NTTF

(MNTC)
WELCOME
THE AVIATION
TEAM
 CENTER’S PROFILE

JOBY PAUL
(PRINCIPAL)

DEEPAK NAZARE PARDEEP SARODE

(MANAGER) (ASST MANAGER)
QC TEAM HEAD

 (DEEPAK OJHA) (AJIT KUMAR)

TEAM MEMBER

PRASHIK KADAM MANJUNATH.C.K

(LEADER) (DY.LEADER)

HARSHAL GOSAVI DHANANJAY NIKAM

(DOCUMENATION) (TIME MANAGER)
 AVIATION MEANING
 MANUFACTURING THE AEROSPACE SPARE PARTS
 OUR SLOGAN

Creating distinct ideas,

for transforming complicated world,
to a trouble-free world…! 8
 OUR MISSION
TO
CREATE A BETTER
TOMORROW
FOR MANKIND SPARTANS
THROUGH
APPLICATION OF
0 KNOWLEDGE
TECHNICAL
AND
SKILL

04
10
 Q.C.C. STATISTICS

 Q.C started on = 04/02/2019

= 07
= 98%
 Number of meeting held = Every Friday
= 3:00pm-4:00pm
 Percentage of attendance = VCS CLASS

= 01

= 01

 Meeting day
 Time
12
 12 STEPS APPROACH FOR QC
1) Selection of problem
2) Define the problem
3) Analysis of problem
4) Identification of causes
5) Root causes analysis
6) Data collection
7) Developing solution
8) Forseeing probable resistance
9) Trial implementation
10) Regular implementation
11) Follow up & review

12) Identification of problem

STEP - 01
IDENTIFICATION
OF
PROBLEMS

14
 LIST OF PROBLEMS
1. INSUFFICIENT CHAIRS IN CLASS ROOM NO. 6
2. ABSENCE OF SPINDLE LOCKS IN SOME BENCH VICES IN
WORKSHOP 2.
3. PROPER WHITE BOARD IS NEEDED IN WORKSHOP
4. WINDOWS OF WORKSHOP NOT PROPER
5. BROOMS AND MOPS ARE NOT PROVIDED IN WORKSHOP
6. RACKS ARE NOT PROPER OUTSIDE WORKSHOP 2.
7. NO STAND FOR SHOUES KEEPING
-
8. THER IS NO GOOD WATER IN CAMPUS
9. HANDLES ARE NOT AVAILABLE IN SOME BENCH
VICES IN WORKSHOP
CONTINUE….

16
10. INSUFFICIENT HACKSAW FRAME IN WORKSHOP

11. NO HAVING CAMERA IN WORKSHOP

12. SAFETY GUARD IS NOT THERE IN THE PEDESTRIAL
GRINDER IN WORKSHOP
13. SOME DRILLING MACHINE ARE NOT IN PROPER WORKING
CONDITION IN WORKSHOP .
14. LESS NO. OF DRILLING VICE.
15. UNEVEN FLOW OF COOLENT IN POWER HACKSAW.
16. GUARD IS NOT PROVIDED IN THE MILLING MACHINE.
17. NO PROPER LIGHT IN WORKSHOP
18. SWITCH BOARD TO BE REPAIRED OF WORKSHOP .
CONTINUE….

17
20. EXAUST FAN ARE NOT PROPER IN WORKSHOP .
21. NO FIRE EXTUINGUISHER IN LIBRARY HALL
22. COTTON WASTE IS NOT PROVIDED IN STORE
23. INSUFFICIENT COOLANT SUPPLY IN THE MILLING M/C
24. VICES OF WORKSHOP 2 ARE NOT ACCORDING TO HEIGHT
OF TRAINEE.
25. NO EMERGENCY BREAK IN POWER HACKSAW.
26. PROPER PLACE IS NOT PROVIDED FOR BROOMS IN BCR.
27. SCRIBER OF HIGHT GAUGE IS NOT PROPER OF
WORKSHOP
28. FREQUENT BREAKAGE OF TAPS.
29. A1 DRAWING SHEET IS NOT ISSUED FOR ENGINEERING
DRAWING
CONTINUE….

