Beruflich Dokumente
Kultur Dokumente
INDUSTRY
A PROJECT REPORT
Submitted by
Meet Patel
(110010119020)
Kirit Patel
(110010119025)
In
MECHANICAL ENGINEERING
DECEMBER 2014
(Dr. V. N. SINGH)
ACKNOWLEDGEMENT
We would like to offer our profoundest gratitude to our project advisors,
Mr. Mehul patel, for offering their unreserved help and guidance which lead us
to finish our project step by step. Their words are always inspiring and bring us
to a higher level of thinking. What we learn from them is not just how to write a
thesis to meet the Graduation requirement, but also to view this world from a
new perspective. Without their kind and patient instruction, it is impossible for
us to finish this project. Moreover, we want to give gratitude to our Head of
Department Dr. Vishal N. Singh to allow us to use all departmental facilities
and we are also thankful to all staff member to provide us their warm support.
Last but not the least; we would like to thank our parents for their constant
encouragement and support.
Abstract
Introduction
What is DMAIC Methodology?
1. DEFINE
2. MEASUREMENT
3. ANALYSIS
4. IMPROVE
5. CONTROL
(1)Defining phase:
Defining is the first step of DMAIC process. This step identifies the pain
area or the process that needs improvement. These also define the type
of the problem.
The objectives for adopting the six sigma improvement process are
defined during this step. To improve current process, a team should be
form and should be aware about the benefits of adopting the six sigma
methodology.
It is important that the team that has been formed is motivated and
believes in the benefits that will be accrued by completing this project.
Next, the team has to identify the customers or the people who would be
impacted by this six sigma project. The critical requirements for these
customers are also documented.
The following table gives idea about the problem.
Phas
e
Potential Answers
Second, currently the company has machine which is not as fast as other
modern machine
available in market now a days.
Third, currently there is no inspection of quality of product produce while
manufacturing
because they think that they are manufacturing better quality product
without any fault.
SIPOC:
SIPOC is the acronym that stands for five elements: Suppliers, Inputs, Process,
Outputs,
and Customers. A SIPOC diagram is shown here:
Suppliers
Local factories
Inputs
HCL & Nitrite
Process
Mix the raw
material
according to
the prices and
quality
requirement
by buyers
Outputs
ACID BLACK
210, ACID
BLACK 234
Customers
The output is
produced
dealers
(2)Measurement phase:
After completing the defining phase here we comes on second phase which is
measuring phase. DMAIC methodology comes in these phase: from which we can
determine
The characteristic that affect the process, these is completed by making the
measurements and collecting data from manufacturing company SHREE
TRIMURTI CHEMICALS.
These step takes more time then the defining phase. These phase will show
which parameters need to be improved for the progress of the company. The
main affecting
Defect will be identified and defined in these phase. Once that is defined data is
collected to analyse the difference between actual performance and desired
performance. Process variation will be established in these phase.
NO.
1
3.
Questions to be Answered?
What is the current
measurement?
What are we going to
measure?
How will we measure it?
4.
5.
6.
2.
Potential Answers
Company produced nearly 90 M ton dyes
in year 2014.
Companys Type of product, total
production in a year, profit and losses.
By visiting the company and collecting
data and by preparing the questionnaire
and taking review from employee of
company.
Owner of SHREE TRIMURTI CHEMICALS
provided all data.
Currently, company does not follow
any standards strictly. So there is a big
difference between the manufacturing
process of industry standard and SHREE
TRIMURTI CHEMICALS.
During this stage team deliverable
will be to collect the data of current
Manufacturing process and Production
from owner of SHREE TRIMURTI
CHEMICALS.
Particularly manufacturing ACID BLACK 210, ACID BLACK 234 (different shades in
black Colour) providing Leather Black colour for dying & tanning the leather.
Leather tanneries are main consumer of the dyes.
Batch process department, Filtration, Drying, Blending, and Packing.
