WELCOME !!!

10th Cycle of Participation in D L Shah Awards

1
 Diamond- Rajasthan

Technology

Core Cold Box & Shell core shooters

DISA 2013 3NOS

Mold
DISA 130B 1NO
Electrotherm & Inductotherm (
Melt Mono Track)
& ( Dual Track)

Finishing 1 TASA & 2 Maus Robo Grinders

Key Products Key Customers

Flywheels Maruti

Turbine Housings Cummins

Brake Calliper Borg Warner

Diff Case JCB
Torque Plate Nissan
Pulleys Renault
Ford
 Overview
...vision to actualisation

DIAMOND OVER VIEW

Established 2007

Production starts 2008

QCC started NOV. 2011

ACTIVE QUALITY 8
CIRCLE

3
 Valuable Customers
EXPORT

DOMESTIC
 Product Segment
Value Added Product Portfolio
Fully integrated manufacturing process to deliver best-in class products

Crankshaft Transmission
Flywheel Intake
Manifold Forks

Ring Gear

Turbo Charger

Connecting Wheel Hub

Rod

Camshaft

Gear Fasteners
Ladder Clutch
Cylinder
Frame Steering Case
Block
5 Knuckles
 Process Flow Diagram

Sand Preparation Pattern Core

Melting
Making Making

Sand Testing Pattern Core

Lab Testing
Inspection Inspection

Process Online Shot Online

Moulding Pouring Inspection Blasting Fettling
Inspection

Heat Online
Packing & Visual Shot Lab Testing Treatment Inspection
Dispatch Inspection Blasting
(Optional)

6
 Casting Manufacturing Flow

Sand plant

Sand Recycling
Dust Exhaust
Moulding Press Pour
machine

SBC Dust Exhaust

Melt Shop

Cooling Drum

Runner Breaking

On line Shot
blast
Continuous Running Operations Finish Part
 Activity Time Plan
S.No. Phase Schedule Sep Oct Nov Dec Jan Feb Mar Apr

Identification of work related PLAN

1
problems ACTUAL
PLAN
2 Selection of Problem
ACTUAL
PLAN
3 Define the Problem
ACTUAL
PLAN
4 Analyze the Problem
ACTUAL
PLAN
5 Identification of causes
ACTUAL
PLAN
6 Finding out the root causes
ACTUAL
PLAN
7 Data analysis
ACTUAL
PLAN
8 Developing solution
ACTUAL
PLAN
9 Innovation
ACTUAL
Trail implementation & Check PLAN
10
performance ACTUAL
PLAN
11 Regular Implementation
ACTUAL
Follow up / review/ PLAN
12
Standardization ACTUAL 8
 TEAM MEMBERS

Suraj Kumar

Sanjay Kumar

Jagmendra

Anil Kumar

Neeraj

9
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 10
IDENTIFICATION OF WORK RELATED PROBLEMS

Sr.no PROBLEM CETEGORY

1 Disa machine Door not closing A
2 M/C Cleaning Not Good A
3 Loose wiring A
4 Sand magazine not clean. A
5 Loosing bolt and nuts A
6 Core taker cleaning not good. A
7 Air pipe not good A
8 Operating button damage A
9 Handling of tooling not good A
10 Filter not Clean A
11 Sand magazine damage. A
12 Air vent not clean . A
13 Core storage not good. A
14 Core box not clean. A
15 Shot Level Indicator not visible A
16 Air leakage A
17 Pressure gauge damage A
IDENTIFICATION OF WORK RELATED PROBLEMS