18
63. INACCURATE DEPTH SETTING IN DRILLING MACHINE.
64. INSUFFICIENT PLACE FOR PARKING.
65. ABSENCE OF ATTENDENCE SENSOR.
66. NO TRANSPORTATION FACILITIES FOR STUDENTS.
67. UNEVEN JAWS IN SOME BENCH VICES
68. DELAY IN GETTING TOOL FROM TOOL CRIB.
69. DIFFICULTY IN SLUG REMOVAL AFTER CHAIN DRILLING.
70. SOME BENCH VICES ARE WITHOUT HANDLE
71. POOR PERFORMANCE IN DRILLING EXERCISES.
000
72. WHY WORKPIECES ARE REJECTED

22
STEP - 02
SELECTION
OF
PROBLEM

37
 PROBLEMS UNDER CATEGORY
[A]
1. FREQUENT BREAKAGE OF DRILLS.
2. FREQUENT BREAKAGE OF TAPS.
3. NO SAFETY GUARD IN PEDESTRIAL GRINDER.
4. HANDLES ARE NOT AVAILABLE IN SOME BENCH VICES IN
WORKSHOP 2.
5. FREQUENT BREAKDOWN OF POWER HACKSAW.
6. VIBRATION OF DRILLING VICES WHILE DRILLING LARGE DIA
HOLE.
7. UNEVEN JAWS IN DRILLING VICES.
S
8. DRILL BITS ARE GETTING BLUNT FREQUENTLY.
9. DIFFICULTY IN CHANGING THE RPM OF DRILLING M/C.
10. UNEVEN FLOW OF COOLENT IN POWER HACKSAW.

` 25
 PROBLEMS UNDER CATEGORY
[B]
1. AUTOCAD SOFTWARES ARE NOT INSTALLED IN SOME OF
THE COMPUTERS.
2. CAMERAS ARE NOT WORKING IN THE WORKSHOP 1.
3. FREQUENT BREAKDOWN OF LATHE MACHINE.
4. INSUFFICIENT NO. OF CHUCK KEY ,BOX SPANNERS.
5. UNSAFE CONDITION WHILE WORKING ON LATHE.
6. FREQUENT DAMAGE DONE IN TOILET.
7. INSUFFICIENT
- PLACE IN CANTEEN.
8. INACCURATE DEPTH SETTING IN DRILLING MACHINE.
9. ABSENSE OF ATTENDANCE SENSOR.
10. NO WHITE BOARD IN ROOM NO.25.

26
 PROBLEMS UNDER CATEGORY
[C]
1. INSUFFICIENT CHAIRS IN CLASS ROOM 25.
2. REPLACEMENT OF JAWS OF BENCH VICE.
3. WINDOWS OF WORKSHOP ARE BROKEN.
4. BROOMS AND MOOPS ARE NOT AVAILABLE.
5. CUPBOARDS ARE NOT MAINTAINED.
6. THEFT CASES ARE INCREASING.
7. BOOKS ARE NOT ISSUED OF PARTICULAR SUBJECTS.
8. PROPER WHITE BOARD IS NEEDED.
9. SOFTBOARD IS NEEDED FOR SHOPTALK.
10. A1 DRAWING SHEET IS NOT BEING ISSUED.
11. MATERIALS OF THE CUPBOARDS ARE GETTING RUSTED.
CONTINUE…

28
 PROBLEM UNDER CATEGORY [AK]

1. PROPER FIRST AID KIT IS NOT AVAILABLE.

2. PROPER PLACE FOR BROOMS ARE NOT PROVIDED.
3. DUSTBIN IS NOT AVAILABLE IN BCR.
4. PROBLEM ON REMOVING CHIPS FROM DRILL MACHINE
BED.
5. BAG RACK IS RUSTED.
6. OIL IS NOT PROVIDED IN WORKSHOP 2.
7. NO COTTON WASTE IN WORKSHOP 2.
8. BROKEN FUSE IN THE SWITCH BOARD IN WORKSHOP 2.