3 ms vessel, 1 filter press, 2 dryers, 1 hot air generator, 1 steam boiler, 2 Boll
mill.
Batch process:
First we diazotise one material with HCL & Nitrite give 3 hours for stirring then
coupled the same with another material, Allow the whole mask stirring whole day
& overnight.
Another day 3rd material being diazotised & coupled with whole mask, set the
PH of the mask with soda.
After that add on more coupler in that mask, allow 3 hours stirring then start
heating the whole mask raise temp. up to 70 c.it takes whole night steaming by
boiler.
Precipitate the mask with salt & HCL & start filtering, after that open the filter
press take press cake to dryer, then drying, pulverising, blending, Packing &
despatch.
Year: 2014-2015
Year: 2013-2014
Year: 2012-2013
70 M Ton.
115 M Ton.11:08
95 M Ton.
(3)Analysis phase
During this phase, the data collected during the measure phase is used to
analyse the gap between the current and desired performance.
Root-cause analysis is done to define the possible reasons for the
performance gap and quality issue.
Basic Information :
1.
7.
Quality of Staff:
I ) Skill Level
II ) No. of employees does
Repetitive Task.
III ) No Of Training conducted
In a year.
IV ) Priority of Organization on
quality/Production
8.
Process Improvement Level:
I) Any Quality Tools Used.
II) Production/Rejection
Analysis done.
III) Technology update
IV) Customer feedback
Evaluation :
9.
10.
11.
Cost of production :
I) Raw Material cost
II) Manpower
III) Reject Cost
Delivery of product
I) Mode of transport
II) Packing material
III) Delivery schedule followed
Plant safety
I)Handling pf hazardous material
II) fire extinguisher used
III) Accident plant handling is there or
not.
No
No
No
No
250 per kg
40 rs per kg
12.5 Lakh per year
Private vehicle
Plastic
Usually
Manually
Yes
No
12.
13.
Organizational characteristics
I) Number of workers
II) Number of machines
III) Type of product
Supplier motive
I) Aware of the product quality
II) Additional care for the material
supplied
III) How Frequently Supplier evaluation
done
15
10
Leather die manufacturing
No
No
No
Are you familiar with the philosophy of Total Quality Management (six
sigma)?
No
Permanent workers 3
Contract based 11
Any policy for your company or you produce product only on order
basis?
No, order based production
On what basis are you choosing supplier for your row material?
Cost and delivery time
N
O
Questio
nnaire
(for
workers)
1. Organizations Manager
A. Manager are warm and caring. He seeks to develop employees full potential and act as
his mentors or guides.
B. Manager are risk-takers. They encourage employees to take risks and be innovative.
C. Manager is rule-enforcers. He expects employees to follow established rules, policies,
and procedures.
D. Manager is coordinator and coach. He helps employees meet the organization
Goals and objectives.
A
.
B
.
C.
D.
2. Organization Character
A. Organization is a very personal place. It is a lot like an extended family. People seem to
Share a lot of themselves.
B. Organization is a very dynamic and entrepreneurial place. People are willing to stick their
Necks out and take risks.
C. Organization is a very formalized and structured place. Bureaucratic procedures generally
Govern what people do.
D. Organization is very production oriented. A major concern is with getting the job done.
People arent very personally involved.
A
.
B
.
C
.
D
.
3. Organization Emphases
A. Emphasizes human resources. High cohesion and morale in the organization are
Important.
B. Emphasizes growth and acquiring new resources. Readiness to meet new challenges is
important.
C. Emphasizes permanence and stability. Efficient, smooth operations are important.
D. Emphasizes competitive actions and achievement. Measurable goals are important.
A
.
B
.
5. Organization Rewards
C
.
D
.
A. Distributes its rewards fairly equally among its members. Its important that everyone from
top to bottom be treated as equally as possible.
B. Distributes its rewards based on individual initiative. Those with innovative ideas and
actions are most rewarded.
