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SHRIRAM FOUNDRY LTD ; KOLHAPUR.

SHRIRAM FOUNDRY LTD ; KOLHAPUR. PRESENTING ZERO DEFECT DAY ACHIVEMENT. DECLARATION OF ZERO DEFECT DAY BY MANAGEMENT. 02 JANUARY 2013. AIM : ACHIVE EXCELLENCE BY WORKING WITH ZERO DEFECT. * GROWTH OF COMPANY & INDIVIDUALS BY CULTURE & SYSTEM DEVELOPMENT.

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SHRIRAM FOUNDRY LTD ; KOLHAPUR.

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  1. SHRIRAM FOUNDRY LTD ; KOLHAPUR. PRESENTING ZERO DEFECT DAY ACHIVEMENT.

  2. DECLARATION OF ZERO DEFECT DAY BY MANAGEMENT. 02 JANUARY 2013 . • AIM : • ACHIVE EXCELLENCE BY WORKING WITH ZERO DEFECT. * GROWTH OF COMPANY & INDIVIDUALS BY CULTURE & SYSTEM DEVELOPMENT. * DEVELOP A CULTURE WHICH WILL BUILT THE PEOPLE. * TO START THE ACTIVITY WHICH WILL WRITE WITH GOLDEN LETTERS IN HISTORY OF ZANVAR GROUP

  3. ACCEPT THE CHALLENGE & COMMITMENT BY ZDT. • FIRST MEETING OF ZDT DATED - • EXPLAINED PURPOSE OF ZDD TO MIDDLE MGT,LOWER MIDDLE MGT.DEPT HEADS ,INCHARGE & SUPERVISORS. • PREPARATION OF ZERO DEFECT TEAM • CO –ORDINATOR – MR.CHILKA S . V. –DIREC.TECH. • FASCILITATOR - MR.JADHAV B K,MR.SAWANT D K ,MR.GARE S D. • LEADING ACTIVITY : • PRODUCTION ; MR.GAVAD V M –RESP : ALL PRD.ACTIVITIES CORE,MOULDING. • QUALITY : MS.I J SHINDE .RESP :REJ.DATA ANALYSIS ACTION PLAN ,COMMUNICATION,QUALITY ASSURENCE METALLURGY,SAND , INSPECTION ,REPORTING & ZDD PRESENTATION. • MAINTAINENCE : MR.KULKARNI S S .; RESP : ALL MAINTAINCE ACTIVITIES ,PREVENTIVE MAINTAINANCE.

  4. ACCEPT THE CHALLENGE & COMMITMENT BY ZDT. • MATERIALS : MR.GHATAGE R B, RESP : PROVISION OF OK.MATERIAL ,ON TIME.. • TOOLING : MR.AMAR MALVI ,MR.UMESH KADAM,MR.CHOWGULE M.A : ALL TOOLING RELATED ACTIVITY. • FETTLING & DISPATCH. :MR.S A PATIL ; ALL ACTIVITY AT FETTLING SHOP UPTO DISPATCH TO CUSTOMER. • PERSONEL : MR.LOKARE DS.MR.UTHALE. : MAN POWER PROVISION,ABSENTISM, 5 S,SAFTY . • CULTURE BUILDING : CBT & SETU SAMITI : WORKERS MOTIVATION • EXCISE & ACCOUNTING : MR. BIRAJE ,MR.VINAIK RESP ; : STOCK,PRD.QTY,ACCOUNTING • TEAM MEMBERS FOR EXECUTION OF WORK. 1.MR.SOLANKURE A A ,MR.VATHARKAR , MR.NITIN PATIL, MR.PAWAR S V .