32
 A-B-C
CATEGORISATION
• A - PROBLEMS THAT CAN BE SELF-SOLVED BY QCC TEAM.
• B – PROBLEMS THAT CAN BE SOLVED WITH THE HELP OF OTHER
DEPARTMENT.
• C – PROBLEMS THAT CAN BE SOLVED WITH THE HELP OF
MANAGEMENT AND REQUIRES SOME CAPITAL EXPENDITURE .
• AK- ‘A’ TYPE OF PROBLEM WHICH CANNO.
TOTAL BE SOLVED INSTANTLY. c
OF LISTED
OF

50 42 PROBLEMS
PROBLEMS

40
30
80
20
20
10 8
10
NO.

0 A
Series1 B C AK

CATEGORY O PROBLEMS

24
 SELECTION OF THE PROBLEM
NO.OF TIMES OCCURED
F
J
E J T
A M A O
B A P M U
No Top 5 problems N T
R
U
U
R R A N A
A C I Y E
R
A L
R H L
Y
Y

1 Wastage of electricty 3 6 6 7 5 6 33
2 Wastage of water 1 0 2 2 0 0 05
3 No white bords in 1&2 1 2 1 1 1 1 07
4 why workpieces are rejected 12 15 10 9 11 13 70
5 Not pipe for coolant 0 1 1 1 0 0 03

As per analysis our problem “MACHINES ARE NOT PROPER

MAINTANCE” was selected.
24
 DECISION MATRIX

1-30

`
` 5

35
STEP - 03
DEFINE
-
THE
PROBLEM

44
 FLOWCHART
START
A
IINTERPRETATION
DRG
DRILLING START
ISSUEING OF R/M
N
IF
NO VIBRATION OF Why workpieces are
OK
DRILLING VICE rejected
Y
MARKING ON W/P
COMPLETION OF JOB
N IF
COMPLETION OF JOB

OK
Y IF N N IF
CLAMPING OF W/P REWORK OK
OK

N IF Y Y
OK
Y
STOP
A

45
 FLOWCHART
A B

A B STOP

46
STEP - 04
ANALYSIS
OF
THE PROBLEM

48
 4) ANALYSIS OF PROBLEM
1) What is the problem?
Why Workpiece are rejected
2) Where it is occuring?
In the workshop.
3) When it is raising?
during the working hours.
4) Who is being affected?
Trainees are got effected.
5)How it is getting effected?
loss of time & work.
 2-EFFECT OF THE
PROBLEM
SPOILAGE OF WORKPIECE SPOILAGE OF
W/P
90 63 Pieces/Year
NO. OF W/P SPOILED

80
70 63 SPOILAGE OF
60 W/P
W/P
50 SPOILAGE OF
0 Pieces/Year
40 W/P
30
20
0
10
W/P
0
Series1
AVG. ACTUAL AVG. SPOILAGE
SPOILAGE / YEAR
/ YEAR
AVG. WASTAG/
WASTAGE OF W/P PER YEAR YEAR
AVG. ACTUAL WASTAGE/
YEAR

RNTC-QCC/ 031
55
 4-EFFECT OF THE
PROBLEM
ACCIDENT AND INJURIES
ACCIDENT OF
49 Trainees/YEAR
90
80 ACCIDENT OF Trainees
NO. OF TRAINEES