18 Safety guard Not working on panel A

19 M/C operation switch damage A
20 Panel locking not properly A
21 Mix up shots on line A
22 M/C operation switch damage A
23 Panel locking not properly A
24 Variation in shot size. A
25 Vent pipe not clear A
26 Cylinder Noise A
27 Proper parameter Setting A
28 Air vent damage. A
29 Position of Sensor get shifted A
30 Shot pressure less. A
31 Bend Plates A
32 Impeller late start A
33 Sand container broken A
34 Sand falling on floor. A
35 Filter choking. A
36 Sand overflow A
37 Shots on floor A
39 Greasing nipple block A
IDENTIFICATION OF WORK RELATED PROBLEMS
40 Safety guard Not on panel A
41 Shots on floor A
42 Shot separation not effective A
43 Drum box damage. A
44 Partial impeller stop A
45 Torn sand bags. A
46 Sand leakages on AMC A
47 Dust controller not effective A
48 High Temp. of shots A
49 Rotary cylinder seal cut A
50 Parts trolley not available. B
51 Proximity damage at auto sand filling. B
Hydraulic Oil Consumption High ( main cylinder seal
52 damage) B
53 Tetra spary on single side B
54 Chamber plate worn out B
55 Core box mounting bolt damage. B
56 Para Pour tilting issue in Line 2 B
57 Less air vent in core box B
58 Drum not rotating B
59 Impeller blade worn out B
60 IMPELLER BLADE DAMAGE B
IDENTIFICATION OF WORK RELATED PROBLEMS

61 Sand leakage from hopper B

62 High noise on top. B
63 Plate damage . B
64 Cover shift B
65 Holes on Body B
66 Leakage from shooting hood. B
67 Play in hood. B
68 Crack plate B
69 More number of process As per Control plan C
70 Variation in Shot consumption C
71 Higher Customer end rejections C
72 variation in shot size C
73 Damage on shake out C
74 Variation in Shot Quality. C
75 High shot cost C
 IDENTIFICATION OF WORK RELATED PROBLEMS

Classification Of Problems C- Type

50 Management
Support
45
B Type
40
( Operator +
Middle Support)
35

30

25
49 A- Type
20 (Operator)

15

10 19

5
7
0
A TYPE B TYPE C TYPE
15
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 16
 Study for Theme Selection

External Customer PPM

Target 30000
PPM
50000
44000
41400
40000 37600 38300

30000
PPM

20000

10000

0
Apr'15 May'15 June'15 July'15
Actual Target Linear (Actual)

The External Customer rejection trend is above Target

Study for Theme Selection

Customer Wise - External PPM

70000
60579
60000
48362
50000 44829
39090
40000
PPM

29695
30000 22950 21244 20499
19322 17038
20000
11038 10556 10309
10000 4500
0

PPM

The Highest PPM is for Lotus Plant

 Study for Theme Selection

Customer Rejection Lotus

25%
21.0%
20%

14.6%
15% 13.4%
PPM

11.0%
9.3%
10% 8.0% 7.8%
7.0% 6.1%
5.9%
4.9% 4.6%
5% 3.6% 3.4% 2.9%
2.7% 2.5% 2.1%2.1% 1.8%
1.4%1.3% 1.2% 1.2% 1.0%
0%

PPM

The Highest Rejection is in Renault Diff Case

STUDY FOR THEME SELECTION

Rejection Trend - CRAM

800 120.0%

700 662 98.0% 98.5% 98.9% 99.3% 99.7% 99.9% 100.0%

95.8% 100.0%
88.2%
600 80.3%
80.0%
500
Percentage

553
400 60.0%

43.8%
300
40.0%

200
120 115 20.0%
100
32
9 6 6 6 2 2
0 0.0%
Blow Casting Sand Over Over Unclean Over Sum of Slag Casting
Shrinkage Hole Dent inclusion shotblast Ground Shot Blast AS cast Dent

The Max Contribution is for Shrinkage & Blow Hole 80.3%

Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 21
422
 Impact of Problem

Low
Productivity

Excess Loss of
Power Rejection

High
External
Rework Transpor
Rejection
tation

Low Customer
Morale Complain
More
Customer
Visits
423
Part Details

Sr. No. Description Specification

1 Metal Grade GS 54 OR FCD 500

2 Bunch Weight 32.90 kg
3 Casting Weight 2.65 kg
4 Monthly Demand 4000 nos.
5 Sand Specification GCS : 1.5-2.2 kg/cm2
Compact : 36-44%
Mold Hardness:80~100

6 Line Allocation Line-4

7 Hardness 150-230 BHN
8 Tensile Strength 500 Mpa MIN.
N/mm2
9 Matrix FERRITE 55% Max.
PEARLITE 45 Max..
CARBIDE-NIL%
10 Customer Renault
Pattern Details

