“ Optimise Grinding Process ”

Team Members and Meeting Schedule

Leader & Champion - H.M.Raste
Black Belt - R.M.Dharkar
Green Belt - H.V.Bhatt
Members - A.V.Gupta , R.J.Trivedi , G.K.Patel , H.B.Raval , A.R.Pandey

Phase No. of Meetings % Attendance

Define 9 92
Measure
Analyse
Improve
Control
 Problem Statement
… as defined by TQMC

Improve the processes of grinding and

purchase / storage / issue / usage of all type of
grinding wheels with the aim of reducing
grinding and consumption of grinding wheels.
Categorization of pain area with rating
(Decision making / Procurement / Storage & Issue / Training / Grinding
Operation)
Sr. Process Cost Quality Cycle Total
No. x y time(z) x*y*z
1 Procurement process of 3.80 4.40 6.60 110
grinding wheel
2. Storage process of 1.80 3.40 4.20 26
grinding wheel
3. Issue process of grinding 5.80 2.60 3.40 51
wheel.
4. Use of grinding wheel 8.60 4.00 7.80 268
5. Unnecessary Grinding 8.60 5.20 9.00 402
(NVA)
6. Selection of correct 6.80 5.20 6.00 212
grinding process /
facility.
Prioritization of Pain areas

Priority Process
1. Unnecessary Grinding (NVA)

2. Optimum use of grinding wheel

3. Selection of correct grinding process /

facility.
4. Procurement process of grinding wheel.

5. Issue process of grinding wheel.

6. Storage process of grinding wheel

 CTQ Tree

Unnecessary Length of
grinding(NVA) unnecessary grinding

Optimizing No. of under utilized

Optimum use of
Grinding
grinding wheel grinding wheels
Process

Selection of No. of instances of

correct grinding incorrect grinding
process/facility. process/facility.
 Modified Problem statement

It has been consistently observed in the past

that there has been a regular high
consumption of grinding wheels in our
manufacturing processes. The process of
grinding includes substantial Non Value
Added activities. This results in high cost &
cycle time of production.
 SIPOC
S I P O C

Supplier Inputs Process Output Customer

Vendors / Grinding wheels Procurement of Grinding Stores
Manufacturers with norms & grinding wheels wheels as
guidelines per specs
Stores Grinding wheels Storage & Issue Issued Workmen
as per specs & grinding
Consumable slip wheels
Workmen Grinding Grinding Ground Customer
wheels,grinding operation component (Internal/
machine & Tools External)
Workmen Grinding wheels Consumption of Consumed Stores
grinding wheels wheels /Customer
(Internal/
External)
 Project - Y

• Y1 = Non-value added grinding

• Y2 = No. of underutilised grinding wheels
• Y3 = No. of instances of incorrect grinding
process/facility
Project Charter
 Steps in Measure phase

 ‘AS IS’ process mapping

 Operational definition & measure method
 Measurement system analysis (Gage R&R)
 Data collection on Y1,Y2 & Y3
 Process capability & DPMO calculation
 Estimation of COPQ
 Value Added Grinding Operations

 UT / MT operations (weld seams, Plates etc.)

 Weld edge preparation after Gas Cutting
 Touch up grinding after removing Temporary
attachments, Cleats etc.
 Chipback Grinding (Standard / Confined spaces)
Measure Phase
 “AS IS” PROCESS MAP
Procurement action is
Procurement triggered by Delivered to Main Stores for
-Manual request (PR) Inspection & Clearance.
-FOS items (VMI)

Receipt , Inspection, -Issue to Shop Stores Issue of Grinding

Store and Storage at Main Stores against MR wheels to users
Issue (For FOS items only). -To initiator (IMR) through SAS.

Allocation of Selection of Grinding

Shops Grinding work Grinding machine Operation
and Wheel
 DATA COLLECTION POINTS

1 . Issue process
2 . Return of grinding wheels to shop stores and main stores.
3 . Grinding Operation
•Data on Grinding length
•Material removal rate (MRR) of grinding wheel till it is
fully consumed.
 Measurement Method
1. Y1 = Non-value added grinding operation

Sample collection of Grinding length ( in mm ) and total Non Value

added Grinding Length ( in mm )

Defect per opportunity ( DPO ) = ( D / ( N x O)) where

D = Non Value added Grinding Length ( in mm)
N = Total Grinding Length ( in mm )
O = No. of NVA Grindings.
Yield % = (1 – DPO ) x 100 NVA

Y
 Measurement Method
2 . Y2 = No. of underutilised grinding wheels

Number of grinding wheels Received and No. of grinding wheels not

optimally used (Based on set criteria ) out of the wheels received over a
particular time.