  5. SHRIRAM FOUNDRY LTD, KOLHAPUR MONTHWISE TOTAL (REGULAR+ WABCO FAMILY ) REJECTION % GRAPH TARGET- REGULAR ITEM – 6 % MAX TOTAL(REGULAR + WABCO FAMILY)- 8 % MAX

  6. ROOT CAUSE ANALYSIS BY FISH BONE. MACHINE\TOOLING. MAN PRODUCTION,INSPECTION MACHINES NOT OK. LACK OF AWARENESS FOR REJECTION. MACHINES NOT CALIBRATED. NEGLIGENE AT WORK PLACE. UNDER PERFORMED MACHINES. INTER DEPARTMENTAL DISPUTES. PATTERN ,CORE BOX NOT OK MOULDING BOX , PALLETS,LADDLES NOT OK. UNSKILED PERSONS. FOUNDRY REJECTION. LACK OF AWARENESS FOR PRD.& INSPECTION PROCESSESS. FAULTY MATERIAL WINTER SEASON.. DAMAGED CORES. FAULTY SLEEVES,CHILLS,CHAPLT PROCESS NOT OK. HUMID CONDITION. RAINY SEASON SYSTEM NOT OK. RUSTY MATERIAL. LACK OF ENTHUSIASTIC \ENCOURAGEING ENVIRONMENT. METHOD. MATERIAL ENVIRONMENT

  7. ROOT CAUSE FIND OUT FOR FOUNDRY REJECTION. MACHINE\TOOLING. MAN PRODUCTION,INSPECTION MACHINES NOT OK. LACK OF AWARENESS FOR REJECTION. NEGLIGENE AT WORK PLACE. NEGLIGENE AT WORK PLACE. UNDER PERFORMED MACHINES. INTER DEPARTMENTAL COMMUNICATION GAP. PATTERN ,CORE BOX NOT OK MOULDING BOX , PALLETS,LADDLES NOT OK. FOUNDRY REJECTION. LACK OF AWARENESS FOR PRD.& INSPECTION PROCESSESS. DAMAGED CORES. WINTER SEASON.,RAINY SEASON.. SYSTEM NOT OK. FAULTY SLEEVES,CHILLS,CHAPLT ABSENCE OF ENTHUSIASTIC \ ENCOURAGEING ENVIRONMENT METHOD. MATERIAL ENVIRONMENT 7

  8. ACTIONS TAKEN ON ROOT CAUSES. • MAN : • LACK OF AWARENESS FOR REJECTION: AWARENESS TO ALL WORKERS,SUPERVISORS GIVEN BY CONDUCTING MEETINGS, INDIVIDUAL ITEM WISE QUALITY IMPORTANCE ,REJECTION,& THEIRE ACTIONS EXPLINTED TO ALL CONCERN INDIVDUALS. • NEGLIGENE AT WORK PLACE & INTER DEPARTMENTAL COMMUNICATION GAP.. • INDIVIDUAL DEPARTMENTS PROBLEM DISCUSED DURING DAILY MEETING TO OVERCOME INTERDEPARTMENTAL COMMUNICATION GAPS & MUTUALY SOLVED WITH IMMEDIETE GUIDENCE FROM HIGHER AUTHORITIES.AWARENESS GIVEN TO ALL SUPERVISORS, WORKERS FOR THEIR ROLE,RESPONSIBILITIES & IMPORTANCE OF WORK AT FIRST TIME &TO DO DEFECT FREE WORK TO ACHIVE ZERO .

  9. ACTIONS TAKEN ON ROOT CAUSES. • MACHINE : PRODUCTION ,INSPECTION MACHINES \ INSTRUMENTS NOT OK. : MOULDING MACHINE MM 3 -SQUIZE PLATE DAMAGED REPLACED WITH NEW ONE. POURING LINE MONORAIL TRACK MECHANICAL PROBLEM - IMMEDIETLY SOLVED . UNDER PERFORMED MACHINES : SAND MIXER CAPACITY CONSTRAINT , RELATED TO SAND SHORTAGE & FREQUENT BREAKDOWNS AFFECTING QUALITY OF SAND ,NEW MIXER WITH HIGHER CAPACITY INSTALLATION DONE WITH TRIALS. PATTERN ,CORE BOX NOT OK : PATTERN & CORE BOX INSPECTION DONE & ALL THE NECESSARY RECTIFICATION AFTER ANALYSIS OF REJECTION DONE IMMEDIETLY.FA SUPPORT,WABCO 176,PULLY 190,F E SUPPORT,ROCKSHAFT CYLINDER. MOULDING BOX ,MATCHPLATE , PALLETS,LADDLES NOT OK. : MOULDING BOX PIN BUSH ,CLAMPS 100 % CHECKED & REPLACED WITH NEW ONE , HOLES PROVIDED TO MOULDING BOX WALLS FOR PROPER ESCAPE OF GAS. UNWANTED MOULDING BOX REMOVED FROM TRACKLINE WHICH IS SUFFERING FOR POURING.MATCHPLATES CHEKED FOR WEAR OUT & PIN BUSH & RECTIFIED.REPAIRED PALLETS OF 20 X 20 LINE(INPROCES ) .LADDLE CONDITIONS CHECKED FOR OK.

