Professional Documents
Culture Documents
FOR
NCQC 2020
QUALITY CIRCLE
CASE STUDY
PRESENTATION
1
WELCOME,
ABOUT YOUR ORGANIZATON,
INTRODUCTION OF TEAM,
TEAM FORMATION DETAILS
5 SLIDES – 5 MARKS
2
3
TO
Case study presentation by
T.S.R.T.C
Tyre Retreading Shop
UPPAL, HYDERABAD
RIDE TO DEVELOPMENT
T E O RATIO
N A STA T CORP
ANGA NSP OR
TEL TRA
AD
RO
9
10
Step : 1
1. New tyre wire exposing 1 ½ OF RC (A)
2. Concussion on tyres (A)
3. Repair Tyre (A)
4. High Generation of scrap tubeless tyres (A)
5. Chiping Tyre at bead (½” of size) on tubeless tyre (A)
6. Radial cracks on tyre (A)
7. Bead cracks both sides (A)
8. Tyre tread separation (A)
9. Tyre ply separation (A)
10. Tyre through cut - 2” & Tread separation (A)
11. Tyre patch loose & ply separation (A)
12. Recaping of tyre between (2mm NSD) (A)
16. Chamber wear worm smooth & Plies exposed – no cap (A)
12
Step : 1
1. Run flat/cords loose tube burst (3”size)or tyre (B)
2. Run flat/cords loose tread separation(1/2” ) (B)
3. Run flat/cords loose drawn value base of the tube air leakage (B)
4. New patch loose (B)
5. Spot loose tread (B)
6. Loose tread right round (LTRR) (B)
Step : 1 13
1. Wires exposed due to brake binding (C)
2. Patch loose by injure extension up to ½” (C)
3. Patch loose by injure extension up to 1 ½” (C)
4. Patch loose by injure extension up to 2 ½” (C)
5. Wires exposed during buffing (C)
6. Ply damage after buffing (C)
7. Casing weak during buffing (C)
8. Old patch loose injury extension (C)
9. Ply separation after curing (C)
10. Tread separation after curing (C)
11. Band ply cut after curing development (C)
12. Through cut on tyre shoulder (C)
13. Through cut on tyre wall (C)
14. Bead damage (C)
15. Tread separation near bead (C)
16. Bead chipping and wire exposed (C)
17. Channel cracks and ply exposed due to OI (C)
18. Deep circumferential crack burst (C)
19. Deep cracks near bead (C)
20. Flow cracks near bead (C)
21. Deep cut near bead (C)
22. Ply damage on walls due to deep scoring (C)
14
Step : 1
Using brain storming, based on productivity, quality, safety, cost, delivery and environment 5
important problems selected.
Criteria of selection :
All Q.C members voted and selected the problem.
Marks allotted : 0~5
S TOTA
DESCRIPTION KKR KMC KBR BMD GRC SS L
RANK
NO
Accumulation of scrap tyres occupied more space in the Work Shop. The
place is could not able to utilize for other works.
RECAPING,
RETREADING, VENTING
PATCHING
PROCESSING BUFFING
AND PROCESS
REPAIR
TO improve productivity
RETREADING SHOP
20
21
22
STEP – 4
COLLECTION OF DATA ON
THE PROBLEM SELECTED,
SHOWING DATA IN GRAPHS,
STRATIFICATION OF DATA,
4W & 1H
6 SLIDES – 10 MARKS
23
Step 4 : Analysis of Problem
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25
where is it occurred?
Tyre shoulder and ply structure
When is it occurred?
Non rotation of tyres, Kin Pin Play and Road camber.
