A CASE STUDY OF FUSE HEAD REJECTIONS AT

M/S PREMIER EXPLOSIVES, HYD

T.SATYANARAYANA, PScO,

V.L.RAJA, PScO

&

QA TEAM OF PREMIER EXPLOSIVES

PROJECT CHARTER

Project TitleFuse Head RejectionTeam MembersMr. T. Satyanarayana, PScO, Mr V.L.Raja PScO.Mr. P. Satyanarayana Mgr (QA), PREMIER EXPLOSIVES.ChampionMr.Y.Durga Prasad Rao.Cell No. 9849645419email:dp@pelgel.com.Master Black beltMr.T.M.Venkatesan Email:tmvenkatesan@yahoo.co.inStart date15-07-2008Target completion date20-09-2008Tools UsedDMAIC / SIPOCExpected project savingRs.30000 direct + Rs.15000 indirect per monthSupport Group members 1.K.S.Reddy 2.Osman 3.K.Sunith 4.S.ChandraiahProject DescriptionYield improvement during manufacturing of Fuse HeadResponse Variable (Y)Fuse head rejection at various stages, mainly due to variation in resistanceData Sources M/s. Premier Explosives, HyderabadCurrent Status:Present sigma level2.73 sigmaObjectivesBase lineGOALCurrent Status12%2Cp0.172

PROBLEM:

DURING PROCESS AUDITING IT WAS OBSERVED THAT LARGE NUMBER OF FUSE HEADS WERE BEING REJECTED AT VARIOUS MANUFACTURING STAGES.

TIN COATING

COMB CUTTING

PVC FITTERING

HEAD FRAME MOUNTING

INSPECTION

TRANSPORTATION

ASSEMBLING

DIPPING

AUTO SORTING

ACCEPTED

REJECTED

DESTRUCTION

SOLDERING

PROCESS MAP

Make issue voucher

Material receipt

to plant

6 months data

MONTHGross ProductionRejection% of rejectionMARCH-08363052238960010.73FEBRUARY-08318689035833011.24JANUARY-0828912272403008.89DECEMBER-0745555883673008.0NOVEMBER-07504597154610010.8OCTOBER-07433082573920017.06834Chart110.731239199211.24387725968.8897019528.062625505210.82249580917.0683414823month% of rejectionfuse head rejection due to resistance variationPARETOSl.noNo.of samples inspectedNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxWire shortBends1302081703230211013043303171702430505160453060138126308011803730603180383041195109307191102103010122061130401276112301304121013302012313143070415131530403144516303022203173020221141830207182119301307901203050520002130501012212230200280023303022401243010325012530509150130263020820003027308012001302830601280430293010151400303030208150530313020818023032301022223303330130980030343020519043035306041910303630401213013037302071902303830304220130393030121500304030301970130Total120019142856192378% of rejection15.91666666670.333333333323.7551.58333333331.91666666676.5100nos%Nil Resistance19115.9166666667Low Resistnce40.3333333333High Resistance28523.75short231.9166666667Bends786.5Good items in rejection box61951.58333333333PARETOGood items in rejection box0.5158333333High Resistance0.7533333333Nil Resistance0.9125Bends0.9775short0.9966666667Low Resistnce11111DataParetoSamplesDataPercentPareto Analysis61928519178234measure dataDatem/c noProductionrejectionNo. samples inspected from rejectionNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxshortbendsmeasuement (sample taken from rejection)15-May136856350030208170330237192350030211013043033678035003031717023016-May19594750305051604301.741.712.831.981.731.821.891.921.721.722.4501.71.71.71.4201.701.811.861.741.992.531.632.3504.032.30294351000306013812302.3302.361.685.443.262.672.532.672.292.3502.952.642.392.373.072.882.432.6702.294.5702.3003.172.047.5339521800308011803301.681.744.462.392.6902.372.532.756.0702.422.612.373.311.7302.451.932.5601.83001.632.3504.032.3017-May1181282000306031803300001.862.622.342.332.51.921.851.72.322.031.742.411.842.3401.791.861.891.942.392.341.7301.7101.711.742187281500304119510302.453.0602.332.813.04002.994.212.623.32.385.422.014.022.862.902.662.441.572.442.912.342.412.72.325.223.7139326800307191102302.572.672.5101.8601.674.4102.48002.571.961.662.421.691.672.382.451.7101.782.461.791.771.891.3601.744924810003010122063019-May218624150030401276130318654150030130412103041865416003020123133020-May118801500307041513302962060030403144530318610150030302220330B219045100030202211430318681150030207182130C11916312003013079013031885615003050520003021-May130501012213023020028003033030224013043010325013023-May30509150130302082000303080120013024-May306012804303010151400303020815053026-May3020818023030102222330301309800303020519043027-May306041910303040121301303020719023028-May303042201303030121500303030197013012001914285619237812003565953175015.920.3323.7551.581.926.50100.00base dataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275245980692742630Monthrejection%productionrejectionDPUDPMOsigmalevel1March-0810.7336305223896000.10726828.09799802893.452Feb-0811.2431868903583300.11228109.69314912033.523Jan-088.8938482733421000.08922224.25488004623.54Dec-078.0645555883673000.08120156.56376300933.655nov-0710.8250459715461000.10827056.23952258153.46Oct-0717.0743308257392000.17142670.85370570273.2MONTHMARCH-08FEBRUARY-08JANUARY-08DECEMBER-07NOVEMBER-07OCTOBER-07PRODUCTION363052231868903848273455558850459714330825REJECTION389600358330342100367300546100739200DPU0.1070.1120.0890.0810.1080.171DPMO26828.128109.722224.320156.627056.242670.9SIGMA LEVEL3.453.43.53.553.413.2resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.791.82.52.134.652.262.321.981.891.862.262.031.91.771.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.951.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05base datamonth% of rejectionfuse head rejection due to resistance variationRR STUDYR-R STUDY DATAlineaty studyPartOperatorResponsepatrReferanceresponse111.7611.61.59111.7511.61.66212.2411.61.81212.2311.61.74312.2311.61.59312.2111.61.61412.1611.61.61412.1911.61.6511.7511.61.61511.7511.61.65613.3111.61.63613.3111.61.62711.8521.81.8711.8421.81.881021.82.0681021.81.97911.7821.81.9911.7821.81.831012.0321.81.841012.0421.81.81121.7521.81.79121.7521.81.81222.2321.81.81222.2321.81.8322.22322.11322.22322.13422.19322.12422.19322.11521.75322.13521.75322.12623.31322.13623.3322.1721.84322.1721.84322.13820322.13820322.09921.7842.22.21921.7742.22.211022.0342.22.241022.0342.22.22131.7642.22.25131.7642.22.26232.2442.22.23232.2342.22.28332.2242.22.26332.2142.22.23432.1942.22.35432.1942.22.3531.7552.42.42531.7652.42.41633.3152.42.43633.352.42.46731.8552.42.41731.8452.42.4483052.42.4183052.42.47931.7852.42.46931.7852.42.41032.0452.42.411032.0352.42.41LINEARITYPatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponse11.61.5921.81.8322.1142.22.2152.42.4211.61.6621.81.8322.1342.22.2152.42.4111.61.8121.82.06322.1242.22.2452.42.4311.61.7421.81.97322.1142.22.2252.42.4611.61.5921.81.9322.1342.22.2552.42.4111.61.6121.81.83322.1242.22.2652.42.4411.61.6121.81.84322.1342.22.2352.42.4111.61.621.81.81322.142.22.2852.42.4711.61.6121.81.79322.142.22.2652.42.4611.61.6521.81.81322.1342.22.2352.42.411.61.6321.81.81322.1342.22.3552.42.4111.61.6221.81.8322.0942.22.352.42.41R-R STUDYPart12345678910operatorobservationA11.762.242.232.161.753.311.8501.782.0421.752.232.212.191.753.311.8401.782.03B11.752.232.222.191.753.311.8401.782.0321.752.232.222.191.753.31.8401.772.03C11.762.242.222.191.753.311.8501.782.0421.762.232.212.191.763.31.8401.782.03

CALCULATION

Total Opportunities of error (OFE) =1

No. of .Defects 389600

DPU = ---------------------= ------------ = 0.107Total numbers inspected 3630522

DPU X 10000000.107 x 1000000

DPMO =--------------------- = --------------------- = 107312 OFE 1

Present sigma Level2.75 (as per chart)

Specification width 2.4-1.60.8

Cp =------------------------ = --------- = ------ = 0.17

Process width 4.65-04.65

(max count-min.count)

