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"The purpose of a business is to create a CUSTOMER"

"Your customer doesn't care how much you know until,


they know how much you care"

"Your MOST unhappy CUSTOMERS ARE YOUR


greatest SOURCE OF LEARNING"
Quality Assurance

Departmental meeting on ideation

Leader : Sandeep Patil


Team Members:
1. Tushar Gujar.
2. Suryaprakash Singh
3. Ankit Rana.
4. Sharad Girase.
5. Pinaki Ghosh
6. Sachin Patil.
Quality Assurance

Idea Generation
Total Idea genertaed : 69 nos

Quality Assurance

In process and Final Quality


Improvement Point

Team

ESD set up at assembly line

Sharad
Omkar

Status

Completed

Target Date

Done

To protect controller from electric charge.


Confidence building to customer.
To reduce field failure, warranty claim.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point
Skill enhancement on
critical process- Electrical &
electronics

Team
Ankit
Suryaprakash

Target Date

Status
Competed for QA
inspectors

By Q3 for
all wiring
operators

To enhance skill in electrical & electronics.


To reduce defect on electrical process.
To improve detection skill of inspectors.

Micros oft
PowerPoint Pres entation

Refer attachment
Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point

Team

IT Innovation for check list


in barcode software

Sachin
Sharad
Tushar

Target Date

Status

Completed

Done

It is go green concept.
Positive checking of machine wrt check list.
Faster implementation of changes required in
check list.
On line availability of records faster retrieval.
Increased costumer confidence.
Micros oft
PowerPoint Pres entation

Refer attachment
Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point
PPM guideline

Team

Sharad

Target Date

Status

Completed

To getting better awareness and reduce conflict


between the team.

Micros oft Excel


Works heet

Refer attachment
Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Team

Status

Contamination test set up

Sandeep
Dharmesh
Pinaki

Pending for
management
approval

Target Date

Required for checking the contamination on


periodic basic for improvement in coils
manufacturing process

Quality Assurance

17.07.2015

Incoming Quality
Improvement Points
Point
IT innovation on fast ECN
implantation

Team

Status

Sachin Patil
Rajan Gore
Ameya

Pending
Approval

Target Date

Many times there is confusion about old and new revision parts.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point

Team

IT Innovation through Bar


coding / Store Bar coding

Sachin Patil
Ashish
Nilesh Patel
Sunil Bhosle

IT Innovation through Barcoding- Coil Shop

Shivnath Katore
Pinaki Ghosh
Ashish Bokade
Vinod Bhamugare

Quality Assurance

Status

Target Date

Pending for
management
approval

Pending for
management
approval

17.07.2015

Incoming Quality
Improvement Point

Extending Quality Software


through Bar-code at supplier place

Team

Sachin
Bijal

Target Date

Status
Pending for
management
approval

To meet correct identification on components.


To get correct qty and stock.
To ensure inspection @ supplier end before
dispatch.
To get dispatch intimation for better planning

Refer attachment
Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
IT Innovation on
assignment of skill operators
for critical operations
(brazing, wiring ,gas charging ....)

Team

Sharad
Tushar
Sachin

Quality Assurance

Status

Target Date

Pending for
management
approval

17.07.2015

Idea Generation
Idea Status

Quality Assurance

Idea Generation

Idea Status In Process

Quality Assurance

Idea Generation

Idea Status In Process

Quality Assurance

Improvement Point

Team

Status

Target Date

THANKU
???

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point

Team

Status

Target Date

Availability of drawing WRT


material code. ( DMS )

Sachin
Rajan Gore

In process

By March'2016

Easy to search for new person , Present method is time


consuming.
To ensure availability of all components drawings.
To Ensure All drawing will have SAP code.
To ensure correct revision available to all
To send correct drawing to supplier.
To implement ECN process smoothly

Refer attachment

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point
Active vendor re-evaluation
on CAPA

Team
Pradeep
Bijal
Sachin

Status

In -Process

Target Date

On going

To get quick corrective actions .


To improve supplier quality level.
To improve supplier quality systems.
To improve delivery.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point
Bench marking visit / Video
for idea generation

Team

All team Member

Status

In process

Target Date

On going

Planned in
Prijay

To learn and adopt best practices.

Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point
Auto send dispatch sr
number to customers

Team

Tushar
Sachin

Status

In process

Target Date

By Q3

Export customer required sr no after dispatches.


Presently it consumes time in downloading and
sending the same.
This will improve productivity .

Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point
IT Innovation on line IVRF /
DVRF testing

Team

Sharad
IT Team
Manish
Vaibhav

Status

In process

Target Date

July end

Testing Process strengthening .