  10. ACTIONS TAKEN ON ROOT CAUSES. • MATERIAL: • FAULTY SLEEVES,CHILLS,CHAPLT FAULTY,DAMAGE,VARIABLE DIAMETER SLLEVES : CALLED TO SUPPLIER( ALTEC) FOR QUALITY PROBLEM & EXPLAINED IMPORTANCE OF OK.SLEEVES .FOR 100 % OK DIMENTIONS TEMPLETS PROVIDED FOR INSPECTION OF SLEEVE TO STORE. CHILLS EXPIRED LIFE : ALL EXPIRED CHILS REJECTED & NEW CHILL POURED WITH IDENTIFICATION . CHAPLETS : 100 % CHAPLETES ARE HEATED BEFORE PRODUCTION. • DAMAGE,FAULTY CORES. CORE BOX 100 % INSPECTED & RECTIFIED.SHOOTING PLATES ,GAS VENTS , MATCHPLATES CHECED & RECTIFIED. INSTRUCTION & AWARENESS GIVEN TO ALL WORKERS SUPERVISORS FOR OK.CORE QUALITY & ITS IMPORTANCE.HANDLING PROCESS IMPROVED BY PROVIDING TABLES ,ROLLERS AT LOCATION TO AVOID DAMAGE.INSTRUCTIONS GIVEN FOR PAINTING , BAKING & 100 % INSPECTION.DAMAGE CORE TO BE REJECTED. FOR COLD,PIN HOLE,GAS PROBLEMS DUE TO RAINY SEASON & COLD CLIMATE CORES ,CHILLS ,SLEEVES ,CHAPLETES REQUIRED TO HEAT IN HOT ROOM BEFORE PRODUCTION,AWARENESS FOR THE SAME GIVEN FOR MOULDING & CORE SHOP PEOPLES ,TEMPERATURE INDICATORS INSTALLED AT CORE SHOP HOT ROOM.

  11. ACTIONS TAKEN ON ROOT CAUSES. • METHOD : LACK OF AWARENESS FOR PRD.& INSPECTION PROCESSESS. AWARENESS FOR POURING PROCESS GIVEN TO POURING SUPRVISORS & TEMPERATURE INSPECTION PROCESS ON LINE EXPLINED TO AVOID COLD ,MISRUN,SHRINKAGE ,SHORT METAL & OTHER POURING & MELTING RELATED REJECTIONS. MOULDING PROCESS ONLINE PROCESS INSTRUCTION GIVEN FOR PROPER MOULDING ,SLEEVE INCERTING,AIR CLLNING OF MOULD,RAMMING AT CRITICAL AREAS ,VENTING ,BOX CLOSURE , PROPER CLAMPING ,FIRST PIECE APPROVAL ,AWARENESS GIVEN TO PERMENANT & ALSO TO TEMPORORY WORKERS AWARENESS & ONLINE INSTRUCTIONS TO SAND PLANT PEOPLES ON MIXER ,COOLER ,HOPPERS & SUPPLY HOPPERS GIVEN FOR PROPER ADDITITIONS OF ADDITIVES,WATER,REMOVAL OF WASTES FROM SAND ,SAND TEMPERATURE MAINTAINANCE ,HOUSEKEEPING & SAFETY. SYSTEM NOT OK METHODING OF F A SUPPRT NOT APPROPREATE FOR POURING 90-100 KG METAL THROUGH ONE GATE ,100 % SAND WASH OUT AT LOCATION ,REWORK & CUSTOMERS UNSATISFACTION FOR EXTRA MANPOWER & PPD.DELAY. METAL PRESSURE REDUCED BY USING TWO FOAM FILTERS. FOR 176 CRANCASE WINDER LOCATIONS NOT OK CAUSING SAND DROP & SAND WASH, WINDERS REMOVED FROM SYSTEM & CARE TAKEN FOR PROPER BAKING OF CORE IN ELECTRIC OVEN. FOR F E SUPPORT COLD LAP & PIN HOLES –IN PATTERN ADDITIONNAL COLD RISER PROVIDED ,CRUSH PADS PROVIDED FOR SAND DROP,WASH PROBLEM .CUSTOMERS SATISFACTION FOR REWORK,MAN POWER,& DELAY IN DISPATCH. • ENVIRONMENT: WINTER SEASON ,RAINY SEASON :