Shift =Mean target= 2.05-2.0 = 0.05

Shift0.05

K =---------=--------= 0.1250.5specification width0.5 x 0.8

Cpk =Cp x (1-k) =0.17(1-0.125) = 0.15

PARETOSl.noNo.of samples inspectedNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxWire shortBends1302081703230211013043303171702430505160453060138126308011803730603180383041195109307191102103010122061130401276112301304121013302012313143070415131530403144516303022203173020221141830207182119301307901203050520002130501012212230200280023303022401243010325012530509150130263020820003027308012001302830601280430293010151400303030208150530313020818023032301022223303330130980030343020519043035306041910303630401213013037302071902303830304220130393030121500304030301970130Total120019142856192378% of rejection15.91666666670.333333333323.7551.58333333331.91666666676.5100nos%Nil Resistance19115.9166666667Low Resistnce40.3333333333High Resistance28523.75short231.9166666667Bends786.5Good items in rejection box61951.58333333333PARETOGood items in rejection box0.5158333333High Resistance0.7533333333Nil Resistance0.9125Bends0.9775short0.9966666667Low Resistnce11111DataParetoSamplesDataPercentPareto Analysis61928519178234measure dataDatem/c noProductionrejectionNo. samples inspected from rejectionNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxshortbendsmeasuement (sample taken from rejection)15-May136856350030208170330237192350030211013043033678035003031717023016-May19594750305051604301.741.712.831.981.731.821.891.921.721.722.4501.71.71.71.4201.701.811.861.741.992.531.632.3504.032.30294351000306013812302.3302.361.685.443.262.672.532.672.292.3502.952.642.392.373.072.882.432.6702.294.5702.3003.172.047.5339521800308011803301.681.744.462.392.6902.372.532.756.0702.422.612.373.311.7302.451.932.5601.83001.632.3504.032.3017-May1181282000306031803300001.862.622.342.332.51.921.851.72.322.031.742.411.842.3401.791.861.891.942.392.341.7301.7101.711.742187281500304119510302.453.0602.332.813.04002.994.212.623.32.385.422.014.022.862.902.662.441.572.442.912.342.412.72.325.223.7139326800307191102302.572.672.5101.8601.674.4102.48002.571.961.662.421.691.672.382.451.7101.782.461.791.771.891.3601.744924810003010122063019-May218624150030401276130318654150030130412103041865416003020123133020-May118801500307041513302962060030403144530318610150030302220330B219045100030202211430318681150030207182130C11916312003013079013031885615003050520003021-May130501012213023020028003033030224013043010325013023-May30509150130302082000303080120013024-May306012804303010151400303020815053026-May3020818023030102222330301309800303020519043027-May306041910303040121301303020719023028-May303042201303030121500303030197013012001914285619237812003565953175015.920.3323.7551.581.926.50100.00base dataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275245980692742630Monthrejection%productionrejectionDPUDPMOsigmalevel1March-0810.7336305223896000.107107312.42Feb-0811.2431868903583300.112112438.83Jan-088.8938482733421000.08988897.04Dec-078.0645555883673000.08180626.35nov-0710.8250459715461000.108108225.06Oct-0717.0743308257392000.171170683.4MONTHMARCH-08FEBRUARY-08JANUARY-08DECEMBER-07NOVEMBER-07OCTOBER-07PRODUCTION363052231868903848273455558850459714330825REJECTION389600358330342100367300546100739200DPU0.1070.1120.0890.0810.1080.171DPMO107312.4112438.888897.080626.3108225.0170683.4SIGMA LEVEL2.752.72.852.92.752.45resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.791.82.52.134.652.262.321.981.891.862.262.031.91.771.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.951.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05base datano.of monthsrejection rate% OF REJECTIONRR STUDY1no.of samplesresistancefuse head resistanceR-R STUDY DATAlineaty studyPartOperatorResponsepatrReferanceresponse111.7611.61.59111.7511.61.66212.2411.61.81212.2311.61.74312.2311.61.59312.2111.61.61412.1611.61.61412.1911.61.6511.7511.61.61511.7511.61.65613.3111.61.63613.3111.61.62711.8521.81.8711.8421.81.881021.82.0681021.81.97911.7821.81.9911.7821.81.831012.0321.81.841012.0421.81.81121.7521.81.79121.7521.81.81222.2321.81.81222.2321.81.8322.22322.11322.22322.13422.19322.12422.19322.11521.75322.13521.75322.12623.31322.13623.3322.1721.84322.1721.84322.13820322.13820322.09921.7842.22.21921.7742.22.211022.0342.22.241022.0342.22.22131.7642.22.25131.7642.22.26232.2442.22.23232.2342.22.28332.2242.22.26332.2142.22.23432.1942.22.35432.1942.22.3531.7552.42.42531.7652.42.41633.3152.42.43633.352.42.46731.8552.42.41731.8452.42.4483052.42.4183052.42.47931.7852.42.46931.7852.42.41032.0452.42.411032.0352.42.41LINEARITYPatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponse11.61.5921.81.8322.1142.22.2152.42.4211.61.6621.81.8322.1342.22.2152.42.4111.61.8121.82.06322.1242.22.2452.42.4311.61.7421.81.97322.1142.22.2252.42.4611.61.5921.81.9322.1342.22.2552.42.4111.61.6121.81.83322.1242.22.2652.42.4411.61.6121.81.84322.1342.22.2352.42.4111.61.621.81.81322.142.22.2852.42.4711.61.6121.81.79322.142.22.2652.42.4611.61.6521.81.81322.1342.22.2352.42.411.61.6321.81.81322.1342.22.3552.42.4111.61.6221.81.8322.0942.22.352.42.41R-R STUDYPart12345678910operatorobservationA11.762.242.232.161.753.311.8501.782.0421.752.232.212.191.753.311.8401.782.03B11.752.232.222.191.753.311.8401.782.0321.752.232.222.191.753.31.8401.772.03C11.762.242.222.191.753.311.8501.782.0421.762.232.212.191.763.31.8401.782.03

Fuse Head resistance data for existing process (Before Dipping)