SP HALF PP HALF

Pattern Photograph- Before

 Part Chemistry

Chemical % Stage Temp. C

Composition
Bath 1540-1580
C 3.35-3.55
Transfer 1490-1540
Si 2.2 2.4
Pouring 1400-1420
Mn 0.3 0.4
P 0.05 max
Stage Hardness in
S 0.02 max C scale
Cr 0.05 max Mould 80~100
Cu 0.2 0.4
Mg 0.035 0.045
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 27
Defect Concentration

Shrinkage was present on window Junction & near riser neck

Defect Concentration

Shrinkage present on L Junction & Mounting hole threading after

machining
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 30
 Cause & Effect Diagram
Material
Man
Carbon % age
Operator
Team Work Knowledge
Innoculation
Mg % age
Fatigue Operator Skill

MS Addition
Pig Iron
Attentiveness

Shrinkage
Squeeze Pressure Gating Design
GCS
Chamber
Shot Pressure Riser Position
Condition
Riser Position
Gating Design Pouring Time
Gating Design Riser Position

Machine Method
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 32
 5W IH (MAN)
Sr.
WHAT WHY WHERE WHEN WHO How
No.
Lack of knowledge Questionnaire
Operator will lead to process on Melt /
1 Melt / Mould 12th Dec. Moazzam
Knowledge not followed as per Mould Practices
defined process
Low work Review of
proficiency of Operator skill
2 Operator Skill Melt / Mould 17th Dec.. Suraj
operator will be matrix
adverse to results
Loss of attention Check by forced
Operator
3 will cause skip of Melt / Mould 05th Dec. Sanjay entry of NG
Attention
process event
Fatigue will cause Operator
low output and NG performance at
4 Fatigue Melt / Mould 15th Dec. Anil Kr.
results different times
of shift
Non sharing of Operator
issues & problems interactions
5 Team Work Melt / Mould 15th Dec. Vijay
will lead to higher during
rejections problems
VALIDATION OF MAN CAUSE
Operator Operator Skill Fatigue Team Work Attentiveness
Knowledge

34
 5W 1H (MATERIAL)

Sr.
WHAT WHY WHERE WHEN WHO How
No.
Low carbon
Carbon Histogram &
1 percentage will Lab 07th Jan. Moazzam
Percentage Micro Study
lead to shrinkage
Less addition will Charge Recipe
CRCA / MS Iron
2 lead to less nuclei Melting 10th Jan. Suraj monitoring as
Addition
of metal per control plan
Mould strength will Study of
Bentonite / reduce with less Compactability
3 Sand plant 17th Jan. Sanjay
Lustron Addition bentonite & Mould
Strength
Higher Magnesium
Histogram &
4 Magnesium will nodule shape Lab 20th Jan. Jagmendra
Micro Study
and count
 STUDY OF MATERIAL
Micro Structure :
Study of Carbon Percentage :
Lesser Nodule Count
Histogram of % C
NG
9

6
Frequency

0
3.45 3.50 3.55 3.60 3.65
%C

There is lesser nodule count due to high

% age of carbon

36
 STUDY OF MATERIAL
Micro Structure :
Study of Mg Addition : High Porosity
NG
Histogram of % Mg

6
Frequency

2
Relation between Mg vs rejection:
1

0
0.034 0.036 0.038 0.040 0.042 0.044 0.046
% Mg

There is higher porosity due to non

uniform addition of Mg
37
 VALIDATION OF MATERIAL
Study Of Mould Strength
Xbar-R Chart of G.C.S kg/cm2 (1.5-2.2)
1.70 U C L=1.69759

1.68
Sample Mean

_
_
1.66 X=1.66095

1.64

LC L=1.62431
1.62
1 6 11 16 21 26 31 36 41 46
Sample

U C L=0.1148
0.100
Sample Range

0.075
_
0.050 R=0.0503

0.025

0.000 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample

38
 VALIDATION OF MATERIAL
Study Of Compactability :
Xbar-R Chart of Compact. % (36-44)
U C L=41.108
41.0

40.5
Sample Mean

_
_
40.0 X=40

39.5

39.0
LC L=38.892
1 6 11 16 21 26 31 36 41 46
Sample

U C L=3.468
3
Sample Range

2
_
R=1.520
1

0 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample

Bentonite addition is Ok as per Compactability & GCS study 39

 5W 1H (MACHINE)

