XCMM

1
FAULT FIGHTERS
2
WORLDS 3RD LARGEST CONSTRUCTION EQUIPTMENT
MANUFACTURE
OUR COMMITMENT Xuzhou Construction Machinery
Group Co., Ltd. (XCMG) was founded in 1943. Since
then, XCMG has stood at the forefront of the
Chinese construction machinery industry and
developed into one of the domestic industry's
largest, most influential, and most competitive
enterprise groups with the most complete product
varieties and series.XCMG is the 3rd largest
construction machinery company in the world. It
is ranked 65th in the list of China's Top 500
Companies, 44th in the list of China's Top 100
Manufacturing Enterprises, and 2nd in the list of
China's Top 100 Machinery Manufacturers. XCMG is
dedicated to its core value of Taking Great
Responsibilities, Acting With Great Morals, and
Making Great Achievements and its corporate
spirit of being Rigorous, Practical,
Progressive, and Creative in order to keep
moving towards its ultimate goal of becoming a
leading world-class enterprise capable of
creating real value.  XCMG For Your Success!
3
INTRODUCTION TO OUR TEAM
Working Area Bay-2
Team Strength 5 Members
Projects No. 1
Date Of Formation June-2023
Meeting Day Tuesday
Meeting Time 3.30PM -4.30PM
No. Of Meetings -
Attendance -
Our Team
Photos to add
Prabakaran.N Facilitator
Muthukumar SPS Coordinator
Tanmony Dy. Leader
Sakthivel S Leader
Akhilesh Gaurav
Thiyagarajan
4
12 Q.C. STEPS USED BY OUR TEAM

• 1. Identification of work-related problem
• 2. Selection of problem
• 3. Define the Problem (Clearly and simply).
• 4. Analyzing the problem
• 5. Identification of Causes
• 6. Find out the Root Causes
• 7. Data analysis (Validation)
• 8. Developing Solutions
• 9. Foreseeing Probable Resistance
• Trial Implementation
• Regular Implementation.
• 12. Follow - up and Review.

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STEP 1 2
1.IDENTIFICATION OF WORK-RELATED PROBLEM
2.SELECTION OF PROBLEM
S.No. Month June-2023 June-2023 June-2023 June-2023 July-2023 July-2023 July-2023 July-2023 Aug-2023 Aug-2023 Aug-2023 Aug-2023 Sep-2023 Sep-2023 Sep-2023 Sep-2023 Oct-2023 Oct-2023 Oct-2023 Oct-2023
S.No. Activity Week Step 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1 Identification of work related problems                                        
2 Selection of the problem                                        