Sheet1Machine wise data at B3 buildingDateshiftHFM m/c NoProductionsample testedRejection30/04/2008A126730 nos110 nos8 nos1.861.761.812.021.861.771.751.81.841.773.921.761.771.781.851.812.131.931.762.232.41.741.761.741.831.771.771.771.962.311.841.762.162.231.791.821.851.761.781.791.8522.11.861.941.771.91.92.631.892.062.012.22.41.761.821.762.071.851.851.891.931.771.961.91.961.761.862.352.021.791.832.131.791.812.062.371.852.91.891.822.521.761.991.841.92.071.872.881.851.761.7622.141.831.781.921.771.761.912.771.771.881.7721.81.91.921.87DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos2.111.771.691.672.142.091.671.731.852.171.991.691.911.641.851.641.681.72.022.121.742.071.71.642.371.861.71.661.741.961.721.781.671.841.671.751.671.661.671.861.652.011.831.942.22.031.711.961.631.941.731.831.671.851.732.781.651.621.961.82.161.722.071.821.631.741.681.831.711.731.641.791.671.831.641.661.751.751.751.671.72.021.881.661.812.252.12.072.021.771.691.641.651.81.721.641.841.791.761.721.831.641.851.791.861.661.661.781.771.7DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos1.961.881.911.971.881.941.881.91.811.931.791.871.91.931.811.762.011.92.021.761.881.91.771.881.731.881.961.821.891.9821.871.891.862.032.011.941.951.851.871.871.841.751.941.891.952.051.841.861.961.771.781.881.881.871.92.012.081.981.961.81.931.751.911.841.971.971.82.171.961.941.921.771.781.851.751.971.811.881.761.892.1221.852.041.972.122.1721.991.752.151.981.931.821.81.8821.87Sheet2date 30.04.2008 A shiftmachine no 1machine no 3machine no 4HFM M/C-1B3TOTAL PRODUCINOREJECTION1.862.111.96AUTO SORTING M/C NOC103.921.991.792.41.741.881.841.7221.851.651.872.061.731.771.892.161.81.791.641.941.81.71.891.851.691.751.911.831.881.761.771.871.761.691.91.742.071.871.761.781.8422.011.782.011.831.931.931.721.921.831.792.1222.022.151.761.641.912.771.641.91.811.691.771.771.911.891.761.71.752.161.671.882.11.831.752.21.671.771.772.0722.131.671.982.41.881.971.761.651.931.771.851.882.021.671.861.781.641.941.741.641.882.231.841.911.861.941.782.481.851.851.961.821.931.791.831.881.761.661.8121.81.731.881.792.031.862.141.891.851.851.871.832.371.841.791.671.851.942.22.041.761.731.821.91.631.941.811.641.761.991.811.882.141.722.011.771.861.951.772.091.91.811.641.971.771.861.751.821.751.971.772.031.81.822.781.881.961.742.012.061.661.961.842.251.941.831.642.0521.662.011.751.671.972.131.681.971.771.72.121.851.671.881.91.711.91.761.651.91.761.681.822.371.751.951.92.11.841.781.842.081.81.661.81.81.731.811.931.72.171.771.6621.761.661.811.91.962.022.071.621.891.861.831.851.851.751.862.072.071.981.921.792.171.91.781.881.841.8521.762.021.871.961.741.931.781.671.762.631.631.981.851.961.872.351.711.962.91.751.961.872.021.961.771.761.761.921.771.991.772.172.232.122.311.961.791.861.891.941.851.82.021.731.891.672.881.771.761.721.871.7Sheet2Sheet3Chart21.863.922.41.841.852.061.891.791.81.851.911.761.761.741.7622.011.931.8321.762.771.811.771.762.162.12.21.772.132.41.761.772.021.781.742.231.862.481.961.791.7621.881.861.851.831.791.941.761.91.811.992.141.771.771.811.771.821.771.821.962.061.841.8321.752.131.771.851.91.761.762.371.91.781.81.81.931.771.761.92.071.861.852.071.921.91.841.761.961.782.631.852.352.91.871.771.921.772.232.311.791.891.852.021.892.881.761.87Sheet1Machine wise data at B3 buildingDateshiftHFM m/c NoProductionsample testedRejection30/04/2008A126730 nos110 nos8 nos1.861.761.812.021.861.771.751.81.841.773.921.761.771.781.851.812.131.931.762.232.41.741.761.741.831.771.771.771.962.311.841.762.162.231.791.821.851.761.781.791.8522.11.861.941.771.91.92.631.892.062.012.22.41.761.821.762.071.851.851.891.931.771.961.91.961.761.862.352.021.791.832.131.791.812.062.371.852.91.891.822.521.761.991.841.92.071.872.881.851.761.7622.141.831.781.921.771.761.912.771.771.881.7721.81.91.921.87DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos2.111.771.691.672.142.091.671.731.852.171.991.691.911.641.851.641.681.72.022.121.742.071.71.642.371.861.71.661.741.961.721.781.671.841.671.751.671.661.671.861.652.011.831.942.22.031.711.961.631.941.731.831.671.851.732.781.651.621.961.82.161.722.071.821.631.741.681.831.711.731.641.791.671.831.641.661.751.751.751.671.72.021.881.661.812.252.12.072.021.771.691.641.651.81.721.641.841.791.761.721.831.641.851.791.861.661.661.781.771.7DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos1.961.881.911.971.881.941.881.91.811.931.791.871.91.931.811.762.011.92.021.761.881.91.771.881.731.881.961.821.891.9821.871.891.862.032.011.941.951.851.871.871.841.751.941.891.952.051.841.861.961.771.781.881.881.871.92.012.081.981.961.81.931.751.911.841.971.971.82.171.961.941.921.771.781.851.751.971.811.881.761.892.1221.852.041.972.122.1721.991.752.151.981.931.821.81.8821.87Sheet2date 30.04.2008 A shiftmachine no 1machine no 3machine no 4HFM M/C-1B3TOTAL PRODUCINOREJECTION1.862.111.96AUTO SORTING M/C NOC103.921.991.792.41.741.881.841.7221.851.651.872.061.731.771.892.161.81.791.641.941.81.71.891.851.691.751.911.831.881.761.771.871.761.691.91.742.071.871.761.781.8422.011.782.011.831.931.931.721.921.831.792.1222.022.151.761.641.912.771.641.91.811.691.771.771.911.891.761.71.752.161.671.882.11.831.752.21.671.771.772.0722.131.671.982.41.881.971.761.651.931.771.851.882.021.671.861.781.641.941.741.641.882.231.841.911.861.941.782.481.851.851.961.821.931.791.831.881.761.661.8121.81.731.881.792.031.862.141.891.851.851.871.832.371.841.791.671.851.942.22.041.761.731.821.91.631.941.811.641.761.991.811.882.141.722.011.771.861.951.772.091.91.811.641.971.771.861.751.821.751.971.772.031.81.822.781.881.961.742.012.061.661.961.842.251.941.831.642.0521.662.011.751.671.972.131.681.971.771.72.121.851.671.881.91.711.91.761.651.91.761.681.822.371.751.951.92.11.841.781.842.081.81.661.81.81.731.811.931.72.171.771.6621.761.661.811.91.962.022.071.621.891.861.831.851.851.751.862.072.071.981.921.792.171.91.781.881.841.8521.762.021.871.961.741.931.781.671.762.631.631.981.851.961.872.351.711.962.91.751.961.872.021.961.771.761.761.921.771.991.772.172.232.122.311.961.791.861.891.941.851.82.021.731.891.672.881.771.761.721.871.7Sheet2Sheet3

Fuse Head resistance data for existing process(after dipping)

PROJECT CHARTERPROJECT CHARTERProject CodePEL/01Project Titleminimize the Fuse head rejectionBlack belt : P.Satyanarayana 9948053141championY.Durga Prasad Rao9849645419Master Black beltT.M.VenkatesanStart date27-04-2008Target completion date27-08-2008Expected project savingRs 30000 per monthSuport Group members (yellow/green belts)1. K.S.Reddy 2. Osman3. K.Sunitha 4. S.ChandraiahProblem statementMore fuse heads rejected Due to Resistance variationGoal and ObjectivesElementsBase lineGOALEntitlementReduce the rejection12%5%7%Rolled Throughput Yield(RTP)CpBusiness case / Stratagic alignmentTo getting more production by reducing rejectionImpactTo develop Industry Health and Financial conditiondataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275Monthrejection%dpudpmosigmalevel1March-0812.3636305224486920.12430897.20982271973.452Feb-0812.6631868004035960.12731661.54135810223.523Jan-089.5338482733666740.09523820.68527882513.54Dec-079.2845555884226080.09323191.73726860293.655nov-0711.8050459715955780.11829507.60121292813.46Oct-0717.8343308257722750.17844580.13196100053.2datano.of monthsrejection rate% OF REJECTIONSheet3resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.79cp1.14285714290.71.82.52.131.791.762.812.812.262.091.841.794.714.6501.811.761.792.031.763.371.781.782.261.781.771.831.81.91.941.971.811.842.321.884.711.812.51.771.91.871.772.31.981.673.121.922.131.951.951.782.062.41.894.611.741.874.652.42.081.782.41.881.862.631.841.782.262.391.771.772.351.972.262.011.681.792.321.91.91.454.31.912.031.7801.681.982.171.981.771.981.91.91.771.751.811.891.921.761.771.921.751.771.911.822.41.8602.381.771.831.91.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.451.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05Sheet3no.of samplesresistancefuse head resistance

Process capability refers to the ability of a process to produce a defect-free product or service. Various indicators are used-some address overall performance, some address potential performance.

PROCESS DATAPLANTB3C10LSL1.61.6USL2.42.4N110100SD0.300.74Cp0.440.18Cpk0.390.16621.txt

CAPA for C1xdcCAPA for C1;; HMF V1.24 TEXT;; (Microsoft Win32 Intel 386) HOOPS 4.50-11 I.M. 3.00-11(Selectability "windows=off,geometry=on")(Visibility "on")(Color_By_Index "Geometry,Face Contrast" 1)(Color_By_Index "Window" 0)(Window_Frame "off")(Window -1 1 -1 1)(Camera (0 0 -5) (0 0 0) (0 1 0) 2 2 "Stretched");; (Driver_Options "disable input,subscreen=(-0.999902,-0.232323,-0.99987,-0.30;; 9765),no update interrupts,use window id=131968")(Edge_Pattern "---")(Edge_Weight 1)(Face_Pattern "solid")(Heuristics "no related selection limit")(Line_Pattern "---")(Line_Weight 1)(Marker_Size 0.421875)(Marker_Symbol ".")(Text_Font "name=arial-gdi-vector,no transforms,rotation=follow path")(User_Options "mtb aspect ratio=0.675953,graphicsversion=6,worksheettitle=\"Worksheet 1\",optiplot=0,builtin=0,statguideid=14001,toplayer=0,angle=0,arrowdir=0,arrowstyle=0,polygon=0,isdata=0,textfollowpath=1,ldfill=0,solidfill=0,3d=0,usebitmap=0,canbrush=0,brushrows=0,light 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POSSIBLE REASONS FOR REJECTION