Confidence building to customer.
Consistency in detection level.

Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point
Test jig to ensure wiring

Team

Ankit
Sachin
Bijal

Status

In process

Target Date

By Q4 for all
models

Testing Process strengthening .


Confidence building to customer.
Consistency in detection level.

Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point

Team

Status

Target Date

Dedicated PDI stage at


assembly lines

Omkar
Suraj
Sachin

In process

Ongoing

To control and focus on outgoing quality.

Quality Assurance

17.07.2015

In process and Final Quality


Improvement Point
Focus on QM Pillar

Team

All Team member

Status

Target Date

In process

To build strong team for getting consistent results on


quality of product.
To enhance skill of Six sigma methodology.
To reduction in customer complaint, warranty
reduction...

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
Increase no of Internal
auditors

Team
Sandeep Patil
Mahesh Nikam

Status
Inprocess

Target Date

By Q3

To build system and enhanced the skill .

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
Process Measurement /
Dash board linked with software

Team
Sandeep
Sachin
Sharad

Status

Inprocess

Target Date

By Q3

On time MIS generation.


Elimination of time wastage in making reports.

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
COPQ monitoring & reduction
by taking project

Team

All team member

Status

Inprocess

Target Date

On going

Scrap reduction.
Productivity improvement.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point

Team

Status

Target Date

No of DAP's increased in
place of operators

Milan
Tushar

In process

By Q3

ITI operators are available for 6 months ,few months


goes away in training and learning ,so effective
utilization time will be less for organization.
DAP's will be available for more period for getting
optimize results.

Micros oft
PowerPoint Pres entation

Refer attachment
Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
Reduce Blower Rejection

Team

Tushar
Sachin
Bijal

Status

Target Date

Inprocess

By Q3

Reduce rework on assembley line.


To improve OEE

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
RFID on machine tracking

Team

N M Rao
Amit Mehta
Hiten Shah
Sanjeev Desai
Sachin

Status

In Process
Trainning
arranged by
HR

Target Date

By Q4

To reduce FG serching time .


Enhanced dispatch.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Team

Status

Oil less coils

Shivnath
Pinaki
Ashish

In process

Target Date

By Q3

Improvement required as Export customer


feedback.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Positive pressure equipment

Team

Status

Target Date

Pinaki
Ashish

Idea need to
explore

By Q4

Best process practices and improved


system.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Storage of overall copper tubes
/ aluminum fins / FG coils
Headers /capillary & system
tubing

Team

Ashish
Pinaki
Shivnath

Status

Idea Shared
-need to take
approval for
action.

Target Date

By Q4

Best practices in material handling and


manufacturing process to get overall good
Quality.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Required Proper storage and


stacking of coils for avoiding
damages and bulging

Team

Shivnath
Ashish
Pinaki

Status

Need to
Explore and
confirm

Target Date

By Q4

To eliminate the process scrap and follow


best practices

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Header brazing area required
proper enclosure for avoid any dust
and moisture inside the tubes
specially capillary

Team

Ashish
Shivnath
Pinaki

Status
Need to
Explore and
confirm

Target Date
By Q4

To eliminate any chances of contaminations


and improve the manufacturing process

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
FG coil handling trolleySpecially Export and
PKG IDU coils

Team

Pinaki
Ashish
Sunil

Status

Target Date

In process

To get defect free coils on the assembly lines

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
N2 Plant to improve moisture
content in system

Team

Dharmesh
Sunil
Sandeep

Status

In process

Target Date

By Q4

To have best manufacturing process

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Floor coating like G3 for avoiding
oil and dustPunching and Expansion area

Team
ME Team

Status
In process

Target Date

By Q4

To have best manufacturing process

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Improvement in Hair Pin bender
machine to avoid heavy clamp mark
and peg length issue

Team

Shivnath
Pinaki
Ashish

Status

In process

Target Date

By Q3

Reduction of defect and control scrap

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Proper Handling required for
movement of coils from Coil
bending to Manual brazingSpecially 11 TR, DVRF
and IVRF coils

Team

Shivnath
Pinaki
Ashish

Status

Target Date

In process

By Q3

To have best manufacturing process

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Team

Tank to be shift to center of


hoist to avoid damages

Sagar
Sunil

Status

In process

Target Date

By Q3

To avoids fins and copper damages from the


process.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Team

Finished coil storage facility to


reduced fins damages & avoid
formicary issue

Shivnath
Pinaki
Ashish

Status

Target Date

In process

To have best manufacturing process.


