RAIL COACH FACTORY

KAPURTHALA
(PUNJAB)

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UJJALA QUALITY CIRCLE

WELCOMES

ALL THE DELEGATES

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 A PRODUCTION UNIT
OF
INDIAN RAILWAYS

FROM SAND DUNES……... …….TO ROLLING GREENS

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 2021
MAJOR 2019
AC ECONOMY CLASS

MILESTONES
MEMU 3PHASE

2017
TEJUS EXPRESS
RAKE

2016
EXPORT OT
BANGLADESH
2012
AC DOUBLE
DECKER
2006
GARIB RATH

2004
LHB RAJDHANI RAKE

2002
LHB DESIGN RACK

1994
AC3 TIER COACH

1988
PRODUCTION
STARTED
1985
FOUNDATION
STONE
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 PRODUCT RANGE
NEW TYPE COACHES

HUMSAFAR TEJAS

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 PRODUCT RANGE
LHB TYPE COACHES

SHATABDI COACH RAJDHANI COACH

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 PRODUCT RANGE

PAINTLESS COACH RACK LHB AC DOUBLE DECKER COACH

DESIGNED & DEVELOPED BY RCF, KAPURTHALA

रेल डिब्बा कारखाना, कपूरथला (पंजाब)
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 PRODUCT RANGE
COACHES OF SUBURBAN TRAINS

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 QUALITY CIRCLE PROFILE

• CHAIRMAN ::: SHRI ASHESH AGRAWAL

(STEERING COMMITTEE) GM/RCF

• DEPARTMENT HEAD ::: SHRI RAMNIK SINGH SINGH

CWE/SHELL

• COORDINATOR ::: SHRI BELI RAM

DY.CME/BOGIE

• PRODUCT ::: RAILWAY COACHES

• NUMBER OF QC IN RCF ::: 39

• QUALITY CONCEPT ::: INTEGRATED MANAGEMENT

SYSTEM

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 ABOUT OUR QUALITY CIRCLE

 QUALITY CIRCLE NAME ::: UJJALA

 QUALITY CIRCLE NO. ::: 11

 SHOP ::: BOGIE

 SECTION ::: FABRICATION

 DEPARTMENT ::: MECHANICAL

 DATE OF FORMATION ::: 26/09/2006

 INAUGURATED BY ::: SHRI PREM

CHAND

 AVERAGE EXPERIENCE ::: 22 Years

 AVERAGE AGE ::: 46 Years

 DAY OF MEETING ::: WEDNESDAY

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 QUALITY CIRCLE TEAM

ASHWANI KUMAR SATYAPAL PARASHAR SHIV KUMAR

(FACILITATOR) Team Leader

Joginder Singh SUNIL KUMAR BHARATINDER SINGH

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 i
E P-
S T

PROBLEMS IDENTIFIED
TYPE OF
S.NO. PROBLEMS IDENTIFIED
PROBLEM
1 TO PROVIDE SAFETY AT VARIOUS WELDING MANIPULATOR. A
2 NEED OF ALTERNATOR TENSION BRACKET OXY-CUTTING A
3 SIDE FRAME FIAT BOTTOM BENDING IMPROPER A
PROBLEM OF LEFT OVER OFF-CUT OF 8MM CORTEN STEEL SHEET DURING CUTTING OF LVP
4 A
SOLE BAR