TIN COATING QUALITY ON BRASS STRIP

IMPROPER PVC FITTERING

NICHROME WIRE GAUGE VARIATION

VARIATION IN HAMMERING LOAD

VARIATION IN BUTT WELDING CURRENT

IMPROPER TRANSPORTATION AND ASSEMBLING

IMPROPER DIPPING

AUTO SORTING MACHINE ERROR

MEASURE

PHASE

IF YOU WANT TO IMPROVE YOU

SHOULD KNOW HOW TO MEASURE

IF YOU KNOW HOW TO MEASURE

YOU KNOW SOMETHING

OR ELSE

YOU DONT KNOW ANY THING

Lord Kelvin

Auto sorting machine rejection

PARETOSl.noNo.of samples inspectedNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxWire shortBends1302081703230211013043303171702430505160453060138126308011803730603180383041195109307191102103010122061130401276112301304121013302012313143070415131530403144516303022203173020221141830207182119301307901203050520002130501012212230200280023303022401243010325012530509150130263020820003027308012001302830601280430293010151400303030208150530313020818023032301022223303330130980030343020519043035306041910303630401213013037302071902303830304220130393030121500304030301970130Total120019142856192378% of rejection15.91666666670.333333333323.7551.58333333331.91666666676.5100nos%Nil Resistance12817.78Low Resistnce40.56High Resistance15020.83short207.36Bends532.78Good items in rejection box36550.693PARETOGood items in rejection box0.5069High Resistance0.7152Nil Resistance0.893short0.9666Bends0.9944Low Resistnce11111DataParetoDataPercentPareto Analysis50.6920.8317.787.362.780.56measure dataDatem/c noProductionrejectionNo. samples inspected from rejectionNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxshortbendsmeasuement (sample taken from rejection)15-May136856350030208170330237192350030211013043033678035003031717023016-May19594750305051604301.741.712.831.981.731.821.891.921.721.722.4501.71.71.71.4201.701.811.861.741.992.531.632.3504.032.30294351000306013812302.3302.361.685.443.262.672.532.672.292.3502.952.642.392.373.072.882.432.6702.294.5702.3003.172.047.5339521800308011803301.681.744.462.392.6902.372.532.756.0702.422.612.373.311.7302.451.932.5601.83001.632.3504.032.3017-May1181282000306031803300001.862.622.342.332.51.921.851.72.322.031.742.411.842.3401.791.861.891.942.392.341.7301.7101.711.742187281500304119510302.453.0602.332.813.04002.994.212.623.32.385.422.014.022.862.902.662.441.572.442.912.342.412.72.325.223.7139326800307191102302.572.672.5101.8601.674.4102.48002.571.961.662.421.691.672.382.451.7101.782.461.791.771.891.3601.744924810003010122063019-May218624150030401276130318654150030130412103041865416003020123133020-May118801500307041513302962060030403144530318610150030302220330B219045100030202211430318681150030207182130C11916312003013079013031885615003050520003021-May130501012213023020028003033030224013043010325013023-May30509150130302082000303080120013024-May306012804303010151400303020815053026-May3020818023030102222330301309800303020519043027-May306041910303040121301303020719023028-May303042201303030121500303030197013012001914285619237812003565953175015.920.3323.7551.581.926.50100.00base dataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275245980692742630Monthrejection%productionrejectionDPUDPMOsigmalevel1March-0810.7336305223896000.10726828.09799802893.452Feb-0811.2431868903583300.11228109.69314912033.523Jan-088.8938482733421000.08922224.25488004623.54Dec-078.0645555883673000.08120156.56376300933.655nov-0710.8250459715461000.10827056.23952258153.46Oct-0717.0743308257392000.17142670.85370570273.2MONTHMARCH-08FEBRUARY-08JANUARY-08DECEMBER-07NOVEMBER-07OCTOBER-07PRODUCTION363052231868903848273455558850459714330825REJECTION389600358330342100367300546100739200DPU0.1070.1120.0890.0810.1080.171DPMO26828.128109.722224.320156.627056.242670.9SIGMA LEVEL3.453.43.53.553.413.2resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.791.82.52.134.652.262.321.981.891.862.262.031.91.771.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.951.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05base datano.of monthsrejection rate% OF REJECTIONRR STUDY1no.of samplesresistancefuse head resistanceR-R STUDY DATAlineaty studyPartOperatorResponsepatrReferanceresponse111.7611.61.59111.7511.61.66212.2411.61.81212.2311.61.74312.2311.61.59312.2111.61.61412.1611.61.61412.1911.61.6511.7511.61.61511.7511.61.65613.3111.61.63613.3111.61.62711.8521.81.8711.8421.81.881021.82.0681021.81.97911.7821.81.9911.7821.81.831012.0321.81.841012.0421.81.81121.7521.81.79121.7521.81.81222.2321.81.81222.2321.81.8322.22322.11322.22322.13422.19322.12422.19322.11521.75322.13521.75322.12623.31322.13623.3322.1721.84322.1721.84322.13820322.13820322.09921.7842.22.21921.7742.22.211022.0342.22.241022.0342.22.22131.7642.22.25131.7642.22.26232.2442.22.23232.2342.22.28332.2242.22.26332.2142.22.23432.1942.22.35432.1942.22.3531.7552.42.42531.7652.42.41633.3152.42.43633.352.42.46731.8552.42.41731.8452.42.4483052.42.4183052.42.47931.7852.42.46931.7852.42.41032.0452.42.411032.0352.42.41LINEARITYPatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponse11.61.5921.81.8322.1142.22.2152.42.4211.61.6621.81.8322.1342.22.2152.42.4111.61.8121.82.06322.1242.22.2452.42.4311.61.7421.81.97322.1142.22.2252.42.4611.61.5921.81.9322.1342.22.2552.42.4111.61.6121.81.83322.1242.22.2652.42.4411.61.6121.81.84322.1342.22.2352.42.4111.61.621.81.81322.142.22.2852.42.4711.61.6121.81.79322.142.22.2652.42.4611.61.6521.81.81322.1342.22.2352.42.411.61.6321.81.81322.1342.22.3552.42.4111.61.6221.81.8322.0942.22.352.42.41R-R STUDYPart12345678910operatorobservationA11.762.242.232.161.753.311.8501.782.0421.752.232.212.191.753.311.8401.782.03B11.752.232.222.191.753.311.8401.782.0321.752.232.222.191.753.31.8401.772.03C11.762.242.222.191.753.311.8501.782.0421.762.232.212.191.763.31.8401.782.03

Category wise rejection

Specification: 1.6 2.4 ohm

Inference

Due to high resistance rejection is 23.7%.

with in the 0.1 variation in resistance it contributes 7.1% and with in the 0.2 variation it is nearly 11%

To avoid this rejection, the existing specification (1.6 to2.4 ohms) should be change 1.7 to2.1 ohms at initial stage (B3)

Type of rejectionNo.of sample inspected fromAuto sorting m/c rejectionRejection Qty(Nos)% of rejectionOverall %(12%)Resistance 2.40 2.50Resistance 1.50 1.60Nil resistance 120019115.91.9------Low resistance40.330.03------High resistance28523.752.85 86 (7.1%)44 (3.66%)Good in rejection(m/c error)61951.586.18------Bends786.50.78------Short231.90.23------

OBSERVATIONS

1.Auto sorting M/c not segregating properly

due to this, rejection is 52%

2.Due to high resistance rejection is 23.7%

3. Due to Nil resistance rejection is 15.9%

Total = 91%

So need to concentrate on these three problems as they contribute 91 % of the total rejection

Sheet1Welcome to the FREEQUALITY.ORG Pareto Analysis Tool* The Pareto Analysis Tool will evaluate user defined data and plot a graphof the top 10 data values and the associated Pareto line.*Step 1:Enter the number of data points to analyze:Note: Up to 100 data points allowed.Designed & Created by: Jeffrey B. Everett, Ralph M. ImmelQuality and Manufacturing Management Program, Class of 2001The Pennsylvania State UniversityStartPareto Definition and ImplementationChart1&APage &PSheet2fuse head rejectionWELCOME to the Data Entry PageRESULTDATAPercentCumulative PercentageSTEP 2:Good items in rejection box50.690.50690.5069High Resistance20.830.20830.7152Please enter data values in Column B and press Calculate ButtonNil Resistance17.780.17780.893below to generate Pareto Chart with top 10 values.short7.360.07360.9666Bends2.780.02780.9944Low Resistnce0.560.0056101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101100CalculateReturn to MainPareto DefinitionPareto ExplainedThe Pareto diagram is utilized to reveal the most significant factors contributing to the data.Return to MainPareto Cumulative Effect LineData Histogram showing ten most significant samples