70
49
0Trainee/YEAR
60
TRAINEES
INJURED

50
40
30 0 49
20
10 0
0 TRAINEES
Series1
ACTUAL ACCIDENTS ACCIDENTS/ YEAR
/ YEAR

ACCIDENT AND INJURIES OCCURED PER

YEAR

RNTC-QCC/ 032
57
 EFFECTS OF THE
PROBLEM
OVERALL EFFECTS

1. PERFORMANCE OF TRAINEES BELOW PAR 45 TRAINEES GETTNG

BELOW AVERAGE MARKS

2. SPOILAGE OF WORKPIECE 63 WORKPIECES PER YEAR

3. WASTAGE OF TIME 65HOUR PER EXERCISE

4. INJURIES OCCURRED 49 TRAINEES PER YEAR

58
 PROJECT GOAL
TO INCRASE AND ENHANCE THE
PERFORMANCE OF TRAINEES AND
REDUCE THE ACCIDENT AND INJURIES
ON DRILLING MACHINE
ON / BEFORE 25th APRIL, 2019

59
 GANTT CHART
QCC NAME: CO-ORDINATOR: FACILIATOR:
DEPARTMENT: CP01 DEEPAK OJHA QCC
NOVATERS AJIT KUMAR
MEMBERS:
PROJECT: 1. PRASHIK
PULSE REASON FOR SELECTION:WHY THE WORKPICES ARE 2. MANJUNA
GENERATO RE0JECTED ? TH
R 3. DHANANJ
PROJECT START OF QCC: 04/02//2019 AY
NO 1 4. HARSHAL
MEETING
DAY: NUMBER OF PROJECTS PLANNED: 01`
EVERY
THURSDAY
(10:00-11:00AM)

35

- PLANNED
MEETINGS
 STEP - 05
IDENTIFICATION OF
CAUSES

60
BRAINSTORMING
(ROUND ROBIN METHOD)

15
 IDENTIFICATION
OF CAUSES
(ROUND ROBIN
METHOD)
1. LACK OF KNOWLEDGE
2. IMPROPER CONDITION OF DRILLING VICES
3. LACK OF INTEREST
4. UNABLE TO DETECT FAULTY ELEMENTS
5. LACK OF MAINTANENCE
6. VIBRATION OF DRILLING VICES WHILE
DRILLING LARGE DIA HOLES
7. IMPROPER SPEED AND FEED
8. FEAR OF TRAINEES
9. WRONG METHOD
10.ECENTRICITY OF DRILLING MACHINE
SPINDLE

62
 ISHIKAWA DIAGRAM
MATERI
MAN IMPROPER USE OF
AL ACCESSORIES

UNABLE TO DETECT LACK OF

FAULTY ELEMENTS KNOWLEDGE

NOT UNSKILLED
APPLICABLE LABOUR
LACK OF
INTEREST

UNSAFE AND
UNPRODUCTIVE
OPERATION
ECCENTRICITY OF
DRILLING M/C SPINDLE
NO DEVICE FOR SUPPORTING
DRILLING VICES NO PROPER SETTING OF
RPM
LACK OF
MAINTAINENCE
VIBRATION OF
DRILLING VICE WRONG
OUTDATED METHOD

MACHIN METHOD
DEFECTIVE
DRILL ANGLE

E
63
 SPLIT-1
MAN

MAN NOT USING PROPER

ACCESSORIES

UNABLE TO DETECT LACK OF

FAULTY ELEMENTS KNOWLEDGE

UNSKILLED LACK OF
LABOUR INTEREST

UNSAFE AND
UNPRODUCTIVE
OPERATION

64
 SPLIT-2
MACHINE

MACHINE

ECCENTRICITY OF
DRILLING M/C SPINDLE

LACK OF
MAINTAINENCE

OUTDATED

UNSAFE AND
UNPRODUCTIVE
OPERATION

65
 SPLIT-3
METHOD

METHOD

NO PROPER SETTING OF RPM

NO DEVICE FOR SUPPORTING
DRILLING VICES

WRONG
METHOD
VIBRATION OF M/C
VICES

DEFECTIVE
DRILL ANGLE

UNSAFE AND
UNPRODUCTIVE
OPERATION

66
 SELECTION OF VALID CAUSES
USING EFFECT MATRIX

YES
NO

= MINOR EFFECTIVE
MORE EFFECTIVE M =m µ =
MICRO EFFECTIVE

68
 SELECTED VALID
CAUSES

1.LACK OF KNOWLEDGE.
2.FEAR OF TRAINEES.
3.VIBRATION OF DRILLING
VICES WHILE DRILLING HOLES
OF DIAMETER 8-12mm.3 CAUSES
7 CAUSES

69
STEP - 06
ROOT CAUSES
ANALYSIS
-

70
 (WHY ?-WHY?)
ANALYSIS FOR FINDING
OUT
THE ROOT CAUSE

71
MAJOR CAUSE NO- 1

LACK OF KNOWLEDGE

WHY?