PROBLEM OF TIGHTNING OF VENT SCREW IN VENT BOSS FOR CONVENTIONAL BOGIE

5 A
FRAME
6 CONDITION OF WELDING SET IS VERY POOR B
7 SIDE FRAME TOP (ICF) BENDING DEFECTIVE B
8 TWIST IN THE BOGIE FRAME AFTER STAGE III A
9 GRINDING NEEDS IN THE BREAK SUPPORT BEFORE FITMENT B
10 LIFE OF JIG IS OVER. SO NEED RENEWEAL OF JIGS B
11 NEED OF GROUTING OF S.A.W TABLE A
12 LONGITUDINALS OF ROLLED BOGIE NEEDS MACHINING INSTEAD OF OXY CUTTING A
13 GAP FOUND IN BSS BRACKET A
14 IMPROPER CUTTING OF MATERIAL IN HOUSE A
15 POOR QUALITY OF OXY-CUTTER B
16 CONTACT TIP, GAS DIFFUSER POOR QUALITY B
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 PROBLEMS IDENTIFIED
TYPE OF
S.NO. PROBLEMS IDENTIFIED
PROBLEM
17 EXHAUST FANS ARE REQUIRED IN THE SHED B
18 LEAKAGE OF ROOF DURING RAINY SEASON AND WATER FALLING ON THE EQUIPMENTS B
19 MISSING PLUG TOP B
20 LOCATION OF BINS NEAR THE WORK STATION A
21 BREAK HANGER BRACKET ON TRANSOM REQUIRED OXY-CUTTING BEFORE FITMENT. B
WELDING QUALITY OF COMPONENTS RECEIVED FROM AMRITSAR WORKSHOP IS VERY
22 B
POOR
23 ALL COMPONENTS OF BOGIE FRAME SHOULD BE SHOT BLASTED BEFORE USE A
BOGIE FRAME COMPONENTS (TRADE) EFFECTING THE WELDING QUALITY DUE TO THICK
24 B
LAYER OF BLACK PAINT
25 PAINTING QUALITY OF BOGIE FRAME IS VERY POOR A
26 OIL ON THE GUIDES MAY BE CAUSE OF AN ACCIDENT B
BEVELLING QUALITY OF BEVELLING MACHINE IS VERY POOR EFFECTING THE WELDING
27 A
& FITTING QUALITY.
28 BENDING QUALITY OF DMC TRANSOM IS DEFECTIVE. B
29 BMBC BRACKET REQUIRES OXY CUTTING BEFORE FITMENT. B
30 NOSE BRACKET OF DMC BOGIE REQUIRES OXY CUTTING BEFORE FITMENT. A

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 PROBLEMS IDENTIFIED
TYPE OF
S.NO. PROBLEMS IDENTIFIED
PROBLEM
31 SIDE FRAME HEIGHT IS OBSERVED MORE. B
32 POSITION OF SCREW PIECE HOLE IN THE SIDE FRAME SHIFTED A
33 GOOD QUALITY OF ADOPTER IS REQUIRED FOR CO2 GAS CONNECTION B
34 SAFETY CAPS ARE REQUIRED ON DA AND O2 CYLINDERS B
35 SOLENOID VALVE OF THE WELDING SETS ARE NOT WORKING B
36 QUALITY OF HAND GLOVES IS VERY POOR. B
37 PROFILE REQUIRED ON THE RIBS OF DMC SIDE FRAME FOR EASY REOMVAL OF GASES B
38 POOR QUALITY OF WHITE GLASS GOGGLES B
39 WATER FILTERS ARE REQUIRED ON WATER COOLERS B
40 EDGE PREPARATION OF RADIOGRAPHY JOINTS IS VERY POOR A
41 QUALITY OF DA & O2 GAS PIPE IS VERY POOR. B
42 BENDING QUALITY OF TRANSOM TOP FOR 13T & 16T BOGIE FRAME IS DEFECTIVE. A
43 DIMENSION VARIATION OBSERVED IN THE RIBS AT STAGE 2 REQUIRED OXY CUTTING A
44 BURR ON COMPONENTS EFFECTING THE WELDING QUALITY A
45 UNEVEN NOTCHING OF THE RIBS SUPPLIED BY MACHINE SHOP A
46 PRESS BREAK MACHINES REQUIRED IN THE BOGIE SHOP C