Pareto Analysis

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Sample8

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Pareto

Pareto Analysis

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Sample11Sample10

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DataPareto

MBD00377A3A.xlsChart1Sample40.1315789474Sample80.2315789474Sample70.3263157895Sample30.4157894737Sample60.5Sample50.5789473684Sample120.6578947368Sample20.7315789474Sample110.8052631579Sample100.8736842105DataParetoSamplesDataPercentPareto Analysis25191817161515141413Sheet1Welcome to the FREEQUALITY.ORG Pareto Analysis Tool* The Pareto Analysis Tool will evaluate user defined data and plot a graphof the top 10 data values and the associated Pareto line.*Step 1:Enter the number of data points to analyze:Note: Up to 100 data points allowed.Designed & Created by: Jeffrey B. Everett, Ralph M. ImmelQuality and Manufacturing Management Program, Class of 2001The Pennsylvania State UniversityStartPareto Definition and ImplementationSheet2Project 1 DataWELCOME to the Data Entry PageSAMPLEDATAPercentCumulative PercentageSTEP 2:Sample4250.13157894740.1315789474Sample8190.10.2315789474Please enter data values in Column B and press Calculate ButtonSample7180.09473684210.3263157895below to generate Pareto Chart with top 10 values.Sample3170.08947368420.4157894737Sample6160.08421052630.5Sample5150.07894736840.5789473684Sample12150.07894736840.6578947368Sample2140.07368421050.7315789474Sample11140.07368421050.8052631579Sample10130.06842105260.8736842105Sample1120.06315789470.9368421053Sample9120.0631578947101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101010101190CalculateReturn to MainPareto DefinitionPareto ExplainedThe Pareto diagram is utilized to reveal the most significant factors contributing to the data.Return to MainPareto DefinitionSample40.1315789474Sample80.2315789474Sample70.3263157895Sample30.4157894737Sample60.5Sample50.5789473684Sample120.6578947368Sample20.7315789474Sample110.8052631579Sample100.8736842105DataParetoSamplesDataPercentPareto Analysis25191817161515141413Pareto Cumulative Effect LineData Histogram showing ten most significant samplesChart1Good items in rejection box0.5158333333High Resistance0.7533333333Nil Resistance0.9125Bends0.9775short0.9966666667Low Resistnce11111DataParetototal Samples 1200 nosDataPercentPareto Analysis61928519178234PARETOSl.noNo.of samples inspectedNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxWire shortBends1302081703230211013043303171702430505160453060138126308011803730603180383041195109307191102103010122061130401276112301304121013302012313143070415131530403144516303022203173020221141830207182119301307901203050520002130501012212230200280023303022401243010325012530509150130263020820003027308012001302830601280430293010151400303030208150530313020818023032301022223303330130980030343020519043035306041910303630401213013037302071902303830304220130393030121500304030301970130Total120019142856192378% of rejection15.91666666670.333333333323.7551.58333333331.91666666676.5100nos%Nil Resistance19115.9166666667Low Resistnce40.3333333333High Resistance28523.75short231.9166666667Bends786.5Good items in rejection box61951.58333333333PARETOGood items in rejection box0.5158333333High Resistance0.7533333333Nil Resistance0.9125Bends0.9775short0.9966666667Low Resistnce11111DataParetoSamplesDataPercentPareto Analysis61928519178234measure dataDatem/c noProductionrejectionNo. samples inspected from rejectionNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxshortbendsmeasuement (sample taken from rejection)15-May136856350030208170330237192350030211013043033678035003031717023016-May19594750305051604301.741.712.831.981.731.821.891.921.721.722.4501.71.71.71.4201.701.811.861.741.992.531.632.3504.032.30294351000306013812302.3302.361.685.443.262.672.532.672.292.3502.952.642.392.373.072.882.432.6702.294.5702.3003.172.047.5339521800308011803301.681.744.462.392.6902.372.532.756.0702.422.612.373.311.7302.451.932.5601.83001.632.3504.032.3017-May1181282000306031803300001.862.622.342.332.51.921.851.72.322.031.742.411.842.3401.791.861.891.942.392.341.7301.7101.711.742187281500304119510302.453.0602.332.813.04002.994.212.623.32.385.422.014.022.862.902.662.441.572.442.912.342.412.72.325.223.7139326800307191102302.572.672.5101.8601.674.4102.48002.571.961.662.421.691.672.382.451.7101.782.461.791.771.891.3601.744924810003010122063019-May218624150030401276130318654150030130412103041865416003020123133020-May118801500307041513302962060030403144530318610150030302220330B219045100030202211430318681150030207182130C11916312003013079013031885615003050520003021-May130501012213023020028003033030224013043010325013023-May30509150130302082000303080120013024-May306012804303010151400303020815053026-May3020818023030102222330301309800303020519043027-May306041910303040121301303020719023028-May303042201303030121500303030197013012001914285619237812003565953175015.920.3323.7551.581.926.50100.00base dataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275245980692742630Monthrejection%productionrejectionDPUDPMOsigmalevel1March-0810.7336305223896000.10726828.09799802893.452Feb-0811.2431868903583300.11228109.69314912033.523Jan-088.8938482733421000.08922224.25488004623.54Dec-078.0645555883673000.08120156.56376300933.655nov-0710.8250459715461000.10827056.23952258153.46Oct-0717.0743308257392000.17142670.85370570273.2MONTHMARCH-08FEBRUARY-08JANUARY-08DECEMBER-07NOVEMBER-07OCTOBER-07PRODUCTION363052231868903848273455558850459714330825REJECTION389600358330342100367300546100739200DPU0.1070.1120.0890.0810.1080.171DPMO26828.128109.722224.320156.627056.242670.9SIGMA LEVEL3.453.43.53.553.413.2resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.791.82.52.134.652.262.321.981.891.862.262.031.91.771.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.951.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05base data000000no.of monthsrejection rate% OF REJECTIONRR STUDY1no.of samplesresistancefuse head resistanceR-R STUDY DATAlineaty studyPartOperatorResponsepatrReferanceresponse111.7611.61.59111.7511.61.66212.2411.61.81212.2311.61.74312.2311.61.59312.2111.61.61412.1611.61.61412.1911.61.6511.7511.61.61511.7511.61.65613.3111.61.63613.3111.61.62711.8521.81.8711.8421.81.881021.82.0681021.81.97911.7821.81.9911.7821.81.831012.0321.81.841012.0421.81.81121.7521.81.79121.7521.81.81222.2321.81.81222.2321.81.8322.22322.11322.22322.13422.19322.12422.19322.11521.75322.13521.75322.12623.31322.13623.3322.1721.84322.1721.84322.13820322.13820322.09921.7842.22.21921.7742.22.211022.0342.22.241022.0342.22.22131.7642.22.25131.7642.22.26232.2442.22.23232.2342.22.28332.2242.22.26332.2142.22.23432.1942.22.35432.1942.22.3531.7552.42.42531.7652.42.41633.3152.42.43633.352.42.46731.8552.42.41731.8452.42.4483052.42.4183052.42.47931.7852.42.46931.7852.42.41032.0452.42.411032.0352.42.41LINEARITYPatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponse11.61.5921.81.8322.1142.22.2152.42.4211.61.6621.81.8322.1342.22.2152.42.4111.61.8121.82.06322.1242.22.2452.42.4311.61.7421.81.97322.1142.22.2252.42.4611.61.5921.81.9322.1342.22.2552.42.4111.61.6121.81.83322.1242.22.2652.42.4411.61.6121.81.84322.1342.22.2352.42.4111.61.621.81.81322.142.22.2852.42.4711.61.6121.81.79322.142.22.2652.42.4611.61.6521.81.81322.1342.22.2352.42.411.61.6321.81.81322.1342.22.3552.42.4111.61.6221.81.8322.0942.22.352.42.41R-R STUDYPart12345678910operatorobservationA11.762.242.232.161.753.311.8501.782.0421.752.232.212.191.753.311.8401.782.03B11.752.232.222.191.753.311.8401.782.0321.752.232.222.191.753.31.8401.772.03C11.762.242.222.191.753.311.8501.782.0421.762.232.212.191.763.31.8401.782.03

MACHINE WISE REJECTION

Machine certifying efficiency need to improve

P

E

L

M/c NONo. of fuse heads collected from RejectionGood fuse headMachine certifying efficiency 130015349230013256330014153430017741

HEAD

FRAME

MOUNT

ING

Nichrome Wire

feeding

Hammering load

Butt welding

Current

Improper

feeding

Low current

High current

High load

Low load

Area

Process

step

CTQs

Effect

Nil Resistance

High Resistance

Low Resistance /

Nil Resistance

High Resistance

Low Resistance

H

A

N

D

L

I

N

G

Comb

cutting

Trays

keeping

Comb strip

Accumulation

Tray hit

Nil Resistance

Bends

Stratification of quality characteristics

ASSEMBLING

AUTO

SORTING

Comb strip feeding

Resistance setting

cutting

Shutter functioning

Improper

feeding

Cutter sharpness

Improper setting

Instrument error

Improper cleaning

Of shutters

Comb setting

Improper inserting

Of combs

Bends

Nil Resistance

Bends

Bends

Wrong

segregation

(Good in rejection

fuse heads )

Area

Process

step

CTQs

Effect

MEASUREMENT
SYSTEM
ANALYSIS

Few causes are identified during measure phase which are more

effecting in the fuse head rejection.

