Monthly strategic quality review

2019-04-08
 2

Quality - CMP
Quality Inflow MB 3

& 2nd stage Out Flow Rejection.

In Process rejected (PPM)
50000

40000 43004
39174
30000 Actual
PPM

28027 27229
20000 24190 Target
20797 19868 20237 21098 16333
17453 15542
10000 15230

0
18 Ap r-18 ay-18 un-1 8 8 8 8 8 8 8 9 9
Mar- M J Jul-1 Aug-1 Se p-1 Oct-1 Nov-1 Dec-1 Jan-1 Feb-1

Month

Compound Wise Rejected Rejection of February-2019

50000
40000 10%
1%
30000 Low SG
High HD
Kg

High Viscosity
20000 38% High SG
High SG-UCD
10000 25% High SG-UCD
High SG High Viscosity
0
High HD Low SG
E

E
8

01

6
3

25

01

1
32

91

45

78

27
R

-R

-R
-6

52

1-
2-

5
F-
-

P-

55
32
IL

TR

52
B-
B-

-
96

R
H
-6

-8
-5

ET
-1

TR

R
IL
R

JT
AT

Compound 26%
Camso 2019
Quality Inflow FM 4

& 2nd stage Out Flow Rejection.

Inprocess Rejected (PPM)
60000
50000 55707
40000
30000 38551 40872
20000
32338 31364 30455 27592 27118
25909
24088 25499
PPM 10000 17241 17009 In process
0 (PPM)

8
8

9
r-1

p- 1
Target

r-1

y -1

n- 1

l- 1

g- 1

t- 1

v -1

c -1

n- 1

b- 1
Ju

Oc
Ma

Ap
(ppm)

Ma

Se

Ja
Ju

Au

No

De

Fe
Month

Compound Wise Rejected (Kg)

Rejected of February 2019
9%
High HD
25000
Scorch particles 6%
20000 28% High SG
Low Viscosity
15000
Low Ts2 Low HD
10000
Kg Low SG Low HD (Without
5000
24% Chemical)
0 Low HD (Without
5 0 2 5 3 4 1 2 2
04 -70 - 60 -38 225 -92 112 - 63 611 - 85 -78
5 1 Chemical) Low SG
-1 -
SM - NS - TR -TR TR R DT 2- H- - TR TR- JTR -HP
2- 2 2 2 2- 2- 2 A 2- 2 Low HD
2-
Low Ts2
Compound High HD
1%
3% 29% Scorch particles

Camso 2019
Quality Inflow Calendering
5

CMP & KTD Rejected due to Calendering Issue

Monthly Rejects Due to Calender - Rejects Due to Calender-Pareto Anal-
2.78
CMP(Kg/Ton) ysis of February
3.80 2.62 2.50
98 100 120
89 94
3.10 2.92 2.71 2.53 2.06 2.22
2.50 4.00 5050 100
2.50
69 76 84
3.00 4050 59 80
2.00
2.5 3050 43 60
Kg/Ton

2050 21 1037805 40
1.00 1048 466 384 360 268 246 168
1050 20

Kg
108
0.00 Achiev 50 0
ment D T T T) D IP LE S E S
EA ES PL ES
Ju 8
Ju 8
Ma 1 8

Au 8
Se 18
Oc 8
No 8

F e 19
19
Ap 8

D e 18
Ja 8
N IN N
EF U ST
R
TI
C
1
l- 1
U
1

t- 1
r-1

1
PO PL JO O KN SAM KN
n-
r-
y-

n-
b-
g-
p-

v-
c-
( W P G R
R P E A IC IC
Ma

M E A M IN P .C
Target C
O
N
D R AG C
O D H TH Q TH
S LE SC AM ER BI
N
R
C
ER SS
S A D O V E
Month LE C V O L
O SC

MTD Rejected Due to Calendering Issue

Rejects Due to Calender-Pareto Analysis
Monthly Rejects Due to Calender -
of Febrouary-MTD93 98 100
CMP(Kg/Ton)-MTD
1.66