  12. ACTIONS TAKEN ON ROOT CAUSES. ABSENCE OF ENTHUSIASTIC \ ENCOURAGEING ENVIRONMENT: ENCOURAGING ENVIRONMENT CREATION WHICH IS VERY PROMISSING &MOST IMPORTANANT WORK OF DEVELOPING CULTURE DONE BY VARIOUS ACTIVITIES WHICH INCLUDES STRONG SUPPORT & ACTIVE PARTICIPATION OF ALL TOP EXCIUITIVES,TOP MEMBERS,CULTURE BUILDING TEAM,SETU TEAM THROUGH ZDD OETH ,VARIOUS AWARENESS PROGRAMMS,ACTIVE PARTICIPATION IN ALL PRODUCTION ACTIVITIES,COMMUNICATION TO ALL LEVELS,POSTERS,BULETINS,SPECTION WORK INSTRUCTIONS.HOUSEKEEPING,CLEANCLINESS,SAFETY.FESTIVE ENVIRONMENT CREATED ON DAY BY BEAUTIFUL RANGOLI ,SANAI,GUDHI,DISTRIBUTING SWEETS & BEST WISHES TO EVERYONE. WHICH WORKS MORE IN ZDD.

  13. SELECTION OF ITEMS FOR ZERO DEFECT .

  14. SELECTION OF ITEMS FOR ZERO DEFECT

  15. ZERO DEFECT DAY TRIAL PRODUCTION -REJECTION & REWORK REPORT

  16. ZERO DEFECT DAY TRIAL PRODUCTION -REJECTION & REWORK REPORT

  17. ITEMWISE REJECTION & ACTION PLANITEM- FRONT AXLE SUPPORT 23898 CASTING DEFECT- SAND WASH MINOR ASTETIC. GATING SYSTEM DUE TO VARIATION IN METAL PRESSURE. ACTION TO BE TAKEN : SAMPLE TO BE TAKEN FOR DIRECT POUR FROM HR2 –HOT RISER NO.2 DOWNSPRUE INTRODUCE BETWEEN TWO RISERS TO LOWER METAL PRESSURE. FOAM FILTER TO BE ADDED AT TOP & BOTTOM OF SLEEVE. CASTING DEFECT- SAND WASH ,SAND DROP MINOR ASTETIC. • GATING SYSTEM DUE TO VARIATION IN METAL PRESSURE. • ACTION TO BE TAKEN : • SAMPLE TO BE TAKEN FOR DIRECT POUR FROM HR2 –HOT RISER NO.2 • DOWNSPRUE INTRODUCE BETWEEN TWO RISERS TO LOWER METAL PRESSURE. • FOAM FILTER TO BE ADDED AT TOP & BOTTOM OF SLEEVE.