LACK OF ATTNENTION

WHY?

LACK OF INTEREST

72
 MAJOR CAUSE NO- 2
FEAR OF TRAINEES

WHY?
VIBRATION OF MACHINE

WHY
?

UNABLE TO DETECT IMPROPER SPEED

WRONG RPM
FAULTY ELEMENT AND FEED

WHY?

WRONG METHOD

73
 MAJOR CAUSE NO- 3

VIBRATION OF DRILLING
VICES WHILE DRILLING
LARGE DIA HOLES

WHY?

NO PROPER DEVICE
WRONG RPM IMPROPER DEPTH FOR SUPPORTING
DRILLING VICES

74
TRAINEES OPINION
MAJOR CAUSE- 1. UNABLE TO
2 DETECT
FAULTY
ELEMENT
2.WRONG METHOD
CAUSE- CAUSE- CAUSE- 3.WRONG RPM
1 2 3

1.WRONG RPM
2.IMPROPER
DEPTH
3.NO PROPER
DEVICE FOR
SUPPORTING
CAUSE- CAUSE- CAUSE- DRILLING VICES
1 2 3

75
STEP - 07
DATA
COLLECTION

SPARTANS 2016
CALENDERS

76
 GRAPH SHOWING
SURVEY RESULT
PROBABLE ROOT CAUSES

100 90.5 1. NO PROPER DEVICE FOR

90
80
70 SUPPORTING DRILLING VICE
AVG. MARKS
OUT OF 100

60
50 2. UNABLE TO DETECT FAULTY
40 37.5
30 20
20 ELEMENTS
10
0
1 2 3 3. LACK OF INTEREST
1 2 3
MAJOR CAUSE NUMBER

* (SURVEY CONDUCTED IN TOOL AND DIE DEPARTMENT)

77
 ROOT CAUSE
IDENTIFIED

NO PROPER DEVICE
FOR SUPPORTING
DRILLING VICE TO
REDUCE IT’S
VIBRATION .

78
ROOT CAUSE
IDENTIFIED

79
STEP - 08
DEVELOPING
SOLUTION

80
 BRAINSTORMING
FOR SOLUTION

ROUND ROBIN METHOD

81
 SOLUTION OF
BRAINSTORMING

1.GET A DEVICE FABRICATED FROM

OUTSIDE.
2.TO MAKE A DEVICE FOR DRILLING
VICE
IN-HOUSE.
3. TO BUY A NEW DEVICE FROM 82
 SELECTION OF SOLUTION
USING EFFECT MATRIX
SOLUTIONS
Sl .No
. CRITERIA 1 2 3

PRACTICABILITY OF THE YES YES YES

1 SOLUTION
2 COST OF THE SOLUTION MORE LESS MORE
3 TIME SAVING YES YES YES
4 SAFETY YES YES YES
5 PRODUCTIVITY YES YES YES
FEASIBILITY OF THE NOT
OK
NOT
1. SOLUTION
GET A DEVICE OK
FABRICATED FROM OUTSIDE. OK
2. MAKE A DEVICE FOR DRILLING VICE IN-HOUSE.
3. BUY A NEW DEVICE FROM OUTSIDE.