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 PROBLEMS IDENTIFIED
TYPE OF
S.NO. PROBLEMS IDENTIFIED
PROBLEM
47 GOOD QUALITY OF BEVELING CUTTERS ARE REQUIRED FOR BEVELLING MACHINE B
48 HIGH TEMPRATURE SCALING ON THE SHEETS EFFECTING THE WELDING QULAITY B
49 WATER COOLED WELDING SETS ARE REQUIRED IN FIAT BOGIE FABRICATION SECTION. B
50 LAYER TO LAYER WINDING REQUIRES ON CO2 WIRE SPOOLS B
51 DIGITIAL MEASURING TAPES ARE REQUIRED FOR BETTER ACCURACY. A
52 GOOD QUALITY TRY SQUARE ARE REQUIRED. A
53 PROBLEM OF DISLOCATION OF COMPONENT IN LHB BOGIE FRAME A
54 ELECTRICAL DISTRIBUTION BOARDS ARE REQUIRED ON PILLARS NEAR WORK STATION B
55 PROBLEM OF IMPROPER MACHINING FOR PIN BRACKET OF LHB BOGIE BOLSTER A
56 POBLEM OF WELDING WIRE SCRAP DUE TO NOT PROPERLY USED A
57 DIGITAL MEASURING TAPE ARE REQUIED FOR BETTER ACCURACY B
58 GOOD QUALITY TRY SQUARE ARE REQUIRED B
59 PROBLEM OF POOR VESIBILITY OF PRESS BREAK MACHINE IN NIGHT SHIFT B
PROBLEM OF REJECTION OF FIAT BOGIE BOLSTER DUE TO LESS THICKNESS OF PIN BKT
60 A
AFTER MACHINING.
PROBLEM OF REQUIRED HEIGHT OF BUFFIER FROM RAIL LEVEL FOR CONVENTIONAL
61 A
COACH
62 PROBLEM OF BOT PROPERLY BENDING OF TOP & BOTTOM WEB OF FIAT BOGIE FRAME A
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 PROBLEMS IDENTIFIED
TOTAL ……..62 NOS.
SOLVED …...10 NOS.

NATURE CATEGORY TOTAL NOS. FOUND

RELATED TO OUR
A 27
DEPARTMENT

ASSISTANCE OF
OTHER B 32
DEPARTMENTS

WITH THE HELP

OF C 03
MANAGEMENT
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 PROBLEMS SOLVED
TYPE OF PROBLEMS SOLVED

CATEGOR
NATURE TOTAL NOS. SOLVED
Y

RELATED TO OUR
A 07
DEPARTMENT

RELATED TO
OTHER B 05
DEPARTMENTS

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 P- Ii
E
ST

SELECTION OF PROBLEM
PARAMETERS FOR RATING

IMPACT ON ENVIRONMENT
WASTAGE OF MATERIAL
PRODUCTIVITY
SAFETY
QUALITY IMPROVEMENT

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 .

WEIGHT INDEX
BY FIVE POINT RATING METHOD
BASED ON THE SELECTION FACTOR WHICH ARE HENCE, EVALUATION BY THE
IDENTIFIED BY THE MEMBERS DURING BRAIN MEMBERS FOR THE SELECTION OF
STORMING, MEMBERS ARE ALLOTED TO CASE STUDY UNDER CATEGORY
FRANCHISE THEIR OPINION BY ALLOTING THE REPRESENTED IN THE BAR CHARTS
MARKS THROUGH SELECTION FORMAT AS

PROBLE TOTA
M NO SK RK SP BS AK L
30
1 4 3 4 5 3 19
20
2 2 3 3 2 2 12
10

Marks
3 3 4 1 3 2 13
0
4 5 5 5 4 4 23 1 2 3 4 5

5 2 5 4 5 2 18 Problem

WEIGHT INDEX 1—5 MEMBERS BAR GRAPH

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 MILESTONE CHART

S.NO. ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12

1 IDENTIFICATION OF PROBLEM

2 SELECTION OF PROBLEM

3 DEFINING THE PROBLEM

4 ANALYZING THE PROBLEM

5 IDENTIFYING THE CAUSES

6 DATA ANALYSIS

7 FINDING OUT ROOT CAUSE

8 DEVELOPING SOLUTION

FORESEEING PROBABLE
9 RESISTANCE

TRIAL IMPLEMENTATION &

10 CHECKING PERFORMANCE

11 REGULAR IMPLEMENTATION

12 FOLLOW UP / REVIEW
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 SELECTION OF THE PROBLEM

PROBLEM OF LEFT OVER OFF-CUT

OF 8MM CORTEN STEEL SHEET
DURING CUTTING OF LVP SOLE
BAR.