87
1.80

1.65

4000 100
72 80
1.67

1.62
1.58
1.96
1.52

1.83
1.45

1.80
1.65

3.00 3000 18 61 80
49 60
2.00 2000 37

664
40
Kg/Ton

1.11

658

446
1.00 1000

428

397

198
20

307

174
255

79
0.00

Kg
Achiev
0 0 %
Au 8
Ap 8
M 18
J u 18
Ju 8

Se 18
O c 18

D e 18
J a 18
F e 19
19
N o 18
l- 1
1
r-1

ment
n-

v-
c-
n-
b-
r-
-

g-
p-
t-
ay
Ma

Target
Month

Camso 2019
RRW-MB,FM & Calendering
6

Rubber Related Waste -MB+FM

Jul-18 Aug-18 Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19
Month

Cleaning rubber-Kg 4470 4219 5660 9154 13533 15788 10679 19778

Scrap compounds-Kg 14153 25560 30596 20614 16476 26540 32254 22856

QC sample-Kg 2474 2330 3160 2280 1800 2317 2407 1720

RRW-FM+MB
PRODUCTION-ton
14845 15660 16160 14813 13960 14706 16005 13543

TOTAL RRW-Kg 21097 32109 39416 32048 31809 44645 45340 44354

Target Kg/ton 3.260 3.238 3.215 3.193 3.170 3.148 3.148 3.100

Achieved RRW-Kg/ton 1.421 2.050 2.439 2.163 2.279 3.036 2.833 3.28

Camso 2018
Quality Out Flow-MB & FM
7

Out Flow–(Properties + Processability ) MB & FM

3000
2400 Processability(p
pm)
1800
1637
PPM 1200
1459
600 261
420 515
144 257 148 163
0 52 69 58
65 99 31
66 27
87 105 58 0 180
0
r-1
8 18 18 18 18 18 t- 1
8 8
1 1 8 19 -1
9
y- n- ul- g- p- c v- c- n- b
Ap M
a Ju J Au Se O No De Ja Fe

Month
Properties Processability

Properties Issue 4850

Processability
4227
Issue
4050
3250
Low Viscosity
Kg
0 2450 Colour out
Kg 1650 Bagging
850 400
120
50
54 - 38
5
- 54
1
Plant R -3 R TR
2 -G B 2- T
Plant
Customer Complain – Outflow details
8

Highlights
Operational issues continuously dropped
due to regular QC checkups and new
Com plaint quality gate
No complaints reported at APD Camso 2019
Customer Complaint
9

Plant Wise Client Complaints(With NCR+Non NCR) of Feb-

ruary-2019
11
9 1
7 With NCR
11 Non NCR
No 5
8
3 1 3
3 1
1 2 2
D - 01 KT
D
D-0
1
D - 02 D 02
ET MT ET MT

Plant.

Processability Issue
4500 4227
4000
3500
3000
2500 Low Viscosity
2000 Colour out
Kg 1500 Bagging
1000 400
500 120
0
D - 02 KT
D
D - 01
ET MT
Plant Camso 2019
 10

Quality - APD
Quality Inflow 11

Quality In Flow
12000

9903

8689
10000

7852
7601
8000

6005
5952
6000
PPM
4000

2000

0
Sep Oct Nov Dec Jan Feb
Achievement Target

Contribution for Internal Defects (February 2019)

500
Defects Categorization (February 2019)
447
450
400
350
300 Short mold (Hole)
250
25% Short mold (Edge)
Pcs

200 41% Flow mark

150
100 71 14%
50 2 1 20%
0
Flap Spacer Bladder Air bag
Camso 2019
Quality Outflow 12

80 Quality Out Flow 71

70
60
50 44 47
40 36 36 36
PPM 32
30
20
10
0
September October November December January February

Customer complaint product wise(Last Six Customer complaint Reason wise (Last six
month) month)
12 11
10
Pleat
8
No of complaint

22% Qty Variation

6 36% Air Leak
Other
4
21%
2
2
22%
0
Air Bag Flap
Camso 2019
Rubber Related Waste ( Last Six month) 13

Sep-18 Oct-18 Nov-18 Dec-18 Jan-19 Feb-19

Ancillary Product 553 1032 479 173 581 486

Recycle Product 0 192 82 492 239 0

Flash 1959 4383 3875 3317 4280 3338

Other 254 407 326 112 218 243

Total (Kg) 2766 6015 4762 4094 5318 4067

Target (Kg/Ton) 4.26 4.26 4.26 4.26 4.26 4.26

Achievement (Kg/Ton) 3.20 5.47 4.26 3.30 4.40 3.25

Camso 2019
Q&A