I OPERATION

1 23.234 23.226 23.227

2 23.236 23.232 23.235
3 23.241 23.238 23.234
4 23.235 23.226 23.224
5 23.238 23.234 23.235
6 23.237 23.231 23.236
7 23.239 23.227 23.231
8 23.236 23.233 23.229
9 23.236 23.234 23.237
10 23.239 23.229 23.232
11 23.234 23.234 23.22
12 23.236 23.229 23.233
13 23.236 23.234 23.232
14 23.239 23.234 23.231
15 23.236 23.23 23.232
16 23.234 23.234 23.229
17 23.237 23.229 23.232
18 23.237 23.234 23.229
19 23.236 23.232 23.234
20 23.236 23.234 23.226
21 23.236 23.239 23.238
22 23.235 23.236 23.235
23 23.237 23.234 23.227
24 23.237 23.232 23.232
25 23.235 23.234 23.236
26 23.233 23.232 23.219
27 23.236 23.229 23.226
28 23.234 23.234 23.232
29 23.238 23.232 23.218
30 23.239 23.233 23.231
31 23.235 23.233 23.231
32 23.234 23.231 23.229
33 23.234 23.234 23.229
34 23.237 23.229 23.232
35 23.237 23.234 23.229
36 23.236 23.232 23.234
37 23.236 23.234 23.237
38 23.236 23.239 23.238
39 23.235 23.236 23.235
40 23.237 23.234 23.234
41 23.237 23.232 23.232
42 23.235 23.234 23.236
43 23.233 23.232 23.227
44 23.236 23.229 23.226
45 23.234 23.234 23.232
46 23.238 23.232 23.237
47 23.239 23.233 23.231
48 23.235 23.233 23.231
49 23.234 23.231 23.229
50 23.232 23.235 23.241
CALCULATION
 Process capability is found using the formula ,
Cp = U-L
6σ
• Process capability index is found using the formula,
Cpk1= U-X
3σ
Cpk2= X-L
3σ
Now Cpk= MIN(Cpk1,Cpk2)
PROCESS CAPABILITY

BOTTOM MIDDLE TOP

II OPERATION I OPERATION
Mean 23.236 23.232 23.230
SD 0.002 0.003 0.007
USL 23.25 23.25 23.25
LSL 23.21 23.21 23.21
Cp 3.316 2.570 0.948
Cpk1 2.345 2.264 0.969
Cpk2 4.288 2.876 0.927
Cpk 2.345 2.264 0.927
UCL 23.242 23.241 23.241
LCL 23.231 23.223 23.224
HISTOGRAM – I Operation

Histogram
30

25

20
Frequency

15

10

0
23.21 23.22 23.23 23.24 23.25 More
Diameter
 HISTOGRAM - MIDDLE
Histogram
40

35

30

25
Frequency

20

15

10

0
23.21 23.22 23.23 23.24 23.25 More
Diameter
 HISTOGRAM – II Operation

Histogram
45

40

35

30
Frequency

25

20

15

10

0
23.21 23.22 23.23 23.24 23.25 More
Diameter
 Run chart- II Operation
II operation
23.25

23.245

23.24

23.235

23.23
Innerdia
Diameter
23.225

23.22

23.215

23.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Number
 Run chart-Middle

Middle
23.25

23.245

23.24

23.235

Diameter23.23 Inner dia

23.225

23.22

23.215

23.21
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Number
 Run chart-I Operation
I Operation

23.25

23.245

23.24

23.235

23.23
Inner dia
Diameter
23.225

23.22

23.215

23.21
1 2 3 4 5 6 7 8 9 1011121314151617181920212223242526272829303132333435363738394041424344454647484950

Number
Findings
 From the histogram ,it is found that the parts undergoing
operation-I has the maximum width of spread.
 Using this information, run charts are drawn for the
operations .
 It is assessed from the run charts that there is a maximum
variation in diameter shown in operation-I’s chart compared
to the middle and operation-II’s.
 ENVIRONMENT MAN MACHINE Dresser guard

handling Tool
Fluids Wrong Offset
Entry centre alignment between tool and IneffectiveClamping
Temperature component
Clamping
Lack of skill
Pressure
Incorrect Inspection Wheel Spindle
Runout Not Ok
Wrong Master Setting
Breakdown
Wrong Loading
Bed Flatness Not ok Inner dia(oversiz
On the job training
undersize)
Incorrect
Inconsistent tool life Wheel, Dresser and Fixture
Measurement
system analysis wrongsetting Seating
Screw
cutting
Wrong airguage cleaningofcomponents Fixture HeadDamage
setting improper Allen
Locating dia under size
calibration Key/spanner Tightening
inspection Damaged Component Damages
Wrongtool grades
Dimensional correction WrongWheel
Incorrect Program Length
Process Capability less oversize
MEASUREMENT METHOD
Slide No 2 MATERIAL
Works to be done:
 Cause and effect diagram is to be drawn for the selected
problem.
 Various causes for the rejection of the sleeve blank is then
found and analysed.
 Brainstorming sessions are to be held
 Suggestions to minimize rejection will be inferred from the
conclusions drawn.
 A report to be submitted to the company.
THANK YOU…