Causes for high resistance

1.Nicrome wire resistance.

2.Butt welding current.

3.Hammering load.

4.auto sorting machine speed.

5.contacting area at the time of fuse head cutting.

Causes for good fuse heads falling in rejection

In the part of analyze phase

we are analyzing above factors one by one

High resistance :

Due to this nearly 23.7% fuse head rejected in total rejection (2.85% in overall)

The nichrome wire quality is more involving in this case.

Specification 1425 ohms to1450 ohms /one meter

It need to be changed to 1300 to 1350 ohm/meter

Trails under process with nicrome wire resistance 1300 to 1350 ohm/meter

Inference

Resistance /meter 1300 to 1350 ohms giving good fuse head resistance

At present our specification is 1425 to 1450 ohm/meter.

It need to changes to 1300 to 1350 ohm/meter

Required resistance

NICHROME WIRE RESISTANCE

Our specification

giving range

Chart1106610661066106610661066106610661066106699099099099099099099099099099099699699699699699699699699699613901390139013901390139013901390139013901363136313631363136313631363136313631363131813181318131813181318131813181318131813351335133513351335133513351335133513351441144114411441144114411441144114411441147314731473147314731473147314731473147314821482148214821482148214821482148214821498149814981498149814981498149814981498ohm/fuse headresistance ohm / meterfuse head resiatance1.421.441.381.41.41.411.421.41.41.41.421.41.391.361.361.351.381.361.391.391.311.331.311.321.331.331.321.331.331.22.032.021.92.021.981.962.151.932.162.162.021.931.981.991.931.931.962.011.91.951.81.791.941.781.761.81.91.891.751.821.841.831.851.811.851.771.81.821.921.962.212.232.232.292.212.232.292.262.262.262.092.072.112.072.12.072.132.082.222.112.152.022.082.162.092.082.062.082.042.122.282.052.192.152.122.132.082.322.122.22Sheet1Machine wise data at B3 buildingDateshiftHFM m/c NoProductionsample testedRejection30/04/2008A126730 nos110 nos8 nos1.861.761.812.021.861.771.751.81.841.773.921.761.771.781.851.812.131.931.762.232.41.741.761.741.831.771.771.771.962.311.841.762.162.231.791.821.851.761.781.791.8522.11.861.941.771.91.92.631.892.062.012.22.41.761.821.762.071.851.85THANKING YOU1.891.931.771.961.91.961.761.862.352.021.791.832.131.791.812.062.371.852.91.891.822.521.761.991.841.92.071.872.881.851.761.7622.141.831.781.921.771.761.912.771.771.881.7721.81.91.921.87DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos2.111.771.691.672.142.091.671.731.852.171.991.691.911.641.851.641.681.72.022.121.742.071.71.642.371.861.71.661.741.961.721.781.671.841.671.751.671.661.671.861.652.011.831.942.22.031.711.961.631.941.731.831.671.851.732.781.651.621.961.82.161.722.071.821.631.741.681.831.711.731.641.791.671.831.641.661.751.751.751.671.72.021.881.661.812.252.12.072.021.771.691.641.651.81.721.641.841.791.761.721.831.641.851.791.861.661.661.781.771.7DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos1.961.881.911.971.881.941.881.91.811.931.791.871.91.931.811.762.011.92.021.761.881.91.771.881.731.881.961.821.891.9821.871.891.862.032.011.941.951.851.871.871.841.751.941.891.952.051.841.861.961.771.781.881.881.871.92.012.081.981.961.81.931.751.911.841.971.971.82.171.961.941.921.771.781.851.751.971.811.881.761.892.1221.852.041.972.122.1721.991.752.151.981.931.821.81.8821.87date 27-05-2008HFM -2 date 27-05-2008HFM -4 date 27-05-2008HFM NO-17.00am9.30am12.30pm7.00am9.30am12.30pm7.00am9.30am12.30pm11.862.091.912.281.942.112.122.191.8621.9222.122.042.32.121.982.221.8531.922.021.9831.9822.0131.962.021.8541.92.092.0242.152.091.9842.042.091.8851.9222.2651.991.962.0252.212.371.961.862.04262.061.852.2562.082.221.9371.892.032.1372.041.92.13722.121.8681.921.991.9781.842.211.9381.952.11.8691.852.12.1792.071.812.1892.022.022.01101.851.92.07102.022.212.02102.121.962.02date 28-05-2008HFM -2 date 28-05-2008HFM -4 date 28-05-20087.00am9.30am12.30pm11.972.011.91.851.791.811.862.122.0621.82.51.91.891.841.871.762.161.8931.872.261.922.091.781.931.842.121.941.842.131.91.841.821.811.792.422.1351.832.811.892.071.741.821.952.012.0761.832.341.831.851.861.871.872.191.9671.862.162.151.951.771.812.0422.3881.872.051.961.911.821.851.831.81.9391.962.42.081.91.761.82.032.21.95101.82.271.832.021.791.971.792.421.98date 30-05-2008date 30-05-2008date30-05-20087.00am1.9312.30pm7.00am9.30am12.30pm7.00am9.30am12.30pm2.151.942.071.911.831.771.992.011.922.191.922.171.91.81.822.021.92.112.491.892.341.921.81.752.031.91.952.241.852.341.831.821.82.0221.812.191.852.271.951.831.81.861.921.982.111.952.271.961.811.831.931.91.932.052.222.181.981.761.791.961.931.852.121.912.231.891.861.751.91.931.812.191.922.441.781.851.772.351.8522.071.952.31.841.831.792.091.881.9Sheet2date 30.04.2008 A shiftmachine no 1machine no 3machine no 4HFM M/C-1B3TOTAL PRODUCINOREJECTION1.862.111.96AUTO SORTING M/C NOC103.921.991.792.41.741.881.841.7221.851.651.872.061.731.771.892.161.81.791.641.941.81.71.891.851.691.751.911.831.881.761.771.871.761.691.91.742.071.871.761.781.8422.011.782.011.831.931.931.721.921.831.792.1222.022.151.761.641.912.771.641.91.811.691.771.771.911.891.761.71.752.161.671.882.11.831.752.21.671.771.772.0722.131.671.982.41.881.971.761.651.931.771.851.882.021.671.861.781.641.941.741.641.882.231.841.911.861.941.782.481.851.851.961.821.931.791.831.881.761.661.8121.81.731.881.792.031.862.141.891.851.851.871.832.371.841.791.671.851.942.22.041.761.731.821.91.631.941.811.641.761.991.811.882.141.722.011.771.861.951.772.091.91.811.641.971.771.861.751.821.751.971.772.031.81.822.781.881.961.742.012.061.661.961.842.251.941.831.642.0521.662.011.751.671.972.131.681.971.771.72.121.851.671.881.91.711.91.761.651.91.761.681.822.371.751.951.92.11.841.781.842.081.81.661.81.81.731.811.931.72.171.771.6621.761.661.811.91.962.022.071.621.891.861.831.851.851.751.862.072.071.981.921.792.171.91.781.881.841.8521.762.021.871.961.741.931.781.671.762.631.631.981.851.961.872.351.711.962.91.751.961.872.021.961.771.761.761.921.771.991.772.172.232.122.311.961.791.861.891.941.851.82.021.731.891.672.881.771.761.721.871.7Sheet200000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000qc reportRESISTANCE DATA (VENDOR REPORT,OUR TESTING REPORT AND FUSE HEAD RESISTANCE)DateName of the partyBobbin.NoMeasured test reportvendor test reportmeasured while processavgMinMaxbobbin resr/mmlowhigh12/12/071107210871.521.671.59510721.0721.521.672110111091.51.691.59511011.1011.51.6926/11/07Natinal enterprises1142413831.862.22.0314241.4241.862.22133513251.772.252.0113351.3351.772.253134313311.752.181.96513431.3431.752.184134913221.932.051.9913491.3491.932.055133513281.741.971.85513351.3351.741.976132913101.772.181.97513291.3291.772.187131813131.752.061.90513181.3181.752.0623/11/07Natinal enterprises1139014051.92.162.0313901.391.92.162136313911.92.122.0113631.3631.92.123137013911.811.931.8713701.371.811.934137613981.832.121.97513761.3761.832.125138014051.812.011.9113801.381.812.016135813961.842.292.06513581.3581.842.297136613911.781.941.8613661.3661.781.9431/7/07Kakathiya alloys1133013541.882.011.94513301.331.882.012133213491.832.031.9313321.3321.832.033133013481.892.061.97513301.331.892.064131413221.851.971.9113141.3141.851.975132513441.881.991.93513251.3251.881.9912/7/07Kakathiya alloys1137213891.922.041.9813721.3721.922.042136913891.881.951.91513691.3691.881.9527/6/07Natinal enterprises1144112812.182.322.2514411.4412.182.322147312402.052.222.13514731.4732.052.223146712602.12.182.1414671.4672.12.18ohm/meterohm/fuse head10661.4210661.4410661.3810661.410661.410661.4110661.4210661.410661.410661.49901.429901.49901.399901.369901.369901.359901.389901.369901.399901.399961.319961.339961.319961.329961.339961.339961.329961.339961.339961.213902.0313902.0213901.913902.0213901.9813901.9613902.1513901.9313902.1613902.1613632.0213631.9313631.9813631.9913631.9313631.9313631.9613632.0113631.913631.9513181.813181.7913181.9413181.7813181.7613181.813181.913181.8913181.7513181.8213351.8413351.8313351.8513351.8113351.8513351.7713351.813351.8213351.9213351.9614412.2114412.2314412.2314412.2914412.2114412.2314412.2914412.2614412.2614412.2614732.0914732.0714732.1114732.0714732.114732.0714732.1314732.0814732.2214732.1114822.1514822.0214822.0814822.1614822.0914822.0814822.0614822.0814822.0414822.1214982.2814982.0514982.1914982.1514982.1214982.1314982.0814982.3214982.1214982.22qc report1.0721.521.671.1011.51.691.4241.862.21.3351.772.251.3431.752.181.3491.932.051.3351.741.971.3291.772.181.3181.752.061.391.92.161.3631.92.121.371.811.931.3761.832.121.381.812.011.3581.842.291.3661.781.941.331.882.011.3321.832.031.331.892.061.3141.851.971.3251.881.991.3721.922.041.3691.881.951.4412.182.321.4732.052.221.4672.12.18MSA00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000ohm/fuse headresistance ohm / meterfuse head resiatance00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000gageaiaglinearity studyPartOperatorresponsepartmasterresponse112.0511.51.51112.0711.51.5211.8511.51.51211.8511.51.5311.7811.51.5311.7711.51.49411.8711.51.5411.9211.51.5511.9811.51.5151211.51.5611.9311.51.5611.9311.51.5711.9421.81.82711.9821.81.82811.921.81.82811.9221.81.81912.1321.81.82912.1221.81.811011.8221.81.811011.8321.81.81122.1721.81.81122.1621.81.81221.9321.81.81221.9521.81.81PartOperatorresponse321.79322.11111.82321.79322.11111.89422322.12111.9422322.11212.02522.01322.1212.07522.05322.11212.07621.91322.12312.48621.91322.11312.54721.99322.11312.64721.99322.11121.94821.93322.11121.96821.93322.11121.96922.1642.22.22222.1922.1542.22.22222.021021.8242.22.22222.11021.8242.22.22322.54132.242.22.22322.76132.242.22.22323.23231.9642.22.21131.99231.9442.22.22132.07331.842.22.22132.09331.8142.22.22232.1443242.22.23232.2143242.22.22232.17532.0452.42.42332.66532.0452.42.42332.55631.9152.42.42332.91631.952.42.42731.9952.42.4273252.42.41831.9452.42.42831.9552.42.42932.1652.42.42932.1652.42.421031.8352.42.421031.8252.42.42GAUGE R-R STUDYpart12345678910operatorno.observationA12.051.851.781.871.981.931.941.92.131.8222.071.851.771.9221.931.981.922.121.83B12.171.931.7922.011.911.991.932.161.8222.161.951.7922.051.911.991.932.151.82C12.21.961.822.041.911.991.942.161.8322.21.941.8122.041.921.952.161.82GAUGE LINEARITY STUDYpartmaster valueresponsepartmaster valueresponsepartmaster valueresponsepartmaster valueresponsepartmaster valueresponse11.51.5121.81.82322.1142.22.2252.42.4211.51.521.81.82322.1142.22.2252.42.4211.51.5121.81.82322.1242.22.2252.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.521.81.82322.142.22.2252.42.4211.51.4921.81.81322.1142.22.2252.42.4111.51.521.81.81322.1242.22.2152.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.5121.81.81322.1142.22.2252.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.521.81.81322.1142.22.2352.42.4211.51.521.81.81322.1142.22.2252.42.42