• Tool used
• Brainstorming Kaizen
• ABC categorization
• Data collection

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MILESTONE CHART
Quality Circle Name Fault Fighters Coordinator Muthukumar SPS Facilitator Prabakaran.N Leader Sakthivel S D.Leader Tanmony Members Gaurav Akhilesh Thiyagarajan
Project Assembly Line Coordinator Muthukumar SPS Facilitator Prabakaran.N Leader Sakthivel S D.Leader Tanmony Members Gaurav Akhilesh Thiyagarajan
Project No 01 Beginning June-2023 Completion Sep-2023 Beginning June-2023 Completion Sep-2023 Members Gaurav Akhilesh Thiyagarajan
Meeting Day Tuesday time -3.30pm-4.30pm No.of Project completed 00 No.of Project completed 00 Members Gaurav Akhilesh Thiyagarajan
MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING MILESTONE CHART - QUALITY CIRCLE ACTIVITY PLANNING
S.No. PDCA Cycle Steps of Problem Solving JUNE-2023 JUNE-2023 JUNE-2023 JUNE-2023 JULY-2023 JULY-2023 JULY-2023 JULY-2023 AUGUST-2023 AUGUST-2023 AUGUST-2023 AUGUST-2023 SEPTEMBER-2023 SEPTEMBER-2023 SEPTEMBER-2023
S.No. PDCA Cycle Steps of Problem Solving W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3
1 PLAN Identification of Work-Related Problems 1
2 PLAN Identification of Work-Related Problems 1
2 PLAN Selection of Problem
3 PLAN Define the Problem
4 DO Analysis the Problem
5 DO Analysis the Problem
5 DO Identification of Causes
6 DO Identification of Causes
6 DO Finding out the Root Causes
7 DO Finding out the Root Causes
7 DO Data Analysis
8 DO Developing Solution
9 CHECK Foreseeing Probable Resistance
10 CHECK Foreseeing Probable Resistance
10 CHECK Trial Implementation Check Performance
11 ACT Regular Implementation
12 ACT Regular Implementation
12 ACT Follow-up Review
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LIST OF PROBLEMS AND CATEGORISATION
QC Project QC Project QC Project QC Project QC Project QC Project QC Project QC Project
SN Issues Category S Q P C Person
1 Engine torque 1030nm - manually 7 m/c per day C 1   1   Umaa
2 140 swing motor mounting bolts torque manually 9 bolts - m/c total 7 m/c per day C 1   1   Umaa
3 Cabin base plate damper change 6nos per m/c - total 7 m/c per day A   1     Umaa
4 Engine hood paint damage issue at incoming B   1   1 Umaa
5 Engine hood beading damage issue in EOL B   1   1 Umaa
6 Engine hood lock issue at EOL B   1     Umaa
7 Door alignment issue B   1     Umaa
8 Diesel filling airlock issue A   1     Umaa
9 HQ assembled dummy bolt broken issue A   1     Umaa
10 All harnesses demasking A     1   Umaa
11 All hyd house demasking A     1   Umaa
12 lower roller torque manually C     1   Umaa
13 Idler sprocket cleaning A     1   Umaa
14 Pump plate lifting by manually A 1   1   Umaa
15 Muffler lifting by  manually A 1   1   Umaa
16 Muffler mounting bracket lifting by manually A 1   1   Umaa
17 Battery lifting by manually A 1   1   Umaa
18 Operator seat lifting by manual A 1   1   Umaa
19 In Paint shop preparation area floor steel plate track are not fixed, some time it's moving. A 1       Somujit
20 Rain water come inside the paint oven on raining time. C 1       Somujit
21 Water cooler not properly working in bay four. A 1       Somujit
22 In bay four front area one old 520 machine occupied more space. The machine is not in working condition. A 1       Somujit
23 SSIPL team not arrangement properly there materials. We need to provide separate arrangement for materials. A 1       Somujit
24 The place where our painter change their dress, the area is not cover. A 1       Somujit
25 In preparation area where using grease house it's not safe, expect of Greece house we need air host attach with wheel craft. A 1       Somujit
26 Huge amount of sending dust come from preparation area inside the paint booth and make paint kitchen dirt. C 1 1     Somujit
27 Gun flushing basin placed in wrong area. A 1       Somujit
28 In preparation area masking time painter are used putty blade for cutting tape properly. It's a very unsafe condition. A 1 1     Somujit
29 Inside the paint both need 2 hand mixture one for Grey and one for yellow. C   1     Somujit
30 We need nylon type cover for cylinder rod masking on painting time. C   1     Somujit
31 Floor paint need for making layout on bay four. A 1       Somujit
32 We need anti fog glass for our painter. They are facing various issue with low quality glass. C 1       Somujit
33 In booth inside on separate pump need for cleaning thinner a drum. C   1 1   Somujit
34 Our painter as well as our quality inspector also face various issue because of low light from evening to night. C 1 1 1   Somujit