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SELECTION OF THE PROBLEM

LEFT OVER OFF-CUT AND WHERE TO USE

THIS OFF-CUT (MAIN PROBLEM)

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 -
T EP
S Iii

DEFINING THE PROBLEM

LEFT OVER OFF-CUT DUE TO LONG

BREAK DOWN OF 800 TON PRESS BREAK
AND ACCUMULATED IN MANUFACTURE
SECTION OF BOGIE SHOP
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 FLOW CHART OF LVP SOLE BAR
SHEET
STRAIGHTENING
BOGIE
MANUFACTURE
SECTION PROFILE CUTTING

SHEET METAL BENDING OF OFF CUT LYING IN

SHOP MANUFACTURE
COMPONENT OFF CUT SEND TO
SCRAP YARD IF SECTION IF
BENDING OF 800 BENDING OF 410
TONS PRESS TONS PRESS
BREAK MACHINE BREAK MACHINE
DURING BREAK
UNDER FRAME READY SOLE BAR DOWN OF 800
SECTION FOR FITMENT TONS PRESS
BREAK MACHINE

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 E P-
ST
IMPACT OF PROBLEM
IV

WORKMAN MANAGEMENT
 MORE TIME TO COMPLETE THE JOB  WASTAGE INCREASED DUE TO
LEFT OVER OFF-CUT
 MENTAL STRESS
 INCREASE IN NON PERFORMING
 BAD IMPRESSION ASSETS.

 RELATION WITH SUPERVISORS NOT  INCREASED COST

GOOD
 UN-NECESSARY OCCUPIED COVERED
 EXTRA WORK LOAD DUE TO LOADING & AREA.
UNLOARDING
 REDUCTION IN PRODUCTIVITY

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LEFT OVER OFF-CUT (8X1250X1500) MM OF
THREE SHEET IN EVERY LVPH COACH

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 IMPACT OF PROBLEM

LEFT OVER OFF-CUT (8X1250X1500) MM UN-

NECESSARY OCCUPIES A LOT OF SPACE.

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 IMPACT OF PROBLEM

HIGH CONSUMPION OF 8MM CORTEN

STEEL

USED 4 MTR. LENGTH OFF-CUT 1.5

MTR

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 TARGETS

जो संगठन अपनी क्षमता को शत-प्रतिशत प्रयोग करता है, वही विश्व

के मानचित्र पर उभरता है, इसलिये

 100% USE OF OFF-CUT

0% LEFT OVER OFF-CUT

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 BRAIN
BRAIN STORMING
STORMING SESSION
SESSION
TO IDENTIFY THE PROBABLE CAUSES OF PROBLEM

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 V
E P-
PROBABLE CAUSES
S T

 BREAK DOWN OF 800 TON PRESS.

 SAME CAPACITY MACHINE IS NOT AVAILABLE

SO 8MM BENDING NOT POSSIBLE NOW.
 RAW MATERIAL PURCHASED IN 5500MM &
6300MM LENGTH (Standard).
 NO OTHER SMALL COMPONENT OF CORTEN
STEEL 8mm LOADED/REQUIRED IN BOGIE MFG.
 LACK OF APPRECIATION OF THE
ACCUMULATED MAGNITUDE OF PROBLEM.

 LARGE QUANTITY UNUSUABLE OFF-CUTS

ACCUMULATED BUT NO COUNSELLING
REGARDING SAME.
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 .

FISH BONE DIAGRAM

PROBABLE CAUSES
METHOD MEN
LACK OF AWARENESS
LIKE SMALL COMPONENT.
NO COUNSELING

COMPONENT OF CORTEN STEEL

8MM NOT LOADED IN BOGIE MFG.
PROBLEM OF
DISLOCATION OF
COMPONENT IN
LHB BOGIE
FRAME
NOT AVAILABLE
OTHER ALTERNATE

RAW MATERIAL PROVIDED

BREAK DOWN OF IN 5500MM & 6300 MM
800 TON PRESS. LENGTH.

