Training Report

Imperial Auto Industries

Bharat Institute of Technology Submitted to: Manoj Kumar sir Submitted by: Aakash Kumar Manu Mittal sir Roll no.: 1212831001

ABOUT THE COMPANY•Established in year 1969•Largest Integrated manufacturer of ‘Fluid Transmission Products’ (FTP’s)•Eight dedicated manufacturing / assembly plants•3000 employees•Global Presence and Scale

Instruments1.DVC 2 .Radius Gauge(Digital Vernier Calliper)

3. Thread plug gauge 4. Micrometer

5. Height Gauge 6. Coating Gauge

7. Ring Gauge 8. Filler Gauge

Profile Projector

Magnatech - Crack Detector

Project- Problem solving using 7QC Tools

There are 7 tools of quality control. They are as follows:-

Flow Chart Check Sheet Pareto Chart Fishbone Diagram Scatter Diagram Histograms Stratification

1.FLOW CHART Flowchart is a type of diagram that represents

an algorithm or process, showing the steps as boxes of various kinds, and their order by connecting them with arrows.

2.CHECK SHEET The check sheet is a form (document)

used to collect data in real time at the location where the data is generated. The data it captures can be quantitative or qualitative. When the information is quantitative, the check sheet is sometimes called a tally sheet.

3. PARETO CHART A Pareto chart, named after Vilfredo Pareto, is a type of

chart that contains both bars and a line graph, where individual values are represented in descending order by bars, and the cumulative total is represented by the line.

4.Fishbone Diagram ISHIKAWA diagram or cause and effect diagram is named

after its inventor of the tool Kaoru Ishikawa. The cause and effect diagram aptly describes the tool to capture the causes of a particular effect and the relationship between the cause and effect.

5.Scatter Diagrams Scatter diagrams are used to study possible

relationships between the two variables and they do indicate the existence of a relationship, as well as the strength of that relationship

6. Histograms A histogram is a graphical representation of the

distribution of data. A histogram is a representation of tabulated frequencies, shown as adjacent rectangles, erected over discrete intervals (bins), with an area proportional to the frequency of the observations in the interval

22.2 22.4 22.6 22.8 23 23.2 23.4 23.6 23.8 24 More0

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Frequency

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Freq

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7. Stratification Stratification is the separation of data

into categories and is used to identify categories contributing to the problem being solved and the category worth consideration for further investigation

ProjectProject Objective To Reduce the Customer Complaints of

blow hole In Casting Flange . Problem In the existing process the rejection % of

Blow Hole due to porosity which is very high because no proper ventilation of air at the time of pouring molten metal.

PartPart no.- 04FL-GIR-040026-06Part name- FlangeTotal lot size- 750Vendor – Ganesh Raj industries

Use of 7QC tools

Check Sheet

2.Fishbone Diagram

3.Histogram

Why –Why Analysis

W1-Blow holes are generated due to porosity

W2-No proper ventilation

W3-Pattern design not adequate

Action Taken The blow holes in the flanges are coming

due to inadequate pattern design . . A new design/pattern is introduced

according to the desired product needed.

ResultIt can be seen that the rejection is reduced from

30% to 5% from 25 june to 10 july. Cost per piece= Rs.40 Daily cost of lot= Rs400 Cost per month= Rs.12,000 Cost saved per year= Rs. 1,44,000

Thank You