35 In paint rework area need LED torch light. C   1     Somujit
36 In Grey paint kitchen have so many expire paint and paint materials. A 1 1     Somujit
37 In our plant maximum person don't no the excavator operating standard signal . That's why all person need training about excavator operating signal. A 1       Somujit
38 In paint booth weight measuring device not working. A   1     Somujit
39 No one using vasline before painting. A 1       Somujit
40 Painting gun shortage. C     1   Somujit
QC Project QC Project QC Project QC Project QC Project QC Project QC Project QC Project
SN Issues Category S Q P C Person
41 In bay four condition not good, here required at least two times deep clean per week. Our cleaning department do clean everyday but, they are not doing its properly. A 1       Vimal
42 We need to make one flexible strainer for paint filtration. C     1   Vimal
43 Gap alignment problem ( H link bucket) B   1     Vimal
44 Seat sliding problem B   1     Vimal
45 Part hitting with fixture while handling and transportation A   1     Vimal
46 Bolt torque mark missing B   1     Vimal
47 Part colour shade variation B   1     Vimal
48 Store handling damage A   1     Vimal
49 Counterweight bolting operator sitting type need to change as sleep bed C 1       Vimal
50 Arm need fixture during h link assembly C 1       Vimal
51 Pin assembly need tools instead of hammering C 1       Vimal
52 Incoming inspection no specific area C   1 1   Vimal
53 Need to focus on every part packaging condition A   1 1   Vimal
54 Boom bottom side scratch mark B   1   1 Amit
55 Bucket cylinder mtg near arm on scratch mark B   1   1 Amit
56 Upper frame bottom side scratch mark B   1   1 Amit
57 Engine door latch paint peel-off B   1   1 Amit
58 Both side top grill paint peel-off B   1   1 Amit
59 Bucket link paint peel-off B   1   1 Amit
60 Battery near upper frame paint peel-off B   1   1 Amit
61 Decal bubble coming A   1   1 Amit
62 Decal area no templates available C   1     Amit
63 Under plate bolt not torque used A   1     Amit
64 Boom arm joint mtg pin gap more as per our standard B   1     Bibek
65 Decal fade out A   1     Bibek
66 C/W to door gap more as per our standard B   1     Bibek
67 Joystick cover fitment gap B   1     Bibek
68 Decal pasting time for marking used pen C     1   Bibek
69 Track rusty B   1     Bibek
70 Swing motor area rust B   1     Bibek
71 Tool box lamp different used A   1     Bibek
72 Seat sliding rear side foul B   1     Bibek
73 Cabin in side lamp not working A   1     Bibek
74 Tool box lamp not working A   1     Bibek
75 Difficult to apply manual torque of "1030Nm" at the engine mounting bolt C 1   1   Reshma
76 Difficult to apply manual torque of "305Nm" at the Swing motor bolt C 1   1   Reshma
77 Rework for cabin base plate damper is not easy to do A   1 1   Reshma
78 Engine hood paint damage due to metal to metal contact with pallet A   1     Reshma
79 Due to heavy weight of door, alignment is difficult A 1   1   Reshma
80 Diesel filling cap opening closing not easy to do A     1   Reshma
81 HQ dummy bolt broken A   1 1   Reshma
82 Time taken process for demasking the harness A     1   Reshma
83 Time taken process for demasking the hoses A     1   Reshma
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LIST OF PROBLEMS AND CATEGORISATION
QC Project QC Project QC Project QC Project QC Project QC Project QC Project QC Project
SN Issues Category S Q P C Person
84 Cabin lifting tackle calibration not updated A 1       Sanju
85 Radiator lifting tackle calibration not updated A 1       Sanju
86 conveyor top nylon sheet damage A 1       Sanju
87 Identification of upper lower coneyor movement is difficult to identity due to same sound A 1       Sanju
88 Upper line UA04 Diesel filling area no FIRE Efire extinguisher present A 1       Sanju
89 Diesel filling machine hoses lying on the floor A 1       Sanju
90 Upper line coneyor emergency switch broken A 1       Sanju
91 Air hose pipe not working at station UA03 A 1       Sanju
92 5'S activity not following proper ways A 1       Sanju
93 Both the side of upper conveyor line ,floor are crack need to be improve C 1       Sanju
94 Gangway map requried for the operator to move on shopfloor A 1       Sanju
95 Our plant has no particular exits entry gate for the shopfloor A 1       Sanju
96 Limited speed are permitted for the forklift operator, moving inside the shopfloor A 1       Sanju
97 Hydra any time comes on line , don't allow the hydra on shopfloor C 1       Sanju
98 Engine tackle , othere line tackle used in Bay 1 bay3 A 1       Sanju
99 Model wise machine parked on at their location C 1       Sanju