TYRE ROTATION
30
31
Step 5 : Identification of Causes
32
STEP - 5 : IDENTIFICATION OF CAUSES 33
(Dispersion Type Cause And Effect Diagram)
EFFECTING
MAN SKILLED REQUIED
MAINTENANCE OTHER JOBS
UNABLE TO REPAIR
DEPOT LEVEL LACK OF MAINTENANCE
IN DEPOT LEVEL
DIFFICULTY TO PROCURE
THE MATERIAL
PRODUCTIVITY REDUCED
NON AVAILABILITY OF
REPAIR & RC WORK
REPAIR MATERIAL
PREPARATION WORK
HIGH COST HIGH BOUNDING
GUM
MORE CONSUMPTION
MORE TIME FOR OF HBG
SPECIALIZED MECHINARY
REPAIR NOT AVAILABLE
METHOD MATERIAL
STEP - 5 : IDENTIFICATION OF CAUSES 34
(Dispersion Type Cause And Effect Diagram)
EFFECTING
MAINTENANCE OTHER JOBS
LACK OF MAINTENANCE
IN DEPOT LEVEL
EFFECTING SECTION
NEGLIGENCY
KING PIN PLY
OF WORK
NON AVAILABILITY OF
REPAIR & RC WORK
REPAIR MATERIAL
HIGH BOUNDING
GUM
MORE CONSUMPTION
OF HBG
MATERIAL
STEP - 5 : IDENTIFICATION OF CAUSES 36
(Dispersion Type Cause And Effect Diagram)
MAN SKILLED REQUIED
UNABLE TO REPAIR
DEPOT LEVEL
LACK OF KNOWLEDGE
EFFECTING JOBS
LIMITATION
OF
FACILITIES
COSTLY
TRAINING
STEP - 5 : IDENTIFICATION OF CAUSES 37
(Dispersion Type Cause And Effect Diagram)
PREPARATION WORK
HIGH COST
METHOD
38
39
Step – 6 : FINDING OUT THE ROOT CAUSES 40
MEN
MATERIAL
LIMITATION OF FACILITY
TECHNOLOGY
CHANGES
METHOD
41
STEP -6 : FINDING OUT THE ROOT CAUSES
(BY PARETO DIAGRAM)
500
480 100
460 96
440 92
420 88
400 84
380 80
360 76
340 72
320 68
300 64
Percentage
280 Useful many 60
Vital few
260 56
Units
24 %
240 52
220 48
200
76%
44
180 40
160 36
140 32
28
120 24
100 20
80 16
60 12
40 8
20 4
0 0
Root causes
A E B D C
Root causes
42
Step : 6
100 %
4
****
3.5 85.43 %
3 Limitation of
LIMITATION OF
FACILITES
facilities
2.5
AMOUNT IN CORES
High CostOF
HIGH COST
RADIAL TYRE
2
Rejected
HIGH COST old
1.5 patches
1 Under Inflation
NOT INFLATING
SPESIFIDE TYRE
0.5 PRESSURE
59
60
10 SLIDES – 10 MARKS
62
63
After repairing of tyres, the camber wear & wire expose tyres has
reduced against Aug’18
Sl Month Nos. of Received tyres Scrap Rate
1 sep’18 3387 12.25%
2 Oct’18 3825 2.69 %
PERCENTAGE
14
12
10
8
6 PERCENTAGE
4
2
0
Sep' 18 Oct' 18
66
5 SLIDES – 5 MARKS
68
69
70
Sl.no Process
1 Tyre camber ware area buffing
5 Final inspection
71
After successful trials, the management has given approval
through Q.C. section to implement from Nov’2018 .
72
BEFORE AFTER
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Customer(Depot’s) satisfied
MILE STONE CHART 75
QUALITY CIRCLE ACTIVITY PLANNING
QUALITY CIRCLE NAME: STAR WHEEL LEADER : K.KARUNAKAR REDDY
DEPARTMENT NO: T.S.R.T.C. DY. LEADER: K.MADHAVA CHARY
MEMBERS : K.BHASKAR
Project: CAMBER WEAR & WIRE TARGET
B.MALYADRI
G.RAMCHANDER
EXPOSE TYRE ACTUAL
S l. Meetings Weeks
1 2 3 4 5 6 7 8 9 10 TARGET
No. & Planning ACTUAL
Tangible benefits:
1. Supply position of REPAIR tyres are improved and they are being given on
counter exchange basics to depots. To reduce the scrap rate 12.65 to 2.69
2. E 05 Vehicles daily going off road for want of REPAIR tyres liminated
INTANGIBLE GAINS
A) CHANGE IN ATTITUDE
- FROM “I DON’T CARE” TO “I DO CARE”
- CONTINUOUS IMPROVEMENT OF QUALITY OF WORK
B) SELF DEVELOPMENT
- BRING OUT ‘HIDDEN POTENTIAL’ OF PEOPLE
- LEARNED ADDITIONAL SKILLS
C) DEVELOPMENT OF TEAM SPIRIT
- “ I COULD NOT DO, BUT WE DID IT”
- ELIMINATE INTER DEPARTMENTAL CONFLICTS
D) IMPROVED ORGANISATIONAL CULTURE
- POSITIVE WORKING ENVIRONMENT
- TOTAL INVOLVEMENT OF PEOPLE AT ALL LEVELS
- HIGHER MOTIVATIONAL LEVELS
78
OUR NEXT
PROJECT
The Dignitaries.
• Achieved Gold award for 29th Chapter Convention on Quality Circle (CCQC 2015) .
• Excellence award in national Convention on Quality circle (NCQC 2015)
Approach to the problem 84
Ide ot C
Ro
Developing es
nti aus
Data
Analysis
Solution
fy es
85
Step : 1
18. Due to (under inflation) circumferential cracks (A)
19. Complaining on mileage irregularity to depot’s (A)
20. Old patch loose (A)
21. Run flat on wall (A)
22. Spot tread separation on shoulder
(A)
23. Ply separation and patch loose (A)
24. Multiple through cuts on crown of tyre (A)
25. Tread chipping on butter of tyre (A)
26. Cracks on shoulder due to UI (A)
27. Ply damage due to under inflation on major repair area (A)
28.Worn smooth/8mm half area on crown of tyre due to heavy
camber ware (A)
86
We are
working
Here
After study of the problem we have observed that the tyres are
Scrapped by camber wear worn smooth & Wire Expose.
m area
Proble