83
SELECTED SOLUTION

TO MAKE A DEVICE
FOR DRILLING VICE
FOR REDUCING
IT’S
VIBRATION
IN-HOUSE.
`

84
 WHAT TO DO NOW ?
DESIGN A DEVICE
FOR A DRILLING VICE
TO REDUCE ITS
VIBRATION .

ECONOMICAL
EASY TO TAKE LESS AND NEED
OPERATE AND TIME AND EASY LESS
EFFICIENT TO FASTEN MAINTAINANCE

85
PDCA CYCLE

DR. EDWARD
DEMING’S

86
 PDCA

ACT PLAN
SL. SL. PLAN
MODIFICATION AND ACTIVITY WHO
NO DATE REMARKS
NO DATE
STANDARDISATION
. LAKSHMI
1 DESIGNING OF DEVICE 17-3-16
KANT
1 DOC . NO. : W/SOP/7501 1-4-16 SOP DONE
TAKING APPROVAL OF
2 AAYUSH 19-3-16
FEEDBACK THE DESIGN
CHECK PERFORMANCE
2 5-4-16 BY
(TAKE FEEDBACK) FABRICATING OF THE BIJOY
TRAINEES 3 21-3-16
DEVICE MAHATO
- - - -
4 CHECK PERFORMANCE HONEY 26-3-16
- - - -

SL
CHECK DO
. ACTUAL ACTUA
ACTIVITY WHO SL.
N RESULT NO ACTIVITY WHO L
O DATE
LAKSHM
DESIGN LAKSHMI
1 DESIGNING OF DEVICE I 1 DESIGNING OF DEVICE 18-3-16
READY KANT
KANT

TAKING APPROVAL OF APPROVAL TAKING APPROVAL OF

2 AAYUSH 2 AAYUSH 20-3-16
THE DESIGN TAKEN THE DESIGN

FABRICATING OF THE BIJOY DEVICE FABRICATING OF THE BIJOY

3 3 22-3-16
DEVICE MAHATO FABRICATED DEVICE MAHATO

4 CHECK PERFORMANCE HONEY CHECKED 4 CHECK PERFORMANCE HONEY 27-3-16

87
STEP - 09
FORESEEING
PROBABLE
RESISTANCE

89
GUIDELINES FOR RISK
PRIORITY NUMBER

90
FAILURE MODE EFFECT
ANALYSIS
RPN
VALUE(5*5*5=125)<ACTION

Unable to
Support

6 6 144
Due to MS , EN31
Threads are Material
not proper taken

Support Not Supporting theUnable to 140

drilling Support drilling
drilling
vice Vice properly Vice properly
Due to smooth
surface

91
 BENEFITS OF CLAMPING
DEVICE

• ACCURACY IN HOLE SIZE.

• ELIMINATE THE VIBRATION WHILE DRILLING LARGE
DIA HOLES .
• NO NEED TO HOLD THE VICE WHILE DRILLING.
• REMOVE FEAR FROM TRAINEES MIND WHILE
DRILLING LARGE DIA HOLES.

94
 LIMITATIONS OF OTHER CLAMP
C-CLAMP NUT AND BOLT
CLAMP
• NEED A LARGE
AREA TO SET
• NOT APPLICABLE
IN BENCH
• AVAILABLE IN LIMITED SIZES DRILLING M/C
• TAKES A LOT OF TIME TO TIGHTEN
AND LOOSEN
• MONOTONOUS WORK
• FAILURE IN RESISTING JERK

TOGGLE
CLAMP • USED IN MASS
PRODUCTION
• DIFFICULT TO DRILL
WHEN THE HOLES IS IN
DIFFERENT CO-ORDINATE
• ONCE SET ,THEN
REQUIRES MUCH TIME TO
RESET
95
 COMPARISON WITH OUR DEVICE

MAY BE
APPLICABLE

APPLICABLE

NOT APPLICABLE

SPARTANS

96
 ARROW DIAGRAM

(1)