100 Shop floor east side road fully jam by the HQ material ,need to moves at particular location C 1       Sanju
101 Shopfloor Bay1 bay 3 storage area visulization not good condition , need to improve the loication A 1       Sanju
102 Bay4 ,PDI To dispatch preparation area need more LED light in night shift C 1 1 1   Sanju
103 Exhaust Fans Issue A 1       Sanju
104 Machine parking issue C   1 1   Akhil
105 Yard arrangement issue C     1   Akhil
106 Store material proper place not provided C     1   Akhil
107 Electric connection in open condition need barication A 1       Akhil
108 Mini excavator are not parked in proper manner as well as Disassembly condition C 1   1   Akhil
109 Material handling defects A 1 1     Akhil
110 Rollout inspection done outside no standard area defined C 1       Akhil
111 Old machine rework separate area not available C     1   Akhil
112 hydraulic oil are waste which is split on surface during washing A 1 1     Akhil
113 lighting need tobe improve C 1 1 1   Akhil
114 Diesel filling nozzle holding stand requried C 1       Prince
115 Two man power required during assembly of door A 1 1     Prince
116 Swing bearing DC tool requried for applying toprque C     1   Prince
117 Boom assembly take place in hinge condition need to be provide alternative method C 1   1   Prince
118 Assembly of o-ring in bucket not easy to do B   1 1   Prince
119 Work device more space requried to store the material as well as assembly A 1       Prince
120 Upper frame placing on conveyor not easy to do A 1       Prince
121 Docking of upper frame with lower frame is not easy to do C 1       Prince
122 Wooden box materal picking is difficult process A 1       Prince
123 Engine hood packing need to be improve in XE215 I-K A 1       Abhishek
124 Bucket packing need to be improve in XE215 I-K A 1       Abhishek
125 Wooden box received in wet condition A 1       Abhishek
126 Wooden box received in damage condition A 1       Abhishek
127 We not having proper kind of material bin A 1       Abhishek
128 Dust bin size need to be reduced (current size is oil barrel tank) A 1       Abhishek
129 We having cutting machine without safety guard A 1       Abhishek
QC Project QC Project QC Project QC Project QC Project QC Project QC Project QC Project
SN Issues Category S Q P C Person
130 Console box came in wet condition A 1       Thiyagarajan
131 LH RH Door Dent Paint Issue B   1     Thiyagarajan
132 Plate are coming in wooden box which is heavy tight condition difficult to pick A 1       Thiyagarajan
133 Cutting tool requried for cutting the rope, plastic cover A 1       Thiyagarajan
134 Dust present on material which placed in shop floor A 1       Thiyagarajan
135 Tool , socket, batterry gun, battery charger are not available in working station A 1       Thiyagarajan
136 wheel are resist the motion due to heavy weight of troley A 1       Thiyagarajan
137 Cabin dent paint issue as well as glass damage . A 1       Thiyagarajan
138 Boom cylinder rod overspray HQ B   1     Tanmoy Akilesh
139 Boom top side metal tube overspray B   1     Tanmoy Akilesh
140 Night time light lux level very less so painting is not good C 1 1 1   Tanmoy Akilesh
141 Lux level low inspection also very difficult C 1 1 1   Tanmoy Akilesh
142 Diesel tank every CBU machine rust Water B   1     Tanmoy Akilesh
143 Upper frame gray area paint damage B   1     Tanmoy Akilesh
144 Arm bottom side paint damage B   1     Tanmoy Akilesh
145 Main pump bolt area rust B   1     Tanmoy Akilesh
146 Rolling shutter damages issue A 1       Tanmoy Akilesh
147 Transfer cart store operator jump from cart during frame shift work A 1       Tanmoy Akilesh
148 Docking issue Operator need to go under the frame to fix the bolt C 1       Tanmoy Akilesh
149 Roof shed damaged condition due to water directly fall on the shopfloor C 1       Tanmoy Akilesh
150 Bay-4 Air hose reel and fitting get damaged frequently A 1       Tanmoy Akilesh
151 Lower frame idler area heavy paint damage B   1     Sakthivel
152 Upper frame Seat slider bend condition B   1     Sakthivel
153 Cabin inside console box damage condition B   1     Sakthivel
154 SKD Cabin glass more damage B   1     Sakthivel
155 Lower frame frame foot rest bend B   1     Sakthivel
156 Lower frame grease fort damage condition B   1     Sakthivel
157 Lower frame LH side bottom side heavy paint damage B   1     Sakthivel
158 SKD boom lamp side bracket bend condition B   1     Sakthivel
159 SKD Boom top side metal bend condition B   1     Sakthivel
160 Torque mark missing issue B   1     Sakthivel
161 Fouling hydraulic hose B   1     Sakthivel
