quality control study on 3 pole mccb mba sip report
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QUALITY CONTROL STUDY ON3 – POLE MCCB PRODUCTION
Under The Guidance Of Mrs. Nisha TaankSenior Manager ,QCDHavells India Ltd, Sahibabad (U.P)
Presented by :Akshay Nair (1527503)Christ University Institute of Management
PRODUCT• MCCB –Moulded Case Circuit Breaker• Project is limited to 3 pole MCCB • Daily production of 200 to 250 No.s
PROBLEM STATEMENT• The present state of product shows lower Cp and
Cpk (process capability) values in many of 3 pole MCCB parameters which is less than the specified 1 and 1.33.
• By virtue of which company is facing high rejection rate & low in customer specification.
PROJECT OBJECTIVE• To study quality control measures by analysing the
3 pole MCCB production process.
• To analyse causes for low Cp and Cpk values.
• To address the issues and necessary improvement required for increasing values of Cp and Cpk .
DATA COLLECTION• After Understanding the production process , 30 random
samples of MCCB is picked up.
• DFSS data is collected for different parametres of MCCB manuualy.
• Data is collected before & after improvements as well.
• Each time 30 random samples are selected.
CALCULATION OF CP & CPK• The number of random samples taken • Upper specification limit (USL)• Lower specification limit(LSL)• Cp = (USL – LSL) ÷ 6σ( Process Variation)• Cpk = Minimum[(USL – X bar)/3σ;(X bar –
LSL)/3σ]
RESULTS OF CP & CPK BEFORE IMPROVEMENT
• DFSS ANALYSIS.xlsx• It shows low Cp & Cpk Values much below the
specified 1 & 1.33.• Many samples were showing high variations.• Fishbone Diagram & Pareto Analysis used to
find out the diff causes for low Cp & Cpk.
FISHBONE DIAGRAM & PARETO ANALYSIS
G frame TP
METHOD MAN
MATERIAL
Fitment not proper
DFS cover
Unskilled Man Power
Problem in Trip Bar
Extra filing in DFS base
Trip bar filing
Delatch
Push button slot dimension
MACHINE
NC
PARETO ANALYSIS
10 5 5 3 2 1 0DL NC DEF BASE DEF COVER OTHERS PBNT OTHERS
0.0
20.0
40.0
60.0
80.0
100.0
120.0
DEFECTS
PERC
ENTA
GE
IMPROVEMENTS TAKEN FOR INCREASING CP & CPK
Step 1 : Cover slot depth in the breakers was less than the required
Action Taken: The Tool has been rectified with specified slot.
Step 2: Another observation in Push to trip spring
Action Taken: New springs has been developed from special springs and the results shown good result.
RESULTS AFTER IMPROVEMENT
• improved data.xlsx• All the parametres show Cp >1.• Cpk values also increased significantly but still short of
specified limit.• Much more improvement is going on from R&D team to
improve Cpk.
12
QUALITY IMPROVEMENT THROUGH 7 QC TOOLS
S.No
Quality Control Tool
Existing
Purpose
Suggestions
1 Control Charts P-Chart
Being used at all the stages and used to calculate the
defect rate of the components as well as process and it is being
updated daily
Using Excel
template for
P-Chart instead of manual filling of
data2 Flow Charts Presen
tIndicate the flow of process
3 Check Sheet Present
It is used while collecting the data from the production
process. 4 Pareto Chart Presen
tWhen analyzing data about the frequency of problems orcauses in a process
5 Fish Bone Diagram(Cause
and Effect Diagram)
Not Existing
Chart which enables to find out the root cause of the problem by analysing each and every possible
opportunity for defect6 Histogram Not
ExistingWhen seeing whether a process change has occurred from onetime period to another.
7 Scatter Diagram
Not Existing
The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them.
Can be used to find the correlation between
Defect rate and various causes for
defects
Quality Improvement through 7 QC Tools Contd..
RECOMMENDATIONS
• Since the defects observed are mainly component defects there is a necessity for a proper inspection of Incoming materials by Internal Quality Control (IQC) Department.
• Raw material should be in proper parameters, it may give law cost and with minimum error’s.
• More number of In-house parts are preferable over vendor.• Usage of Cpk in control charts to understand the variation in
the product parameters.• Scrap should be reduced drastically.
HAVELLS EXPERIENCE• Bridge the gap between theoretical knowledge we possess
with the real time hands-on practical experience at Havells.• Huge importance of “Quality Control Management system”.• Patience to gather the right information, how to organize that
data and use the necessary tools to make the data speak for itself.
• Importance of Customer Satisfaction, Customer Retention, Customer Loyalty.
THANK YOU
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