C. Distributes its rewards based on rank. The higher you are, the more you get.
D. Distributes its rewards based on the achievement of objectives. Individuals who provide
leadership and contribute to attaining the organizations goals are rewarded.
A
.
B
.
C
.
D
.
4. Organization Cohesion
A. The glue that holds together is loyalty and tradition. Commitment to this organization runs
high.
B. The glue that holds together is commitment to innovation and development. There is an
emphasis on being first.
C. The glue that holds together is formal rules and policies. Maintaining a smooth running
Operation is important here.
D The glue that holds together is the emphasis on tasks and goal accomplishment. A
production orientation is commonly shared.
A
.
B
.
C
.
D
.
Disagree
Neither
Agree
Strongly
Dont
Disagree
1
Agree Nor
Disagree
3
Agree
Know
2.
Empowering
employees
to
identify
quality
problems
and
Yes
NO
NO
NO
NO
if yes what :
2. Management Commitment
5. Senior management establishes quality policy and quality objectives and
communicates to organisation.
1
2
3
4
5
0
.
9. The behaviour of the senior executives is consistent with values relevant to quality
and continuous quality improvement.
1
2
3
4
5
0
.
3. Quality policy
10. Quality policy is appropriate to the organisation.
1
2
3
4
.
4. Customer Satisfaction
14. The organization does a good job of assessing current customer needs and
expectations.
1
2
3
4
5
0
.
15. Customer complaints are studied to identify patterns and prevent the same
problems from recurring.
1
2
3
4
5
0
.
17. The organization uses data on customer expectations and/or satisfaction when
designing new services and products.
1
2
3
4
5
0
.
6. Resource Management
22. Sufficient resources are allocated for implementing, maintaining and
improving
quality management system.
1
2
3
4
5
0
25. Staff are given education and training in how to identify and act on
quality improvement opportunities.
1
2
3
4
5
0
26. Staff are given education and training in statistical and other quantitative
methods that support quality improvement.
1
2
3
4
5
0
27. Staff are given the needed education and training to improve job skills
and performance.
1
2
3
4
5
0
7. Purchasing
28. Organisation as established and documented the criteria for evaluation and
selection of suppliers that provide materials and services.
1
2
3
4
5
0
.
29. The organization works closely with suppliers to improve the quality of their
products and services.
1
2
3
4
5
0
34. Organisation has effective system to ensure that product which doesnt
conform to
product requirements is identified and controlled to prevent its unintended
use or delivery.
1
2
3
4
5
0
35. Organisation has system in place to take action to eliminate the cause of
nonconformities in order to prevent reoccurrence.
1
2
3
4
5
0
37. Organisation promotes the use of statistical tools to monitor and measure
product and processes for effectiveness and/or improvement.
1
2
3
4
5
0
0
.
40. Getting recognition (i.e., praise, promotion, etc.) from your superiors.
1
2
3
4
5
0
Questionnaire Graph.