RAW MATERIAL NOT

PROVIDED IN 4000MM

MACHINE MATERIAL
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 DATA COLLECTION
DATA COLLECTION FOR BREAK DOWN OF 800 TONS PRESS
BREAK MACHINE
S. MONTH LVD PRESS BREAK LVD PRESS BREAK
NO & MACHINE 800 TON -I MACHINE 800 TON -II
YEAR
1 JAN.,21 624
2 FEB.,21 576
3 MAR.,21 600
4 APR.,21 576
5 MAY.,21 600
6 JUNE.,21 REDUCED CAPCITY UPTO 6MM 600
THINKNESS SHEET FOR
7 JULY,21 BENDING 600
8 AUG.,21 576
9 SEPT.,21 624
10 OCT.,21 600
11 NOV.,21 504
12 DEC.,21 469

BREAK DOWN DATA MENTIONED IN PCDO 33

 DATA COLLECTION
DATA COLLECTION FOR MANUFACTURED LVPH COACHES
S. MONTH & LVPH GENRATION OFF- CUT
NO YEAR MANUFACTURED
1 JAN.,21 17 51
2 FEB.,21 34 102
3 MAR.,21 62 186
4 APR.,21 4 12
5 MAY.,21 3 09
6 JUNE.,21 33 99
7 JULY,21 38 114
8 AUG.,21 44 132
9 SEPT.,21 42 126
10 OCT.,21 41 123
11 NOV.,21 37 111
12 DEC.,21 45 135
TOTAL 400 1200
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 -
EP
VALIDATION OF CAUSES
T
S VI

S.NO PROBABLE CAUSES ANALYSIS

MATERIAL
1 RAW MATERIAL PROVIDED IN VALID REASON,
5500MM & 6300MM LENTH.
MACHINE
1 BREAK DOWN OF 800 TON PRESS VALID REASON
BREAK MACHINE

METHOD
1 CONPONENT OF CORTEN STEEL INVALID REASON,
8MM NOT LOADED IN BOGIE

MEN
1 LACK OF AWARENESS INVALID REASON
2 NO COUNSELLING OF WORKER VALID REASON.

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 5 W ANLYSIS
RAW MATERIAL PROVIDED IN 5500MM & 6300 MM LENGTH.

WHY
RAW MATERIAL NOT PURCHASE IN 4000MM LENGTH

HOW
NOT READY FOR BREAK DOWN OF MACHINE

WHAT
RAW MATERIAL PURCHASED IN 4000MM LENGTH FOR 8MM
THICK SOLE BAR

WHAT
RAW MATERIAL USED IN 4000MM & 5500MM LENGTH

WHEN
BOGIE MANUFACTURE SECTION

36
 5 W ANALYSIS
BREAK DOWN OF 800 TON PRESS BREAK MACHINE.

WHY
MAY BE NOT FOLLOWED OF MAINTIANCE SEHEDULE

HOW
PLANT DEPARMENT

WHAT
FOLLOWED OF MAINTIANCE SEHEDULE STRICKLY

WHERE
PRESS BREAK SECTION IN SHEET METAL SHOP
.

37
 PARETO ANALYSIS
SAME REASONS LISTED IN CAUSES REPRESENTED IN PARETO
DIAGRAM UNDER “VITAL
“ FEW TRIVAL MANY” CONCEPT
BASED ON THE DATA COLLECTION FROM FOUR MAIN CAUSES, WE
HAD THE DISCUSSION WITH THE CONCERNED DEPARTMENT AND
FOUND THE PERCENTAGE INVOLVEMENT ON EACH CASE.

100

90
80
70
60
MACHINE 45%
50
40 MATERIAL 40%
30
METHOD 10%
20
10 MEN 5%
0
MACHINE MATERIAL MATHOD MEN
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 -
T EP I
S II
V
DEVELOPMENT OF SOLUTION
PURCHASE 0F CORTEN STEEL OF LENGTH 4000 mm WHILE
MACHINE BREAK DOWN.