Sr. WHAT WHY WHERE WHEN WHO How

No.
Mould strength
1 Squeeze Pressure DISA - 1 03rd Dec. Moazzam IMR Chart
variation
Shift in mould due Core Setter
2 Core settling to Misalignment of Tool Room 7th Dec. Neeraj alignment
core report
Uneven filling of
Sand Shooting
3 sand in mould Disa-1 11th Dec. Suraj IMR Chart
pressure
cavities
Main Ram Mould Strength
4 Moulding 22nd Dec. Sanjay IMR Chart
Pressure variation
Pressure leakage
Moulding Prev. Maint.
5 with the chamber Disa - 1 25th Dec. Anil Kr.
Chamber status Check Sheet
wear out
VALIDATION OF MACHINE CAUSE
Study Of Shot Pressure :
I-MR Chart of Shot Pressure
U C L=2.0208
2.0
Individual Value

1.9 _
X=1.8755

1.8

LC L=1.7302
1.7
1 5 9 13 17 21 25 29 33 37
O bser v ation

0.20
U C L=0.1784
0.15
Moving Range

0.10
__
0.05 M R=0.0546

0.00 LC L=0
1 5 9 13 17 21 25 29 33 37
O bser v ation
41
VALIDATION OF MACHINE CAUSE
Study Of Squeeze Pressure :

I-MR Chart of Squeeze Pressure

11.34
U C L=11.3156
11.28
Individual Value

11.22
_
X=11.1868
11.16

11.10
LC L=11.0579
1 5 9 13 17 21 25 29 33 37
O bser v ation

0.16 U C L=0.1583

0.12
Moving Range

0.08
__
M R=0.0485
0.04

0.00 LC L=0
1 5 9 13 17 21 25 29 33 37
O bser v ation
42
VALIDATION OF MACHINE CAUSE
Verification of Chamber Plate

Cleaned Air Vents

Chamber Bracket Dimensions & Wear
Inspection
VALIDATION OF MACHINE CAUSE
Verification of Core mask

Core mask part clearance inspection

Core mask alignment inspection

 5W 1H (METHOD)
Sr. WHAT WHY WHERE WHEN WHO How
No.
Uniform Metal
Magma
1 Patten Gating filling pattern in all Pattern 04th Dec Suraj
Simulation
cavities
Metal feeding to
Magma
2 Riser Volume part in solidification Pattern 11th Dec. Neeraj
Simulation
process
Uneven pouring due Check by stop
3 Pouring time to pouring time Para Pour 14thDec. Moazzam watch and
variation record
High pouring temp.
4 Pouring temp. Pouring station 25th Dec. Suraj IMR Chart
results in cold shut
Mould hardness /
5 GCS strength reduction Sand 17th Jan. Sanjay IMR Chart
due to GCS variation
Higher cooling rate
of metal due to
6 Sand Moisture Mould 24th Jan Anil Kr. IMR Chart
higher moisture
content
 VALIDATION OF METHOD CAUSE
Study Of Pouring Time Operator 1:

I-MR Chart of Pouring time - Rakesh

12.4
U C L=12.3578
Individual Value

12.2

_
12.0 X=12.01

11.8

LC L=11.6622
11.6
1 5 9 13 17 21 25 29 33 37
O bser v ation

U C L=0.4273
0.4
Moving Range

0.3

0.2
__
M R=0.1308
0.1

0.0 LC L=0
1 5 9 13 17 21 25 29 33 37
O bser v ation 46
 VALIDATION OF METHOD CAUSE
Study Of Pouring Time Operator 2:

I-MR Chart of Pouring time - Vikas

12.4 U C L=12.3775
Individual Value

12.2

_
12.0 X=12.0147

11.8

LC L=11.6520
11.6
1 5 9 13 17 21 25 29 33 37
O bser v ation

U C L=0.4457
0.4
Moving Range

0.3

0.2
__
M R=0.1364
0.1

0.0 LC L=0
1 5 9 13 17 21 25 29 33 37
O bser v ation
47
 VALIDATION OF METHOD CAUSE
Study Of Moisture Content :
Xbar-R Chart of Moisture%(3-5)