162 Hydraulic tank breather cover part damage B   1     Sakthivel
163 CBU 80C machine dozer fully foul floor A 1       Sakthivel
164 Lower frame edges rust condition B   1     Sakthivel
165 Upper frame number plate scratch B   1     Sakthivel
166 Grease nipple port broken B   1     Sakthivel
167 Track chain loose condition B   1     Sakthivel
168 Boom tube mounting bracket damage B   1     Sakthivel
169 Under cover bolt loose B   1     Sakthivel
170 Door stopper loose condition B   1     Sakthivel
171 Diesel Hydraulic tank paint damage B   1     Sakthivel
172 Tools box logo cover paint damage B   1     Gaurav
173 Under cover plate paint damage B   1     Gaurav
174 Mirror damage condition B   1     Gaurav
175 Water separator tube bend B   1     Gaurav
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CLASSIFICATION OF PROBLEM
A
81
B
Quantity
53
C
41
ABC categorization
A Categories problem solved by Kaizen and
Brainstorming
A - SELF
B - SELF AND OTHER DEPT.
C - BY MANAGEMENT, OTHER DEPT. MONEY
10
THREE MONTHS PROBLEM DATA
SN Issues Qty
1 Paint Damage in Pin area 153
2 Engine hood beading damage issue in EOL 77
3 Door alignment issue 63
4 Upper frame bottom, LH RH side scratch mark 50
5 LH RH Door Dent Paint Issue 42
6 Bolt torque mark missing 39
7 Hydraulic tank breather cover part damage 20
8 Engine hood lock issue at EOL 17
9 Door stopper loose condition 12
10 Torque missing 11
11 Part colour shade variation 11
12 Diesel tank every CBU machine rust Water 9
13 Boom cylinder rod overspray HQ 8
14 Swing motor area rust 8
15 Upper frame gray area paint damage 8
16 Engine hood paint damage issue 6
17 Track rusty 6
18 Upper frame number plate scratch 6
19 Seat sliding problem 5
20 SKD Cabin glass more damage 5
21 Boom top side metal tube overspray 4
22 C/W to door gap more 4
23 Cabin inside console box damage condition 4
24 Fouling Radiator hydraulic hose 4
25 Joystick cover fitment gap 4
26 Lower frame edges rust condition 4
SN Issues Qty
27 SKD boom lamp side bracket bend condition 4
28 Under cover bolt loose 4
29 Bucket cylinder mtg near scratch mark 3
30 Mirror damage condition 3
31 Arm bottom side paint damage 2
32 Assembly of o-ring in bucket not easy to do 2
33 Diesel Hydraulic tank paint damage 2
34 Track chain loose condition 2
35 Water separator tube bend 2
36 Upper frame paint peel-off 1
37 Boom arm joint mtg pin gap more as per our standard 1
38 Boom tube mounting bracket damage 1
39 Both side top grill paint peel-off 1
40 Bucket H- link paint peel-off 1
41 Engine door latch paint peel-off 1
42 Gap alignment problem( h link bucket) 1
43 Grease nipple port broken 1
44 Upper frame frame footrest bend 1
45 Lower frame grease fort damage condition 1
46 Lower frame idler area heavy paint damage 1
47 Lower frame LH side bottom side heavy paint damage 1
48 Main pump bolt area rust 1
49 Seat sliding rear side foul 1
50 SKD Boom top side metal bend condition 1
51 Tools box logo cover paint damage 1
52 Under cover plate paint damage 1
53 Upper frame Seat slider bend condition 1
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SELECTION OF PROBLEMS WITH PARETO
Problem Selected for Team A,BC
Vital few
Useful Many
S.NO Problem selected Team Name
1 Paint Damage in Pin area ( hammer Less Operation) Fault Fighters (Team-A)
2 Engine hood beading damage issue XCMG Rockers (Team-B)
3 Door alignment issue Innovators (Team-C)
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STEP 3 DEFINE THE PROBLEM
13
SELECTION OF PROBLEM
Paint damage Pin Damage is Major contributor
which impact company Quality, Productivity Cost
So, Our Project is
TO ELIMINATE
?????
14
MANUFACTURING PROCESS OF XXX
Engine fitment
H.T D.T fitment
U/F Loading
Swing motor fit
Radiator fitment
Engine sub assy
Evaporator, Joystick, Foot lever fitment
H.T D.T Return hose connection
Battery Air filter fitment
Hood fitments
Pump connection fitment
Radiator cooler line fitment
Water separator, handrail, throttle motor fitment
Diesel filling
AC gas filling
Coolant filling
Seat fitment
Cabin, Hardness, console cover fitment
15
MANUFACTURING PROCESS OF XXX
Track chain Lower frame fitment
Center joint fitment
Lower frame rollers fitment
Swing bearing fitment
Travel motor hose connection
Travel motor Sprocket fitment
Counterweight fitment
Docking U.F L.F fitment
Hydraulic oil filling
Boom cylinder mounting
Pre Door fitment
Bucket cylinder ,H-link Side Link fitment
Arm cylinder Arm Boom connecting fitment
Boom cylinder to boom fitment
All cylinder greasing filling
Tools box cover fitment
Bucket to H-link Arm pin fitment
Hydraulic oil re-filling
16
IMPACT OF PROBLEM

