TQM PROJECT DEEPAK SPINNERS LIMITED BADDI (H.P.) Group No:- 3
Feb 24, 2016
TQM PROJECT
DEEPAK SPINNERS LIMITEDBADDI (H.P.)
Group No:- 3
To increase the utilization of ringframes to 92 %.
TQM PROJECT TITLE
.
TQM PROJECT NEED (REASON TO CHOOSE THE PROJECT)
Utilization is one of the major factor for survival of any industry specially Textile. It affects over all profitability
of the Mill.
UTILIZATION IS LIFE LINE OF THE MILL
TO IMPROVE IT
UTILIZATION IS LIFE LINE
JOIN HANDS
.
FACILITATOR,TEAM LEADER & MEMBERS
Facilitator : Syt. Shantanuji Daga(Arrangements & Guide lines)Team Leader : Sh. Sudesh Tiwari (Guide lines)Members : Sh. V.B. Shrivastava(Participation- B.S.) : Sh. S.K. Thakur (Participation- B.S.) : Sh. H.S. Sharma (Data collection -”-) : Sh. M.K. Mishra (Data collection -”-)
.
ATTENDENCE SHEETS.N
. DATE Topics S.Tiwari V.B.S. S.K.T. H.S.S. M.K.M.1 20.07.11 TQM Team formation P P P P P
2 25.07.11 Problem & mission statement P P P P P
3 29.07.11 Project disscussion P P P P P4 02.08.11 Flow diagram P p p P P
5 05.08.11 Brain storming P p p P P
6 09.08.11 Evaluation of brain storming P p p P P
7 17.08.11 Cause & effect diagram p p p P P
8 02.09.11 Data collection & data analysis p p p P P
9 16.09.11 Test theory p p p P P
10 30.09.11 Data analysis of test theories p p p P P
11 19.10.11 Project review p p p P P
Utilization is low i.e. 77% since last 12 months, leading to a production loss of 5.5T/day or Rs.25 Lac/month.
PROBLEM STATEMENT
To improve average Ring Frame utilization from 77% to 92% by
30TH Nov.2011 to save the amount of Rs.300Lacs/annum.
MISSION STATEMENT
Data for validation of problem statement
Month Utilization L/SPower
Fail Prog.Unav.Fiber
changeProgram change Total
June-10 59.30 31.53 1.44 4.37 2.72 0.64 100July-10 70.09 19.91 1.24 4.50 3.30 0.96 100Aug-10 82.22 6.78 1.33 4.82 3.86 0.99 100Sep-10 83.59 5.80 1.49 4.98 3.45 0.69 100Oct-10 83.23 7.80 0.53 4.16 3.50 0.78 100Nov-10 77.81 14.49 0.29 4.01 3.05 0.35 100Dec-10 83.22 7.91 0.51 4.61 3.00 0.75 100
Jan-11 81.83 9.25 0.68 4.41 3.06 0.77 100Feb-11 84.97 5.85 0.97 4.50 2.93 0.78 100Mar-11 78.11 14.02 0.81 3.65 2.61 0.80 100Apr-11 70.87 21.27 1.02 3.74 2.31 0.79 100
May-11 70.87 21.27 1.02 3.83 2.29 0.72 100June-11 67.42 25.59 1.70 2.76 1.93 0.60 100July-11 71.79 20.77 1.93 2.43 2.42 0.66 100
Average 76.09 15.16 1.07 4.06 2.89 0.73
Validation of problem Statement
Detail of factors & lossesS.N. Description %age
1 Labour Short 14.152 Prog. Not available 3.713 Fiber Change 2.684 Programme Change 0.785 G.P.F. 1.49
Total loss 22.81Production loss (Per Day) 5.5 T
Loss in Rs. (Profit@Rs15/kg) 25 Lac/M
QC TOOLS USED
Brain storming Flow diagram Cause & effect diagram Pareto
• .
DIAGNOSTIC JOURNEY
Take issue R/M as per program
Start
Single Ply
End
Yes
Mixing laid
Spinning Process
Packed
Processed for
Double
NO
Inspected
OK
Not OKProcessed to rectify
fault
OKDispatch to
customer
BRAIN STORMING
.