3.80 U C L=3.8055
Sample Mean

3.75
_
_
X=3.7195
3.70

3.65
LC L=3.6336
1 6 11 16 21 26 31 36 41 46
Sample

0.3
U C L=0.2690
Sample Range

0.2

_
R=0.1179
0.1

0.0 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample

48
 VALIDATION OF METHOD CAUSE
Study Of Pouring Temp.:
Xbar-R Chart of Pouring temp.
1420 U C L=1419.29

1415
Sample Mean

_
_
1410 X=1410.6

1405

LC L=1401.91
1400
1 3 5 7 9 11 13 15 17 19
Sample

16
U C L=15.09

12
Sample Range

8
_
4 R=4.62

0 LC L=0
1 3 5 7 9 11 13 15 17 19
Sample
Cold Shut
Metal temp. is uniform still there is Cold Shut observance on Part
observation in part due to Low temp.
Note : The process was confirming to control standards, still observation of
cold shut Required more study ( Relation of temp. vs cold shut) 49
VALIDATION OF METHOD CAUSE
Relationship between Metal temp. & Cold Shut

TEMP. VS COLD SHUT

4.5

3.5

3
Cold Shut

2.5

1.5

0.5

0
1400 1404 1408 1412 1416 1420 1424 1428 1432 1436
Temp

Cold Shut is high at Low temp.

50
 VALIDATION OF METHOD CAUSE
Study Of Sand Compressive Strength:

Xbar-R Chart of G.C.S kg/cm2 (1.5-2.2)

1.70 U C L=1.69759

1.68
Sample Mean

_
_
1.66 X=1.66095

1.64

LC L=1.62431
1.62
1 6 11 16 21 26 31 36 41 46
Sample

U C L=0.1148
0.100
Sample Range

0.075
_
0.050 R=0.0503

0.025

0.000 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample

51
 VALIDATION OF METHOD CAUSE
Study Of Sand Compactability
Xbar-R Chart of Compact. % (36-44)
U C L=41.108
41.0

40.5
Sample Mean

_
_
40.0 X=40

39.5

39.0
LC L=38.892
1 6 11 16 21 26 31 36 41 46
Sample

U C L=3.468
3
Sample Range

2
_
R=1.520
1

0 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample 52
 VALIDATION OF METHOD CAUSE
Study Of Sand Moisture.:

Xbar-R Chart of Moisture%(3-5)

3.80 U C L=3.8055
Sample Mean

3.75
_
_
X=3.7195
3.70

3.65
LC L=3.6336
1 6 11 16 21 26 31 36 41 46
Sample

0.3
U C L=0.2690
Sample Range

0.2

_
R=0.1179
0.1

0.0 LC L=0
1 6 11 16 21 26 31 36 41 46
Sample
53
 Pattern Study

NG

Riser Volume less

Riser Dia. Less

Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 55
 Part Simulation Study
Part Simulation for Metal flow.:
NG
There is slow
metal fill up in
Upper cavities

56
 Part Simulation Study
2.Porosity

Porosity Simulation:
NG

Porosity observed in this location

 Summary of NG Findings

Mg percentage in metal

Carbon percentage in metal

Slow metal feeding in upper cavities

Low Pouring Temp.

Higher Velocity of Metal Filling

58
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 59
 Action Plan on NG Findings

Sr.
Problem Effect Countermeasure T. Date Resp.
No.

To eliminate the porosity

1 Magnesium addition Maintain Mg content 20th Feb VNS
chunk in part

To increase the nodule

2 Carbon % age in metal Maintain carbon % age 24th Feb. AP
count in micro structure

Increase the temp. of

3 Low Pouring Temp. Elimination of cold Shut 10thFeb. SK
metal

Non uniform metal filling Smooth uniform Increase riser dia. & neck
4 17th Feb. NS
in parts solidification size

Provide runner bar in

High Velocity of metal Squirreling motion of
5 two halves with choke 14th Feb. Anil
Filling in cavities metal inside mould
point in middle

60
Pattern Modification
Before After

A1 A4
2

1 A2 A3

Action performed:-
1. Bottom cavity rear side riser only dia. increased
2. Top cavity rear side Riser dia. & height increased.
3. Riser neck size increased
Pattern Modification