  18. ITEMWISE REJECTION & ACTION PLANITEM- FRONT ENGINE SUPPORT 3631 CASTING DEFECT- SAND WASH PATTERN PROBLEM. ACTION TO BE TAKEN : CRUSH PAD \RELIEVE TO BE PROVIDED AT PATING LINE & EDGES AT SAND DROP LOCATION IN PATTERN. CASTING DEFECT- SAND DROP. CORE BOX WARE OUT PROBLEM. ACTION TO BE TAKEN : 0.5 MM MACHINING ALLOWANCE INCRASE IN PATTERN AT LOCATION.

  19. ITEMWISE REJECTION & ACTION PLANITEM- ROCK SHAFT CYLINDER 20343 CASTING DEFECT- GAS. POURING ,MOULDING PROBLEM ACTION TO BE TAKEN : AVOID INTRUPTED POURING , OPEN GAS AT FULL LENGTH OF MOULDING BOX. 100 % INSPECTION OF MOULD • CASTING DEFECT- SAND WASH ,SAND INCLUSION –MINOR DEFECT MOULDING & SAND QUALITY PROBLEM ACTION TO BE TAKEN : MOULDING SAND TO BE FREE FROM ALL TYPE OF IMPURITIES ,FOREGIN MATERIAL TO BE REMOVED BY SIEVES,MAGNETS , REFINORY ( DUST COLLETOR ) SYSTEM TO BE OK.DO NOT ALLOW WASTE SAND TO ADD ON RETURN SAND BELT .THROW OUT IT OUTSIDE. PROPER CLEANING OF MOULD BY AIR,DO NOT CLEAN THE MOULD BY AIR AFTER CORE INTRODUCTION.DO NOT ALLOW THE SAND CLEANED FROM ANOTHER MOULDING MACHINE TO DROP ON READY MOULD FOR CLOSING.

  20. ITEMWISE REJECTION & ACTION PLANITEM- WABCO CRANKCASE 9119060176 SYSTEM PROBLEM- ACTION TO BE TAKEN : FOR GAS AT NECK WINDER PROVIDED AT HEA FACE NECK. NEAR POURING BAR 4 WINDERS NOT OPEN PATTERN PROBLEM. ACTION TO BE TAKEN : SHARP RADIUS TO BE FILLED PROPERLY & PERMENTLY,SHARP EDGES TO BE SMOOTHEN IN PATTERN. CASTING DEFECT- GAS • CASTING DEFECT- SAND DROP

  21. ITEMWISE REJECTION & ACTION PLANITEM- CLAAS PULLEY 603190 CASTING DEFECT- MOULD BREAKAGE ACTION TO BE TAKEN : Molding Box Pallets to be Repaired.

  22. WORKERS AWARENESS FOR FURTHER ACTIONS

  23. WORKERS AWARENESS FOR FURTHER ACTIONS

  24. WORKERS AWARENESS FOR FURTHER ACTIONS

  25. WORKERS & STAFF AWARENESS FOR FURTHER ACTIONS

  26. ZDD TRIAL REJECTION REPORT FRONT AXLE SUPPORT 23898 1st TRIAL DT-05.12.12 PRD.QTY-251 NOS. INSP QTY- 251 NOS. REJECT QTY-0 NOS REJ %- 0% 2nd TRIAL DT-19.12.12 PRD.QTY-46 NOS. INSP QTY- 46 NOS. REJECT QTY-0 NOS REJ %- 0%

  27. ZDD TRIAL REJECTION REPORT FRONT ENGINE SUPPORT 3631 1st TRIAL DT-18.12.12 PRD.QTY-294 NOS. INSP QTY- 294 NOS. REJECT QTY-4 NOS REJ %- 0.39% 2nd TRIAL DT-19.12.12 PRD.QTY-294 NOS. INSP QTY- 294 NOS. REJECT QTY-1 NOS REJ %- 2.40%

  28. ZDD TRIAL REJECTION REPORT ROCK SHAFT CYLINDER 20343 1st TRIAL DT-05.12.12 PRD.QTY-444 NOS. INSP QTY- 444 NOS. REJECT QTY-FLOOR-01 NO REJ - 0.22% M/C SHOP-05 NOS REJ-1.13%