DURING BREAK DOWN OF MACHINE, IF WE HAVE BEEN

PROVIDED CORTEN SHEET OF 4.1m AND 5.5m IN THE RATIO
OF 6:1, TWO COACHES CAN BE PREPARED WITH MINIMUM
OFF CUT.

39
 DEVELOPMENT OF SOLUTION
SOLE BAR CUTTING AND BENDING AS PER UNDER FOLLOWED

NOT ACCEPTED DUE TO STRENGTH

40
 DEVELOPMENT OF SOLUTION
SOLE BAR CUTTING AND BENDING AS PER UNDER FOLLOWED

41
 DEVELOPMENT OF SOLUTION
SUGGESTION FOR NON LEFT OVER OFF-CUT

DURING BREAK DOWN OF 800 TON PRESS (8M BED MACHINE),

THE ABOVE GIVEN 2 CUTS SHOULD BE PROVIDED ON THE
SOLE BAR PLATE. THIS PLATE CAN NOW BE BENT ON ANY
LOW CAPACITY MACHINE (PROBABLY ON 4M BED CAPACITY
MACHINE) WHICH WILL RESULT IN LESS LEFT OVER OFF-
CUT. THESE CUT LENGTHS SHOULD BE DECIDED BY DESIGN
DEPARTMENT AFTER ANALYSIS.

42
DEVELOPMENT OF SOLUTION
OFF-CUT USED OF OTHER SHOP

SHEET METAL INCHARGE COUNSELLING

FOR USED THE OFF CUT & AGGRE

FOR USED THE OFF CUT

FOR SLRD COACHES COMPONENTS

43
 DEVELOPING SOLUTIONS
 OFF-CUT CAN BE USED IN OTHER SHOP E.G SHEET METAL SHOP.

 MATERIAL OF 4100MM &5500MM LENGTH (IN RATIO OF 6:1) SHOULD BE

PURCHASED INSTEAD OF 5500MM & 6300MM FOR USE.

 OUR SOLUTION HAS HUGE COST/MATERIAL SAVING BENEFITS FOR RCF.

 MATERIAL 8 MATERS PROVIDE BECAUSE PROFILE CUTTING MACHINE

BED 10 MATERS AND SHOP THE OFF-CUT GERNATION,

 OFF CUT CAN BE SALE OTHER RAILWAY UNIT E.G DIVISION WORKSHOP.

 PRECURE THE 800 TON PRESS BREAK.

 MAINTENANCE SEHEDULE STRICKLY FOLLOWED BY PLANT

DEPARTMENT,

 COUNSELLING OF STAFF REGARDING PROBLEMS, SOLUTIONS AND

MUTUAL COORDINATION.

44
 DEVELOPING SOLUTIONS

EXISTING PROPOSED
 THE OFF-CUT NOT USED  OFF-CUT USED IN SHEET METAL
SHOP OF CNC PLASMA PROFILE
CUTTING MACHINE (PARI).

 ONLY TWO MACHINE IS  ONE MACHINE OF 800 TON

AVAILABLE OF 800 TON PRESS PRESS BREAK IN SHEET METAL
BREAK IN SHEET METAL SHOP. SHOP REQUIRED FOR EXPADITED
INSTALLATION

 NOT ALTERNATE OF 800 TON  ALTERNATE SUGGESTION IS

DURING BREAK DOWN UNDER INVESTIGATION BY
DESIGN DEPTT.

 NO COUNSELLING OF STAFF.  STAFF IS COUNSELLED

REGARDING THIS.

45
 -
T EP
S IX

FORESEEING PROBABLE RESISTANCE

 DESGIN MAY NOT AGREE WITH OUR NEW SUGGESTION.
 OTHER SHOPS MAY NOT AGREE FOR USE OF OFF-CUT.
 SOME EXTRA ACTIVITY/STEPS MAY BE REQUIRED DURING
THE BENDING.
 HIGHLY SKILL OPERATOR FOR SPECIALY PRESS BREAK
MIGHT BE DEMONDED.
 BETTER MUTUAL COORDINATION OF OTHER SHOP E.G.
SHEET METAL SHOP & UNDER FRAME SECTION (FSAS).
 DELAY FOR PERMISSION OF ADMINISTRATION.
 SHOP INCHARGE MAY NOT AGREE DUE TO FEAR
INDUSTRIAL ISSUE.