TOTAL TIME TAKEN

IS =3.0h

98
ARROW DIAGRAM

TOTAL TIME TAKEN

IS =1.75h

100
 ESTIMATED COST OF DEVICE

DESIGNING COST:
NO OF TOTAL
MAN DESIGN/
PEOPL TOTAL DESIGNING
HOUR HRS
E COST
1 2.5h 2.5 Rs.100 Rs.250/-
MATERIAL COST:
S.NO ITEMS MATERIAL WEIGH PRICE/KG MATERIAL
T COST
1. GUIDE MS 2.4Kg Rs50/- Rs240/-
PLATES (2)
2. LEAD SCREW EN31 0.200Kg Rs100/- Rs40/-
(M 16) (2)
3. ARRESTING MS 0.250Kg Rs50/- Rs25/-
PLATE(2)
4. LOCKING STD - Rs5/- Rs20/-
SCREW(4)

Rs325/-
TOTAL
101
 ESTIMATED COST OF DEVICE

FABRICATION COST:
Operation Hours Rate/hour Total
Milling 4.5h Rs.60/- Rs.270/-
Lathe 1.75h Rs.50/- Rs.87/-
Bench work 3.0h Rs.80/- Rs.240/-
TOTAL FABRICATION Rs.517/-
COST

Total Cost = Designing Cost+ Material

Cost+
Fabrication cost
= Rs.250 + Rs.325 + Rs.517
= Rs.1092/-
102
 AFFINITY DIAGRAM

MOR Y TO
TO S
ACC E NO SY E EA NDE
URA
T VIBR EA MBL HA
E ATIO SSE
N A

EAS
L AT IN NEE
D FAST TO
Y
F ST LESS E NE
D JU TE MAI D
A PLA NTA
G ANC IN
E LIGH
S S KNU W T
E E I
LOW
C OS KE L IME H RLED G E G HT
T TA E T EAD AR H
L
TIM PIT
C

103
 AFFINITY DIAGRAM

COST &
DESIGN FUNCTION EASY TO USE
WEIGHT

MORE EASY TO EASY TO LIGHT

ACCURAT FASTENED HANDLE WEIGHT
E
NEED
LESS
KNURLED TAKE LESS MAINTAIN LOW COST
HEAD TIME ANCE

FLAT LARGE NO
ADJUSTIN PITCH EASY TO VIBRATIO
G PLATE ASSEMBLE N

104
STAGES OF FABRICATION

105
STEP - 10
TRIAL
IMPLEMENTATIO
N

106
 TRIAL
IMPLEMENTATION

108
 TRIAL
IMPLEMENTATION
CONSOLIDATED OCCURRENCE CHART AFTER TRIAL
IMPLEMENTATION
PROBLEMS
1 2 3 4 9
PERIODS 0 1 1 0 2
(14/3/16 to 13/4/16) 1 0 1 0 1
0 1 0 0 1
1 1 1 0 1
GRAND TOTAL 2 3 3 0 5
NO. OF OCCURRENCES

5
5

4
3 3
3
2
2

1 0
0
1 2 3 4 9

NO. OF PROBLEMS
109
PERFORMANCE CHECK DURING
TRIAL IMPIMENTATION

1. LOW COST.

2. USER FRIENDLY.

3. SAFE AT WORK.

4. NO VIBRATION.

5. SUPPORTS PROPERLY.

110
 BEFORE AND AFTER
IMPLEMENTATION DATA
OCCURANCE BEFORE
200 IMPLEMENTATION
151
OCCURENCES

150
NO. OF

100
51
50
12 11 06
0
1 2 3 4 9

NO. OF PROBLEMS
OCCURANCE AFTER
IMPLEMENTATION
6
05
5
OCCURENCES

4
03 03
3
NO. OF

02
2
1
0
0
1 2 3 4 9

NO. OF PROBLEMS
111
STEP - 11
REGULAR
IMPLEMENTATIO
N
 TANGIBLE GAINS
SPOILAGE OF WORKPIECE SAVINGS

BEFORE IMPLEMENTATION NET SAVINGS/YEAR =RMC+LC

SPOILAGE OF WORKPIECE
R.M.C. =No. of w/p x Wt. of one w/p x Rate/Kg
= 63pieces/year =61nos x 2Kg x Rs.40.00
=Rs.4,880.00/-
AFTER IMPLEMENTATION
L.C =No. of w/p x utilized time/w/p x hour rate
SPOILAGE OF WORKPIECE =61nos x 120h x Rs.50.00
=Rs.3,66,000/-
= 2 piece /year
NET SAVINGS / YEAR= Rs.4,880 + Rs.3,66,000
TOTAL WORKPIECE SAVED IN A = Rs.3,70,880/-
YEAR=61nos