P

E

L

Nichrome wire resistance 1310 ohm/meter result

After Dipping

Before dipping

53%rejection due to 1.5 to 1.6 resistance.

operator setting nearest lower specification limit

Chart11.881.81.871.671.832.11.81.961.921.861.651.751.82.111.761.951.91.961.821.681.811.91.841.741.891.841.921.82.021.81.791.781.861.661.881.91.831.991.71.751.621.791.631.761.781.881.921.781.671.76Sheet1Machine wise data at B3 buildingDateshiftHFM m/c NoProductionsample testedRejection30/04/2008A126730 nos110 nos8 nos1.861.761.812.021.861.771.751.81.841.773.921.761.771.781.851.812.131.931.762.232.41.741.761.741.831.771.771.771.962.311.841.762.162.231.791.821.851.761.7851.791.8522.11.861.941.771.91.92.631.892.062.012.22.41.761.821.762.071.851.85THANKING YOU1.891.931.771.961.91.961.761.862.352.021.791.832.131.791.812.062.371.852.91.891.822.521.761.991.841.92.071.872.881.851.761.7622.141.831.781.921.771.761.912.771.771.881.7721.81.91.921.87DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos2.111.771.691.672.142.091.671.731.852.171.991.691.911.641.851.641.681.72.022.121.742.071.71.642.371.861.71.661.741.961.721.781.671.841.671.751.671.661.671.861.652.011.831.942.22.031.711.961.631.941.731.831.671.851.732.781.651.621.961.82.161.722.071.821.631.741.681.831.711.731.641.791.671.831.641.661.751.751.751.671.72.021.881.661.812.252.12.072.021.771.691.641.651.81.721.641.841.791.761.721.831.641.851.791.861.661.661.781.771.7DateshiftHFM m/c NoProductionsample testedRejection30/04/2008A326730 nos110 nos8 nos1.961.881.911.971.881.941.881.91.811.931.791.871.91.931.811.762.011.92.021.761.881.91.771.881.731.881.961.821.891.9821.871.891.862.032.011.941.951.851.871.871.841.751.941.891.952.051.841.861.961.771.781.881.881.871.92.012.081.981.961.81.931.751.911.841.971.971.82.171.961.941.921.771.781.851.751.971.811.881.761.892.1221.852.041.972.122.1721.991.752.151.981.931.821.81.8821.87date 27-05-2008HFM -2 date 27-05-2008HFM -4 date 27-05-2008HFM NO-17.00am9.30am12.30pm7.00am9.30am12.30pm7.00am9.30am12.30pm11.862.091.912.281.942.112.122.191.8621.9222.122.042.32.121.982.221.8531.922.021.9831.9822.0131.962.021.8541.92.092.0242.152.091.9842.042.091.8851.9222.2651.991.962.0252.212.371.961.862.04262.061.852.2562.082.221.9371.892.032.1372.041.92.13722.121.8681.921.991.9781.842.211.9381.952.11.8691.852.12.1792.071.812.1892.022.022.01101.851.92.07102.022.212.02102.121.962.02date 28-05-2008HFM -2 date 28-05-2008HFM -4 date 28-05-20087.00am9.30am12.30pm11.972.011.91.851.791.811.862.122.0621.82.51.91.891.841.871.762.161.8931.872.261.922.091.781.931.842.121.941.842.131.91.841.821.811.792.422.1351.832.811.892.071.741.821.952.012.0761.832.341.831.851.861.871.872.191.9671.862.162.151.951.771.812.0422.3881.872.051.961.911.821.851.831.81.9391.962.42.081.91.761.82.032.21.95101.82.271.832.021.791.971.792.421.98date 30-05-2008date 30-05-2008date30-05-20087.00am1.9312.30pm7.00am9.30am12.30pm7.00am9.30am12.30pm2.151.942.071.911.831.771.992.011.922.191.922.171.91.81.822.021.92.112.491.892.341.921.81.752.031.91.952.241.852.341.831.821.82.0221.812.191.852.271.951.831.81.861.921.982.111.952.271.961.811.831.931.91.932.052.222.181.981.761.791.961.931.852.121.912.231.891.861.751.91.931.812.191.922.441.781.851.772.351.8522.071.952.31.841.831.792.091.881.9Sheet2date 30.04.2008 A shiftmachine no 1machine no 3machine no 4HFM M/C-1B3TOTAL PRODUCINOREJECTION1.862.111.96AUTO SORTING M/C NOC103.921.991.792.41.741.881.841.7221.851.651.872.061.731.771.892.161.81.791.641.941.81.71.891.851.691.751.911.831.881.761.771.871.761.691.91.742.071.871.761.781.8422.011.782.011.831.931.931.721.921.831.792.1222.022.151.761.641.912.771.641.91.811.691.771.771.911.891.761.71.752.161.671.882.11.831.752.21.671.771.772.0722.131.671.982.41.881.971.761.651.931.771.851.882.021.671.861.781.641.941.741.641.882.231.841.911.861.941.782.481.851.851.961.821.931.791.831.881.761.661.8121.81.731.881.792.031.862.141.891.851.851.871.832.371.841.791.671.851.942.22.041.761.731.821.91.631.941.811.641.761.991.811.882.141.722.011.771.861.951.772.091.91.811.641.971.771.861.751.821.751.971.772.031.81.822.781.881.961.742.012.061.661.961.842.251.941.831.642.0521.662.011.751.671.972.131.681.971.771.72.121.851.671.881.91.711.91.761.651.91.761.681.822.371.751.951.92.11.841.781.842.081.81.661.81.81.731.811.931.72.171.771.6621.761.661.811.91.962.022.071.621.891.861.831.851.851.751.862.072.071.981.921.792.171.91.781.881.841.8521.762.021.871.961.741.931.781.671.762.631.631.981.851.961.872.351.711.962.91.751.961.872.021.961.771.761.761.921.771.991.772.172.232.122.311.961.791.861.891.941.851.82.021.731.891.672.881.771.761.721.871.711.8821.9231.8641.9452.0161.8871.9682.0691.87101.94111.92121.84131.91141.86151.94161.99171.88182.05192.05202.01211.96221.85231.87241.86251.93261.98272.01281.94291.86301.89Sheet200000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000qc reportfuse head resistanceoperator name: Date: Shift:Sheet3RESISTANCE DATA (VENDOR REPORT,OUR TESTING REPORT AND FUSE HEAD RESISTANCE)DateName of the partyBobbin.NoMeasured test reportvendor test reportmeasured while processavgMinMaxbobbin resr/mmlowhigh12/12/071107210871.521.671.59510721.0721.521.672110111091.51.691.59511011.1011.51.6926/11/07Natinal