AS ON DATE 20.01.2022, MEETING OF UJJALA TEAM WITH

RESPECTABLE CQM, DY CQM-I,III,IV AND THE ABOVE POINTS
WERE HIGHLIGHTED

46
 DEMING WHEEL

PLAN

ACT

DO
CHECK

47
 DEMING WHEEL

PLAN…...... PLANNED TO CONDUCT THIS EXERCISE

ON DATED 27TH JAN, 2022.

DO…………. WORK TO BE STARTED

TRAINING OF WORKERS.
AFTER

CHECK…… TRIAL IN SHEET METAL SHOP

OF OFF-CUT.
FOR USE

ACTION….. REGULAR IMPLEMENTATION IN SHEET

METAL SHOP.

48
 X
E P-
TRIAL IMPLEMENTATION
S T

 COUNSELLING OF SSE/PROFILE CUTTING (SHEET METAL SHOP ON

DT.27.01.2021)
 SEND THE OFF-CUT SHEET (12Nos.) AFTER COUNSELLING FOR TRIAL

49
IMPLEMENTATION & PERFORMANCE
TRIAL IS SUCCESSFUL: OFF-CUT PIECES ARE USED
TO MAKE COMPONENTS FOR OTHER SHOPS

AS ON DATE 03.02.2021, 20 MORE PIECES OF

OFF-CUT HAS BEEN SENT TO SHEET METAL
SHOP FOR USE. 50
IMPLEMENTATION & PERFORMANCE

BEFORE AFTER
 NOT USED OFF-CUT, SO • OFF- CUT USED IN SMS. SO
ACCMULATED IN SHOP. N.P.A REDUCED.

• STAFF AWARE FOR PROCESS

 LACK OF AWARENESS FOR THROUGH COUNSELLING.
PROCESS AMONG STAFF.

 MATERIAL CUTTING NOT

• MATERIAL CUTTING AND
ALTERNATER METHOD. BENDING NEW PROPOSED
METHOD. SO OFF CUT
GERNATION STOP.

51
 -
T EP
S XJ
REGULAR IMPLEMENTATION

 OFF CUT USED FOR SHEET METAL SHOP.

 NEW PROPOSED METHOD CUTTING & METHOD

THE MATERIAL

 ORDER THE 800 TON NEW MACHINED

INSTALATION

52
 COMPARISON

BEFORE AFTER

A LOT OF OFF CUT NO OFF CUT

OFF CUT MATERAIL ACCUMULATE OFF CUT USED IN SHEET METAL

IN SHOP SHOP

MATERIAL CUT NOT AS PER PROFILE CUTTING AS PER MACHINE

AVAILABLE MACHINE

NO COUNSELLING REGARDING THIS COUNSELLING CAN BE DONE

REGARDING THIS.
UNNECESSARY OCCUPIED SPACE. NOW SPACE CAN BE USED FOR
OTHER PURPOSE.

53
 -
T EP
S XII
FOLLOW UP & REVIEW

 REGULAR UTILISELISATION OF OFF-CUT OF

8MM CORTEN STEEL IN SHEET METAL SHOP .
 MAKING OF SMALL COMPONENTS OF OFF
CUT.
 SPACE OCCUPIED WILL BE CLEARED.
 FURTHER NO OFF CUT GENERATION.
 5 S IS PROPERLY FOLLOWED.
54
 MILE STONE CHART

S.NO. ACTIVITY 1 2 3 4 5 6 7 8 9 10 11 12

1 IDENTIFICATION OF PROBLEM

2 SELECTION OF PROBLEM

3 DEFINING THE PROBLEM

4 ANALYSING THE PROBLEM

5 IDENTIFYING THE CAUSES

6 DATA ANALYSIS

7 FINDING ROOT CAUSES

8 DEVELOPING SOLUTION

9 FORESEEING PROBABLE RESISTANCE

10 TRIAL IMPLEMENTATION & CHECKING

PERFORMANCE

11 REGULAR IMPLEMENTATION

12 FOLLOW UP / REVIEW

55
 CONCLUSION

 UTILISATION OF OFF-CUT FOR 8MM CORTEN STEEL

 IMPROVEMENT IN WORKING CULTURE.
 INCREASE IN PRODUCTIVITY.