To reduce coils leakages due to formicary

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point
Proper data capturing for
reduction in process scrap

Team

Shivnath
Pinaki

Status

Target Date

Started

To reduction in scrap and improve the


productivity

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Team

Eye to sky coil un loader

Ashish
Shivnath
Pinaki

Status
Idea
Generated

Target Date
First week of
Aug'15

Benchmarking best practices of


manufacturing process and ease in
operations.
- This will reduce the issues in copper
crack issues......
-No of roll change over reduce...

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Improvements on handling
process on SS panels

Team

Shivnath
Pinaki
Ashish

Status

In process

Target Date

By Q3

To eliminate the issues like scratch ,dents


marks on panels.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Elimination on burr issues

Team

Sagar
Ashish
Sunil

Status

In process

Target Date

By Q3

Due to safty concern as well as service


Mandatory requirment on internation standered
(RHEEM)
Ashthetic requiremnt.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Reduction on touching spray use


in final unloading @ Paint Shop

Team

Lomesh
Pinaki

Status
Need to
Explore

Target Date

By Q4

To eliminate rework and process


improvement.

Quality Assurance

17.07.2015

Feeder Shop
Improvement Point

Standeriazation of Fab parts

Team

R&D
Pinaki
Shivnath

Status

Need to
Explore

Target Date

By Q3

So as to reduce variety ,results less chances


of error

Quality Assurance

17.07.2015

Improvement Point

Team

Status

Target Date

THANKU
???

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
Pokayoke on wiring measurement
& out put

Team

Status

Ankit
Sachin
Bijal

YTS

Target Date

By Q4 for all
models

Testing Process strenthning .


Confidence building to customer.
Consistency in detection level.

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
Master set up Simulator
required for controllers

Team

Status

Ankit
Sachin

YTS

Target Date

By Q4 for all
models

Testing Process strenthning .


Confidence building to customer.
Consistency in detection level.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point

Team

Status

Send Drawing along with PO


(automatically )

Sachin
Bijal
Rajendra

YTS

Target Date
By March'2016

To ensure avability of Correct Rev Drawing with


supplier.
Faster implementation of ECN.
Recept of Correct Material.
Lesser Line stopages.
Less Rework / Scrap.

Refer attachmenet

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point
F3 line Run test set up

Team
Tushar
Omkar
Vaibhav
Maniram

Status
YTS

Target Date

By Q4 for all
models

Testing Process strenthning .


Confidence building to customer.
Consistency in detection level.

Quality Assurance

17.07.2015

Incoming Quality
Improvement Point

Team

Status

Separate identified area on


server for Sample / Pilot Drg

Sachin
Rajan Gore

YTS

Target Date
By March'2016

Refer attachmenet

To ensure avability of all components


drawings .
To ensure correct revision available to all
To send correct drawing to supplier.
To impliment ECN process smothley

Quality Assurance

17.07.2015

Inprocess and Final Quality


Improvement Point

Team

Status

Dedicated PD support of
Product validation

Suraj
Sachin
R&D

YTS

Quality Assurance

Target Date

17.07.2015

Inprocess and Final Quality


Improvement Point

Team

Test Jig for field failure


analysis

Sachin
Ankit

Quality Assurance

Status

Target Date

YTS

17.07.2015

Inprocess and Final Quality


Improvement Point
On line Supplier Test report
through supplier Portal

Team
Sachin
Bijal

Quality Assurance

Status

Target Date

In process

17.07.2015

Inprocess and Final Quality


Improvement Point

Team

Approved raw material


supplier

Sachin
Bijal
Ankit

Quality Assurance

Status

Target Date

In process

17.07.2015

Inprocess and Final Quality


Improvement Point
All raw material mfg name
to given in drg

Team

Sachin
Rajan Gore
Sachin Shah

Quality Assurance

Status

Target Date

In process

17.07.2015

Inprocess and Final Quality


Improvement Point
Dedicated area for
customer / third party test
inspectors ( PRO)

Team
Sharad
Omkar

Quality Assurance

Status
In process

Target Date
By month end

17.07.2015

Incoming Quality
Improvement Point
Pallets redesign to avoid
damages ( W/c )

Team
Sachin
Suraj
Omkar

Quality Assurance

Status

Target Date

In process

17.07.2015

Inprocess and Final Quality


Improvement Point
Couplers for IDU & ODU
IVRF / DVRF to avoid current
Brazing process

Team

Sharad
Omkar

Quality Assurance

Status

Target Date

YTS

17.07.2015