REFLECTED POINT OF BRAIN STORMING
1. On roll labour shortage 2. Labour negligent.3. In disciplined labour.4. Late reporting & early leaving labour.5. Taking out lighter doffs & delaying doffs.6. Working idle spindles.7. Poor training of workers.8. Poor water quality.9. Scaling problem.10.High moisture in the raw material.11.Higher breakage rate.12.Higher cuts/ faults at autoconer.13.Sub standard recipe.14.Scheduled machine spares delayed.15.Sub standard spares.16.Machine setting disturbed.17.Frequent program change.18.High turnover of skilled labour.19.Frequent setup change.20.Communication gap
METHOD MAN
MACHINE MATERIAL
CommunicationPoor
Production Planning
High Turn Over of Skilled Worker
Indiscipline
On Roll labor shortage
High moisture in raw material
Poor Water Quality
Frequent Set Up Change
Change In Programme
Poor Training
High Work Load
Miscommunication
Delay
Idle Spindle
Deliberately Slow Down M/C
36 Hour & more Duty
Not Habitual of Night Duty Late Reporting
Early Leaving
Non Standard spare
Delayed Supply
Poor WorkingScaling Problem
Poor Working
Scaling
Cause & Effect Diagram
LOW R/F UTILIZATION
Delay Doff
Light Doff
Negligency
Lack of ownership at
shop floorImproper Production
Monitoring
Poor charge
Sub Standard RecipeHigh Waste Generation
Poor Working
High Breakage
High A/C Cuts
M/C Spares
Automation System Failure
M/C Setting Disturb
Production Loss
Low Ringframe Utilization
JUN 10
JUL 1
0
AUG 10
SEP 10
OCT 10
NOV 10
DEC 10
JAN 11
FEB 11
MAR 11
APR 11
MAY 11
JUN 11
JUL
11
AUG 11
SEP 11
OCT 11
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
L/SProg.Unav.Fiber ChangeG.P.F.Prog.Change
GROUPED BAR GRAPHFACTORS AFFECTING UTILIZATION
JUN 10
JUL 10
AUG 10
SEP 10
OCT 10
NOV 10
DEC 10
JAN 11
FEB 11
MAR 11
APR 11
MAY 11
JUN 11
JUL 11
AUG 11
SEP 11
OCT 11
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
45.00
Prog.Change
G.P.F.
Fiber Change
Prog.Unav.
L/S
STACKED BAR GRAPHFACTORS AFFECTING UTILIZATION
• .• .
PARETO ANALYSIS
L/S Prog. N/A Fiber Change
G.P.F. Recipe Change
0100200300400500600700800900
1000
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
freq. Cum.%age
USEFUL MANY
REASONS FOR LOW UTILIZATION
Freq
uenc
y
Reason
Cum. %
age
VITAL FEW
REMEDIAL JOURNEY
PRIORITAZATION OF CAUSES SELECTED FROM BRAINSTORMING & GRAPH
Labour short Program not available
REMEDY OF CAUSE (TO MINIMIZE L/S)
1. Facilities of workers should be increased & should be reviewed from time to time.
2. Revise wages annually according to industry standard.3. Strength of female workers should be maintained at 10 % of workforce. 4. Transport facility should be provided for commute of female workers. 5. Search & recruit workers from non – traditional areas such as Nepal &
Assam. 6. Implement incentive schemes to increase daily attendance of workers
and discourage them from long leaves.7. Incentive schemes for maintaining on roll are implemented for jobbers. 8. Hostel facility for female workers is provided & new hostel is under
construction. 9. Various motivational activities have been started.
REMEDY OF CAUSEFollowing points are under consideration for
remedy of other causes like non availability of Program, recipe change & Program change.
1. To build customers of big houses to get large orders.
2. Collaborate with purchase department in order to reduce losses due to change in recipe.
3. To search new stations for marketing to achieve higher realization.
Validation of gains (After)
Month UTI. L/S G.PF.Prog.Unav.
Fiber change
Prog.change
Aug-11 81.67 7.74 3.02 3.67 2.88 1.02 100
Sep-11 88.61 1.63 3.45 3.05 2.60 0.66 100
Oct-11 88.95 0.56 3.50 3.62 2.58 0.79 100
Nov-11 89.83 1.73 2.20 3.01 2.48 0.75 100
Average 87.27 2.92 3.04 3.34 2.64 0.81 100
GAIN AFTER IMPLEMENTATION
JUN 10 JUL 10 AUG 10
SEP 10 OCT 10 NOV 10
DEC 10 JAN 11 FEB 11 MAR 11
APR 11 MAY 11
JUN 11 JUL 11 AUG 11
SEP 11 OCT 1150.00
60.00
70.00
80.00
90.00
100.00Utilization
Utilizationmonth & year
utili
zatio
n %
age
Avg 77.19% before implementation
Avg 86.41% after implementation
Validation of gains(Aug to Nov. 2010 & 2011)
Utilization L/S0
10
20
30
40
50
60
70
80
90
100
Aug-10 to Nov-10Aug-11 to Nov-11
HOLDING THE GAINS1. Worker’s retention to be increased by 10% and above.2. Facilities like residence , hostel will be completed till
31st of march.3. Various motivational incentives to maintain on roll
strength will be continued.4. Inflow of workers from other areas like Nepal will be
continued & new areas like Assam, W.B. will be explored.
5. Strength of female workers 7 to 10% will be maintained.
6. Transport facility will be continued & maintained.7. Trainee strength will be maintained according to
turnover , it would be continuously monitored & and new recruitments will be done regularly.
8. Extra precaution will be taken during festival season & peak labour shortage period.