Defect per opportunity ( DPO ) = ( D / (N x O)) where

D = Grinding Wheels not optimally used
N = Total number of used Grinding wheels received
O = No. of factors considered for making
Decision on optimum use of GW.
Yield % = (1 – DPO ) x 100
 OPERATIONAL DEFINITION

1 . Unnecessary Grinding length : The grinding which is

not desired as per definition of value added grinding.
2 . Total length of seams : Length of all the seams in a
section / Job as per drawing.
3 . Optimum condition of grinding wheels : The
wheel used upto the sticker mark pasted on wheel.
 OPERATIONAL DEFINITION
UT : Ultrasonic testing mentioned as per NDT plan .
RT: Radiographic testing mentioned as per NDT plan.
MRR:The amount of material removed by grinding
process/grinding wheel per hour with optimum
utilization of wheel.
 DATA COLLECTION SHEETS

1 . Grinding Length Data Sheet

2 . Grinding Length Data Sheet

 PROCESS CAPABILITY

1. Sigma level for Y1

( Non value added grinding length ) : 1.34

2. Sigma level for Y2

(Underutilized Grinding wheels ) : 1.08
 ESTIMATED COPQ OR SAVING

1. COPQ (Non value added grinding length ) : Rs 1111 per kg

2. COPQ (Underutilized Grinding wheels ) : Rs 34373 per week

 NEXT STEPS FOR ANALYZE

1. Walk through AS IS process map.

2. Identification of probable causes.
3. Prepare fishbone diagram for Y1 & Y2.
4. Pareto of causes for Y1 & Y2
4. Validation of root causes.
5. Root cause analysis
6. Categorization of root causes in controllable,non controllable
and direct improvements.
7. Identify counter measures.
8. Design experiments
Thank You
Some major causes of NVA Grinding
(Defect Opportunities)

Merging of seam for UT/MT because of poor bead finish.

Merging of external/internal due to poor gas cutting.
Merging of external/internal due to extra green-material.
Dry survey / more temporary support used for set up.
Root face merging due to ovality in shell after machining
/ WEP grinding.
Merging due to extra re-enforcement welding .
 Six Sigma Lev el Calculation
(Y1=NVA Grinding Length)

Tota l Grinding Le ngth(in MM ) 1055742

Tota l NVA Grinding Le ngth(in MM) 601382

No. of de fe ct Opportunitie s 6

De fe ct Pe r Opportunity 0.095

Yie ld Pe rce nta ge 90.506

2.84
Sigma Le ve l(Long Te rm )

1.34
Sigma Le ve l ( Short Te rm )
 Six Sigma Level Calculation
(Y2=Underutilized Grinding Wheel)

Total wheels 290

Partially consumed wheels 192

No. of defect Opportunities 1

Defect Per Opportunity 0.662

Yield Percentage 33.793

1.08
Sigma Level(Long Term )
-0.42
Sigma Level ( Short Term )
 Defects
Number of units 290
Number of opportunities per unit
(Min. 1) 1
Number of defects observed 192

Defects per Opportunity (DPO) 0.66207

Defects per Million Opportunities
(DPMO) 662,069

Equivalent Measures of Capability

DPU 0.662068966
DPMO 662,069
Yield 33.79%
Cpk P pk 0.14
Process Sigma 1.082
 Steps for calculation of COPQ Of Y1
(Unnecessary Grinding Length)

1 Total NVA Grinding Length(in mm ) 452382

2 Density of CS material (gm/cu. cm ) 7.86

Are a of cross-se ction of a se a m
(Considering WEP as rectangle of 45 mm
length and 3 mm height and grinding of
3 3mm .) 135

4 Volume of weld deposited (mm^3) 61071570

5 Weight of material grinded ( In KG ) 480

Time taken to remove I kg of material by

grinding ( Time taken till Grinding wheel is
6 optimally used ) in HRS/KG. 2.74

7 Man Hrs required for grinding 1315.3

8 Man-hours rate ( RS ) 385

9 Total Man-hrs cost 506375.78

10 Man-hrs cost per kg( Cost/kg ) 1054.9

Time taken to consume one wheel
11 optimally( time consumed in hrs. / wheel ) 3.57

12 Number of wheels 368.42

13 Cost of 412 wheels( 67 Rs per wheel ) 24684.18

Tota l cost pe r kg
( Include.Man-hrs cost & Grinding Wheel
14 cost) 1106

Total cost per kg 1111

Sr. No. Steps for calculation of Y2
Approx. Wheeks return per week during
1 measure phase (Jan '06) 140
No. of under utilized wheels
2 ( 60 % ) 0.6

Assuming 40 % of area is underutilised

3 of Sl. 2 0.40
Considering Rs 67 per wheel
4 (DC Wheel 180 x 7th ) 67

5 COPQ Y2-1(Per Week ) 2251

Approx. Wheels issued per week
6 based on 3 years data 533
Approx. non-returned wheels per week
7 based on 3 years data( 90 % of Sl. 6 ) 479

COPQ Y2-2(Per Week) 32121

COPQ Y2(Per week ) 34373

SUMMARY OF DATA COLLECTED