RMC=RAW MATERIAL
COST
LC=LABOUR COST
116
 TANGIBLE GAINS
TIME FACTOR SAVINGS

BEFORE IMPLEMENTATION
TIME UTILIZED IN COMPLETING
WORK = 4.25h
AFTER IMPLEMENTATION
TIME UTILIZED IN COMPLETING
WORK = 3.25h
TOTAL TIME SAVED PER YEAR
=Before Implementation- After Implementation
=No. of w/p x Time taken – No of w/p x Time taken
= 60 w/p x 4.25h – 60 w/p x 3.25h
So,
TOTAL TIME SAVED PER YEAR = 60h

TOTAL TIME SAVED IN A

YEAR= 60h

117
 INTANGIBLE GAINS
 IMPROVED LEADERSHIP QUALITY.

 ELIMINATED THE STAGE FEAR.

 IMPROVED THE FLUENCY IN SPEACH.

 IMPROVED INDIVIDUAL PERFORMANCE.

119
 TREE DIAGRAM
INTERNAL 1. NO
ECCENTRICITY
2. LESS
DEVICE BREAKAGE OF
FOR DRILL
DRILLING 1. NO VIBRATION
EXTERNAL
VICE FOR 2. PROPER HOLES
REDUCING
ITS
VIBRATIO
N 1. EASY TO USE
PERSONAL
2. NON RISKY
3. FULL
PROOFING

120
 MILESTONE
PROJECT-SUPPORTING
DEVICE FOR DRILLING VICE
TO

- TARGET - ACTUAL
DATE DATE

121
STEP - 12
FOLLOW UP AND
REVIEW

122
 FOLLOW UP ACTION
SECTION CHART DISPLAY PHOTO

ISOMETRIC
VIEW

124
 FEEDBACK BY
TRAINEES
5 1
20% 23%

PLE
M T
4 SA RMA
17 FO
2
% 3 21%
19%

1. It is safe to
operate.
FEEDBACK PERCENTAGE BY OUR 2. It is user friendly.
3. Easy to clean and
TRAINEES maintain
4. Easy functioning
5. Time saving

126
 TOOLS & TECHNIQUES USED FOR
SOLVING THE PROBLEM

SPARTAN 128
TOOLS & TECHNIQUES USED FOR
SOLVING THE PROBLEM

128
 OUR FUTURE PLAN

TO MODIFY OUR DEVICE

MAKING IT MORE USER FRIENDLY
BY REDUCING IT’S WEIGHT
AND
TO MAKE IT
UNIVERSALY APPLICABLE.

130
 TOOLS & TECHNIQUES USED FOR
SOLVING THE PROBLEM
• CATEGORISATION TOOLS &
• P-D-C-A TECHNIQUES
• DATA COLLECTION
• BRAINSTORMING
• GRAPH
VIDEOS
• FLOW CHART
• FISHBONE DIGRAM
PHOTOS
• MILESTONE CHART
• PARETO ANALYSIS
• TRIAL
• PICTORIAL FLOW CHART IMPLEMENTATION
• AFFINITY DIAGRAM • STATUS OF THE
PROBLEM
• ARROW DIAGRAM • ROOT CAUSE • USER MANUAL
• MODEL
• DECISION MATRIX VIDEO
DIAGRAM2
• ANIMATED VIDEO
• TREE DIAGRAM • OTHER CLAMP
S
• EFFECT MATRIX • COMPARISION
• COMPARISION
• FMEA

132
131
THANK YOU
95