  29. ZDD TRIAL REJECTION REPORT WABCO CRANKCASE 0176 1st TRIAL PRD DT-12.12.12 PRD.QTY-400 NOS,INSP QTY-400 NOS, REJ QTY-29 , REJ – 7.25% 2nd TRAIL PRD DT- 19.12.12 PRD QTY-624 NOS, INSP QTY- 624 NOS, REJ QTY- 3 NOS, REJ – 0.48%

  30. COMMITMENT FOR ZERO DEFECT.

  31. GREETINGS FOR ZERO DEFECT DAY

  32. ZERO DEFECT DAY INSPECTION PATTERN INSPECTION SAND INSPECTION CORE INSPECTION INCOMING INSPECTION

  33. ZERO DEFECT DAY PRODUCTION MOULDING PROCESS MOULDING PROCESS MOULDING PROCESS MOULDING HARDNESS INSPECTION

  34. ZERO DEFECT DAY PRODUCTION MELTING MELTING POURING K/OUT

  35. ZERO DEFECT DAY PRODUCTION FETTLING FETTLING FETTLING INSPECTION FETTLING INSPECTION

  36. INSPECTION AT M/C SHOP

  37. INSPECTION -THIRD PARTY. ZDD PRODUCTION F.A.SUPPORT QUANTITY VARIFICATION ZDD PRODUCTION F.A.SUPPORT SAMPLING FOR THIRD PARTY INSPECTION ZDD PRODUCTION F.A.SUPPORT THIRD PARTY CASTING QUALITY INSPECTION ZDD PRODUCTION F.A.SUPPORT DISCUSSION & SUGGESTIONS

  38. INSPECTION -THIRD PARTY. ZDD PRODUCTION FRONT ENGINE SUPPORT QUANTITY VARIFICATION ZDD PRODUCTION FRONT ENGINE SUPPORT SAMPLING FOR THIRD PARTY INSPECTION ZDD PRODUCTION FRONT ENGINE SUPPORT THIRD PARTY CASTING QUALITY INSPECTION ZDD PRODUCTION FRONT ENGINE.SUPPORT DISCUSSION & SUGGESTIONS

  39. INSPECTION -THIRD PARTY. ZDD PRODUCTION R.S.CYLINDER SAMPLING FOR THIRD PARTY INSPECTION ZDD PRODUCTION R.S.CYLINDER QUANTITY VARIFICATION ZDD PRODUCTION R.S.CYLINDER THIRD PARTY CASTING QUALITY INSPECTION ZDD PRODUCTION R.S.CYLINDER DISCUSSION & SUGGESTIONS

  40. INSPECTION -THIRD PARTY. ZDD PRODUCTION CRANKCASE 0176 SAMPLING FOR THIRD PARTY INSPECTION ZDD PRODUCTION CRANKCASE 0176 QUANTITY VARIFICATION ZDD PRODUCTION CRANKCASE 0176 THIRD PARTY CASTING QUALITY INSPECTION ZDD PRODUCTION CRANKCASE 0176 DISCUSSION & SUGGESTIONS

  41. CELEBRATION OF ZERO DEFECT DAY SUCESS

  42. ZDD REJECTION REPORT

  43. ZDD THIRD PARTY INSPECTION REPORT (MOM)

  44. ZDD THIRD PARTY INSPECTION REPORT (MOM)

  45. ZERO DEFECT DAY REJECTION GRAPH

  46. ZERO DEFECT DAY REJECTION GRAPH

  47. ZERO DEFECT DAY PRODUCTION DT – 02.01.2013ITEM – CLAAS PULLEY 603 190

  48. ZERO DEFECT DAY REJECTION GRAPH

  49. ZERO DEFECT DAY REJECTION GRAPH

  50. INTERNAL\EXTERNAL CUSTOMERS SATISFACTION FEEDBACK REPORT.INTERNAL CUSTOMER- FETTLING DEPT. ITEM- F.A.SUPPORT

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