हमारा प्रयास छोटा सा , लेकिन परिणाम बड़ा सा।

56
 OUR SOCIETY GAIN
 MATERIAL IS CONSERVED LIKE CORTEN STEEL SHEET.
 THE EMMISSION OF GREENHOUSE GASES DURING
PRODUCTION OF RAW MATERIAL IS REDUCED .
 DUE TO REDUCTION IN GREENHOUSE GASES OUR
ENVIRONMENT BECOMES HEALTHY.

स्वच्छ भारत, स्वस्थ भारत

बनेगा पर्यावरण के प्रति जागरुकता से।

57
 TANGIBLE GAIN
 OFF CUT CORTEN SHEET WEIGHT
(8X1250X1500MM) ::: 117.75KGS

 PRICE OF CONTEN STEEL @ ` 60 per kg. ::: 117.75x60= `.7065/-

 TOTAL COST OF LEFT OVER OFF-CUT IN YEAR 2020 (1200 NOS SHEET) :::
1200X7065= ` 84,78,000/-

TOTAL SAVINGS PER YEAR WILL BE

` 84,78,000/-
हमारी ईमानदारी ही हमारी पहचान हैं।

58
 INTANGIBLE GAIN
 IMPROVED PRODUCTIVITY.
 GOOD WORKING ENVIRONMENT
DEVELOPED.
 REDUCTION OF PHYSICAL EXERTION.
 CUSTOMER SATISFACTION.
 WORK SATISFACTION.
 SELF SATISFACTION.
 INSPIRATION FOR OTHERS.
 APPRECIATION FROM MANAGEMENT.

हमारा परिश्रम, निरन्त्रण सुधार से उपभोक्ता की सन्तुष्टी।

अतः हमारा आत्मविश्वास ही हमें प्रगति के पथ पर अग्रसर करता है।
59
 APPRECIATION LETTER

RAIL COACH FACTORY, KAPURTHALA

CERTIFICATE OF MERIT
HEARTIEST CONGRATULATIONS TO ALL THE MEMBERS OF UJJALA QUALITY CIRCLE OF
BOGIE SHOP FOR DOING EXCELLENT WORK IN SOLVING THE PROBLEM OF ‘UTILISED OF
OFF-CUT OF 8MM CORTEN STEEL’. IT HAS CONSIDERABLY IMPROVED PRODUCTIVITY,
ELIMINATED THE HARASSMENT AND SCRAP.

I WISH THEM SUCCESS IN THEIR FUTURE PLANS.

CHIEF WORKSHOP ENGINEER

DATED : 19.10.2022
MEMBERS OF UJJALA QUALITY CIRCLE :-

SHRI ASHWANI KUMAR, FACILITATOR

SHRI SHUBHAM AGGRAWAL, DY. FACILITATOR
SHRI RAMAN KUMAR, TEAM LEADER
SHRI SATYA PAL PARASHAR, MEMBER
SHRI SUNIL KUMAR, MEMBER
SHRI BHARTINDER SINGH, MEMBER

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 SHRI BELI RAM, DY.CME/BOGIE

 SHRI ROHIT BANSAL, WM/BOGIE

 SHRI RAMESH DRUV, SSE/PROFILE/SMS

 STAFF OF ALL SECTIONS OF BOGIE SHOP

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 ANY QUESTIONS PLEASE?

ASHWANI KUMAR RAMAN KUMAR

SHIV KUMAR
(FACILITATOR) TEAM LEADER

SATYAPAL PARASHAR SUNIL KUMAR BHARATINDER SINGH

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