• Impact on RFT (Right first time)

• Increases operator fatigue

• Additional Rework cost

• Internal Customer dissatisfaction

• Impact on product Quality

• Increases pin cost

• Effects company delivery schedule

• Increases Accident chance

17
TEAM OBJECTIVES

• Improve RFT( Right First Time)

• To remove operator fatigue

• Remove Rework cost

• Internal Customer satisfaction

• To improve product Quality

• Decrease pin cost

• Delivery schedule achievement

• Remove Accident chance

18
TEAM GOAL
TO ELIMINATE ALL PINS DAMAGE PINS
PAINT DAMAGE ISSUES IN OUR MACHINES
FROM- 25 TO 0 BY - 30st Sep-2023
19
STEP 4 ANALYZING THE PROBLEM
Team photos on Gemba
20
FREQUENCY OF THE PROBLEM
Source Internal Data Feed back Collected by
Sakthivel S
21
ANALYSIS OF PROBLEM
Consumable Cost
Manpower Cost

• Sanding R/W minutes 9mins/2minutes per m/c
  18Min

• Sanding paper consume 3 piece/per machine

• Masking R/W minutes 15minutes per m/c 15Min

• Masking roll paper consume 0.25/per machine

• Painting R/W minutes 10minutes per m/c 10Min

• Painting consume 0.25litre / per machine

• Total Manpower R/W minutes 43 Minutes

• Sanding paper price Rs.7.5 per piece

• Painters' monthly salary 21000

• Masking roll paper price Rs.287 per piece

• Painters per day salary 21000/26 Rs.808

• Painting 1 Littre price Rs.435

• Painters per hour salary 808/8 Rs.101

• Total consume per machine Rs.203

• Painters per minute salary 101/60 Rs.1.68

• Annual machines plan 2200 Machine

• Manpower R/W cost per machine 431.68
  Rs.72.24

• Total Consumable cost Rs.4,46,600

• Annual machines plan 2200 Machine

• Total manpower R/W cost Rs.1,58,928

• Total manpower R/W cost Rs.1,58,928

• Total Consumable cost Rs.4,46,600

Total cost Rs.605,528
22
STEP 5 IDENTIFYING THE CAUSES
23
IDENTIFYING THE PROBABLE CAUSES
Machine
Method
Man
Vibration of crane belts
Inadequate cycle time
Hammer usage in all stages
Unskilled operators
Low Awareness / Training not given
Improper packaging receiving
Inadequate pin pressuring M/c on Sub station
Wrong Pin Usage
Improper handling of components
SOP Not followed (Pin Pressuring M/c
Adjustable Fixture not available
Absence of mind
Improper anti rust cleaning in bore area
Pin Damage
Pin holes not match
Trolley wheels stack
Pin Environment rust
Pin Bore dimension variation
Trolley pin rest area fully dust
Sub assy storage on open condition formed rust
Pin Material poor quality
Tools
Material
Environment
24
STEP 6 7 FINDING OUT THE ROOT
CAUSE VALIDATION (DATA ANALYSIS)
25
FINDING OUT THE ROOT CAUSES DATA ANALYSIS
S.NO CAUSES METHOD OF VERIFICATION SPECIFICATION ACTUAL VALIDATION EVIDENCE STATUS
1 UNSKILLED OPERATORS Skill Matrix LEVEL(1-4) New operator not update Skill matrix Not Ok
2 LOW AWARENESS / TRAINING NOT GIVEN
3 WRONG PIN USAGE
4 SOP NOT FOLLOWED (PIN PRESSURING M/C