The organization as a whole
A
10
Percentage
B
17
C
40
D
33
33%
10%
17%
C
D
40%
Percenta
ge
Strongly
Disagree
Disagree
17
33
Neither
agree
Nor
disagree
27
Strongly
Agree
Strongly
Agree
Dont
know
15
5%
3%
15%
17%
Strongly disagree
Disagree
Neiter agree nor disagree
33%
27%
Agree
Strongly agree
don't know
Percenta
ge
Strongly
Disagre
e
Disagre
e
20
40
Neither
agree
Nor
disagree
27
Strongly
Agree
Strongly
Agree
Dont
know
9%
1%
3%
Strongly disagree
20%
Disagree
Neither agress nor disagree
Agree
27%
Strongly agree
Dont know
40%
2. Management commitment
Strongly
Disagre
Disagre
e
Neither
agree
Strongly
Agree
Strongly
Agree
Dont
know
e
Percenta
ge
10
Nor
disagree
20
25
20
21
Management commitment
Strongly Disagree
21%
Disagree
10%
25%
4%
Agree
Strongly agree
20%
dont know
20%
3. Quality Policy
Percenta
ge
Strongly
Disagre
e
Disagre
e
12
34
Neither
agree
Nor
disagree
16
Strongly
Agree
Strongly
Agree
Dont
know
11
23
Quality Policy
Strongly disagree
20%
Disagree
12%
3%
27%
4. Customer satisfaction
Agree
38%
Strongly agree
dont know
Percenta
ge
Strongly
Disagree
Disagree
11
34
Neither
agree
Nor
disagree
16
Strongly
Agree
Strongly
Agree
Dont
know
11
25
Customer satisfaction
Strongly disagree
23%
11%
5%
Disagree
Neither agree nor disagree
Agree
34%
Strongly agree
11%
16%
Percenta
ge
Strongly
Disagree
Disagree
10
25
Neither
agree
Nor
disagree
20
Strongly
Agree
Strongly
Agree
Dont
know
21
15
15% 10%
9%
Disagree
Neither agree nor disagree
25%
agree
Strongly agree
21%
Dont know
20%
6. Resource management
Percenta
ge
Strongly
Disagree
Disagree
10
30
Neither
agree
Nor
disagree
16
Strongly
Agree
Strongly
Agree
Dont
know
26
10
Resource management
Strongly disagree
Disagree
10% 10%
8%
30%
26%
Strongly agree
Dont know
16%
7. Purchasing
Strongly
Disagree
Disagree
Neither
agree
Nor
Strongly
Agree
Strongly
Agree
Dont
know
Percenta
ge
disagree
39
27
14
18
Purchasing
Strongly disagree
17%
3%
9%
14%
Disagree
Neither agree nor disagree
27%
agree
Strongly agree
Dont know
29%
Percenta
ge
Strongly
Disagree
Disagree
27
Neither
agree
Nor
disagree
30
Strongly
Agree
Strongly
Agree
Dont
know
17
19
19%
7%
27%
17%
agree
Strongly agree
Dont know
30%
9.
Percenta
ge
Strongly
Disagree
Disagree
14
Neither
agree
Nor
disagree
23
Strongly
Agree
Strongly
Agree
Dont
know
47
8%
8% 14%
Disagree
Neither agree nor disagree
23%
47%
agree
Strongly agree
Dont know
1) Internal factors
- Process of Production
- Leadership
- Company policy & strategy
- Workers
- Safety tools
- Availability of raw material
- Faulty machines
- Bad environment of plant
- Lack of technology
2) External factors
- Supplier of row material
- Customer
- Government policies
- Failure in delivery due to transportation
Cause-and-Effect Diagram
environment
Material
Workers are
not encouraged
lack of
communication
worker
lack of experience
Poor raw
material
lack of education
lack of skill
Improper mixing
of raw
bad working
environment
lack of internal
lack of prior
outdated process
machines are in
dirty condition
lack of customer
lack of
consistency
Company does
Absence of
measurement
Lack of standard
process
process
decrease in
productivity
of plant
lack of maintenance
outdated machines
Machines
14)
15)
16)
Improve phase
Below are few suggestion given to the industry to overcome the
above factors that affect the productivity of the Plant
1) Batter manpower should be hired
2) Understand customers need properly & increase communication with
customer
3) Planning of regular training and development of manpower are needed.
Organisation is to plan such training programme in its site or can
depute the persons to related training institute. The training curriculum
should be both technical and managerial
4) Suppliers evaluation, Quality Control at supplier site, to make aware of
voice of customer and voice of process.
5) Improvement in Safety tools
6) Up gradation of machines available in plant
7) Do regularly maintains of machines
8) Improve plant environment for workers
The multiple gains achieved by Six Sigma efforts over
different productivity problems in a company amply prove the
usefulness of this strategy for small industries as well.