SP HALF PP HALF

Choke Provided in
reducing metal flow in
bottom cavities
SP HALF
Before - After

PP HALF
Before
Modification

PP HALF
SP HALF

After
Modification

Bottom vertical runner bar side change from SP to PP

Comparative Simulation

BEFORE AFTER

Non Uniform Filling of Metal Uniform Filling of Metal 64

Comparative Simulation
BEFORE AFTER

Porosity observed Still Porosity is observed in this location

in this location but porosity intensity reduced which
encourages our modification
 Result

Rejection Trend
30

24.3
25
21
20 17.8
Percentage

15.4 15.7 Not

14.5
15 13.4 Meeting
10.4
10
target

0
July Aug. Sep. Oct. Nov. Dec. Jan. Feb
Series 1
 Introspection

Analyze again Innovate

67
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 68
 Brainstorming
Need to study
cooling Pattern
What Next ? Let us form
further strategy

469
Study of Metal Cooling pattern

Late cooling at L -
Junction Shrinkage Generation

70
Idea Generation

71
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 72
Idea Implementation

Relieve formation in part

Projection on Core to act as

chiller
Prototype Trail

Idea Implementation Modifications :

Core box modification to accommodate projection in core 10th Jan
Mould Modification to fix in the projected core . 10th Jan
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 75
 Regular Implement
Micro Structure :
Study of Mg Addition :
No Porosity
Histogram of Magnesium %

6
Frequency

2
Relation between Mg vs rejection:
1

0
0.030 0.032 0.034 0.036 0.038 0.040
Magnesium %

There is no porosity visible in micro

structure of part due to uniform addition
of Mg
76
 Regular Implement
Study of Carbon Percentage : Micro Structure :
Higher Nodule Count
Histogram of Carbon %

5
Frequency

0
3.46 3.48 3.50 3.52 3.54
Carbon %

There are higher nodules in micro

structure at reduced carbon percentage
and uniform addition

77
 Regular Implement
Study of Pouring Temp.
Xbar-R Chart of Pouring temp. 2
U C L=1436.92
1435
Sample Mean

1430 _
_
X=1427.3
1425

1420
LC L=1417.68
1415
1 3 5 7 9 11 13 15 17 19
Sample

U C L=16.71
16
Sample Range

12

8
_
R=5.11
4

0 LC L=0
1 3 5 7 9 11 13 15 17 19
Sample
78
 Final Result

Rejection Trend
30

24.3
25
21
20 17.8
Percentage

15.4 15.7
14.5
15 13.4
10.4
10 7.7
5.86
4.73
5

0
July Aug. Sep. Oct. Nov. Dec. Jan. Feb Mar Apr Till 15th
May
Series 1
Problem Solving Steps
Identify
the
Problem Select the
Standardize
Problem

Regular Define the

Implement Problem

Prototype Defect
Trial Concentration

Identify
Innovation
Cause

Develop Find Root

Solution Cause
Simulation 80
Method Sheet

81
Method Sheet

82
Method Sheet

83
Control Plan Revision

84
Control Plan Revision

85
 ACTIVITY TIME PLAN

S.No. Phase Schedule Sep Oct Nov Dec Jan Feb Mar Apr

Identification of work related PLAN

1
problems ACTUAL
PLAN
2 Selection of Problem
ACTUAL
PLAN
3 Define the Problem
ACTUAL
PLAN
4 Analyze the Problem
ACTUAL
PLAN
5 Identification of causes
ACTUAL
PLAN
6 Finding out the root causes
ACTUAL
PLAN
7 Data analysis
ACTUAL
PLAN
8 Developing solution
ACTUAL
PLAN
9 Innovation
ACTUAL
Trail implementation & Check PLAN
10
performance ACTUAL
PLAN
11 Regular Implementation
ACTUAL
Follow up / review/ PLAN
12 86
Standardization ACTUAL
Projected Savings

87
Horizontal Deployment

Study & implementation of same

method & countermeasure is in
process for similar part

CD YC5

88
INTENGIBLE BENEFITS

Customer Satisfaction

Lesser Visits to Customer

Volume Share increase

Employee Satisfaction

Morale Increased

Learning to All
89
 SUPPORT TEAMS

PLANT QUALITY
TOOL ROOM
ENGG. CONTROL

THANKS TO SUPPORT TEAMS

90
THANKS !