5 ABSENCE OF MIND
6 VIBRATION OF CRANE BELTS
7 INADEQUATE PIN PRESSURING M/C ON SUB STATION
8 ADJUSTABLE FIXTURE NOT AVAILABLE
9 INADEQUATE CYCLE TIME
10 HAMMER USAGE IN ALL STAGES
26
FINDING OUT THE ROOT CAUSES DATA ANALYSIS
S.NO CAUSES METHOD OF VERIFICATION SPECIFICATION ACTUAL VALIDATION EVIDENCE STATUS
11 IMPROPER PACKAGING RECEIVING
12 IMPROPER HANDLING OF COMPONENTS
13 IMPROPER ANTI RUST CLEANING IN BORE AREA
14 PIN HOLES NOT MATCH
15 PIN BORE DIMENSION VARIATION
16 PIN MATERIAL POOR QUALITY
17 PIN ENVIRONMENT RUST
18 SUB ASSY STORAGE ON OPEN CONDITION FORMED RUST
19 TROLLEY WHEELS STACK
20 TROLLEY PIN REST AREA FULLY DUST
27
IDENTIFYING THE PROBABLE CAUSES
Machine
Method
Man
Vibration of crane belts
Absence of mind
Inadequate cycle time
Hammer usage in all stages
Unskilled operators
Low Awareness / Training not given
Improper packaging receiving
Inadequate pin pressuring M/c on Sub station
Wrong Pin Usage
Improper handling of components
SOP Not followed (Pin Pressuring M/c
Adjustable Fixture not available
Absence of mind
Improper anti rust cleaning in bore area
Pin Damage
Pin holes not match
Trolley wheels stack
Pin Environment rust
Pin Bore dimension variation
Trolley pin rest area fully dust
Sub assy storage on open condition formed rust
Pin Material poor quality
Tools
Material
Environment
28
D
IDENTIFYING THE PROBABLE CAUSES
xxxx.
xxxx.
Cause
Cause
Why
Why
OPTION 01
Why
Why
Why
Why
Why
Why
Root Cause
Root Cause
17
29
STEP 8 DEVELOPING SOLUTION
30
PROBABLE SOLUTION
DEVELOPING SOLUTION
CAUSE
Reference
INCREASE THE SIZE OF FOAM MASKING
NO PROPER MASKING
1.)
USE OF SILICON RUBBER MASKING INSTEAD OF FOAM
MASKING AND 100 BUFFING AT THE TIME OF FEEDING
USE HEAVY MALLET HAMMER FOR HAMMERING
USE OF IRON HAMMER
2.)
WELD ROUND PLATE ON IRON HAMMER FOR HAMMERING
INSTALL PRESSING TOOLS FOR INSERTING PIVOT PINS
TO AVOID DENT MARK
DENT MARK ON PIN DUE TO HAMMERING
IMPLEMENT IRON CAPS/MANDREL TO PROTECT PIVOT PIN
FACE
3.)
IMPLEMENT THREAD MANDREL FOR HEAVY PINS
31
COST AND QUALITY COMPARISON BETWEEN FOAM AND
RUBBER SILICON MASKING.
FOAM MASKING
RUBBER SILICON MASKING
Reference
RUBBER SILICON MASKING USED PER MACHINE 25
NOS PER DAY PRODUCTION
110 NOS TOTAL MASKING USED PER DAY
(11025) 2750 NOS COST OF RUBBER SILICON
MASKING 600 per Kg. ONE KILOGRAM OF
MASKING 25 PCS TOTAL COST
OF MASKING PER DAY
(600110) 66000 INR RUBBER SILICON
MASKING CAN BE UTILIZED AGAIN AND AGAIN SO WE DO
NOT HAVE TO PURCHASE IT EVERY MONTH. NOTE
RUBBER SILICON MASKING CAN BE USED TILL LIFETIME
.
FOAM MASKING USED PER MACHINE 25
NOS PER DAY PRODUCTION
110 NOS TOTAL MASKING USED PER DAY
(11025) 2750 NOS COST OF FOAM MASKING
.60 INR TOTAL COST OF
MASKING PER DAY (.6025110)

1650 INR TOTAL COST FOR ONE MONTH (221650)
36300 INR TOTAL COST PER YEAR (1236300)
435600 INR NOTE FOAM MASKING CAN BE
USED ONLY ONCE .