enterprises1142413831.862.22.0314241.4241.862.22133513251.772.252.0113351.3351.772.253134313311.752.181.96513431.3431.752.184134913221.932.051.9913491.3491.932.055133513281.741.971.85513351.3351.741.976132913101.772.181.97513291.3291.772.187131813131.752.061.90513181.3181.752.0623/11/07Natinal enterprises1139014051.92.162.0313901.391.92.162136313911.92.122.0113631.3631.92.123137013911.811.931.8713701.371.811.934137613981.832.121.97513761.3761.832.125138014051.812.011.9113801.381.812.016135813961.842.292.06513581.3581.842.297136613911.781.941.8613661.3661.781.9431/7/07Kakathiya alloys1133013541.882.011.94513301.331.882.012133213491.832.031.9313321.3321.832.033133013481.892.061.97513301.331.892.064131413221.851.971.9113141.3141.851.975132513441.881.991.93513251.3251.881.9912/7/07Kakathiya alloys1137213891.922.041.9813721.3721.922.042136913891.881.951.91513691.3691.881.9527/6/07Natinal enterprises1144112812.182.322.2514411.4412.182.322147312402.052.222.13514731.4732.052.223146712602.12.182.1414671.4672.12.18ohm/meterohm/fuse head10661.4210661.4410661.3810661.410661.410661.4110661.4210661.410661.410661.49901.429901.49901.399901.369901.369901.359901.389901.369901.399901.399961.319961.339961.319961.329961.339961.339961.329961.339961.339961.213902.0313902.0213901.913902.0213901.9813901.9613902.1513901.9313902.1613902.1613632.0213631.9313631.9813631.9913631.9313631.9313631.9613632.0113631.913631.9513181.813181.7913181.9413181.7813181.7613181.813181.913181.8913181.7513181.8213351.8413351.8313351.8513351.8113351.8513351.7713351.813351.8213351.9213351.9614412.2114412.2314412.2314412.2914412.2114412.2314412.2914412.2614412.2614412.2614732.0914732.0714732.1114732.0714732.114732.0714732.1314732.0814732.2214732.1114822.1514822.0214822.0814822.1614822.0914822.0814822.0614822.0814822.0414822.1214982.2814982.0514982.1914982.1514982.1214982.1314982.0814982.3214982.1214982.22Sheet3000000000000000000000000000000000000000000000000000000000000000000000000000000DOEohm/fuse headresistance ohm / meterfuse head resiatanceMSAMEASURMENT DATAsample noTrue responseOPERATOR-1OPERATOR-2OPERATOR-3Trial-1trial-2Trial-1trial-2Trial-1trial-211.751.751.761.751.751.761.7521.921.921.921.861.841.921.9231.841.881.861.841.851.841.8541.921.91.911.921.921.921.9252.42.412.42.42.42.42.462.32.312.312.312.32.312.372.112.112.112.112.132.122.1181.921.91.921.921.931.931.9492.962.962.962.962.942.952.98101.911.931.931.911.911.911.91111.961.871.922222122.021.9822.012.052.042.04131.91.851.851.931.951.961.94142.152.052.072.172.162.172.15151.981.941.981.991.981.992161.781.781.771.791.791.81.8171.821.821.831.821.821.831.82182.522.512.522.462.52.512.51192.162.132.122.162.152.162.16202.382.372.382.42.42.382.39GO NOGOsample noTrue responseOPERATOR-1OPERATOR-2OPERATOR-3Trial-1trial-2Trial-1trial-2Trial-1trial-21YYYYYYY2YYYYYYY3YYYYYYYY=GON=NO GO4YYYYYYYUSL=2.42.362.36 above5NNNNNNN6YYYYYYYLSL=1.61.641.56 below7YYYYYYY8YYYYYYY9NNNNNNN10YYYYYYY11YYYYYYY12YYYYYYY13YYYYYYY14YYYYYYY15YYYYYYY16YYYYYYY17YYYYYYY18NNNNNNN19YYYYYYY20NNNNNNNiam not understand how to calculate repeatability and raproducibilitylc22.713821002.0822.710022.713821601.9022.716022.713001001.8122.410022.713001601.7922.416022.413821003.0322.413821602.2822.413001002.9422.413001602.08ABCRTestHammering Load (screw length in mm)nicrome wire resistance/mtrButt welding currentfusu head resistance122.713821002.081.921.841.872.011.871.932.032.032.041.872.012.221.761.932.392.622.462.342.122.352.08222.713821601.901.971.91.91.881.852.061.871.81.981.881.941.941.91.781.781.911.931.781.9421.90322.713001001.811.851.711.861.741.981.761.81.781.971.791.741.731.681.81.851.871.811.821.941.781.81422.713001601.791.831.811.721.821.731.841.761.731.781.811.81.91.761.761.741.781.831.71.81.811.79522.413821003.033.12.413.242.942.693.143.813.672.922.732.593.493.722.852.912.852.852.992.672.983.03622.413821602.282.242.112.12.12.162.372.262.32.272.912.182.322.322.422.212.352.122.132.392.342.28722.413001002.942.822.962.863.142.942.892.872.793.052.83.032.732.642.932.913.483.642.752.932.642.94822.413001602.082.092.111.892.062.061.642.22.162.182.161.962.192.22.042.182.11.972.082.12.162.08ABC122.413001002.942.942.822.962.863.142.942.892.872.793.052.83.032.732.642.932.913.483.642.752.932.642.94222.413001602.082.082.092.111.892.062.061.642.22.162.182.161.962.192.22.042.182.11.972.082.12.162.08322.413821003.033.033.12.413.242.942.693.143.813.672.922.732.593.493.722.852.912.852.852.992.672.983.03422.413821602.282.282.242.112.12.12.162.372.262.32.272.912.182.322.322.422.212.352.122.132.392.342.28522.713001001.811.811.851.711.861.741.981.761.81.781.971.791.741.731.681.81.851.871.811.821.941.781.81622.713001601.791.791.831.811.721.821.731.841.761.731.781.811.81.91.761.761.741.781.831.71.81.811.79722.713821002.082.081.921.841.872.011.871.932.032.032.041.872.012.221.761.932.392.622.462.342.122.352.08822.713821601.901.901.971.91.91.881.852.061.871.81.981.881.941.941.91.781.781.911.931.781.9421.90Fuse head resistanceFactorABCABACBCABCNOTELevel121212121212122.942.942.942.942.942.942.942.942.082.082.082.082.082.082.082.0822.4=0.493.033.033.033.033.033.033.033.032.282.282.282.282.282.282.282.281.811.811.811.811.811.811.811.811.791.791.791.791.791.791.791.792.082.082.082.082.082.082.082.081.901.91.91.91.91.91.91.9Total17.9110.337.588.629.299.868.058.9198.259.668.988.939.098.82Avg2.238752.58251.8952.1552.32252.4652.01252.22752.252.06252.4152.2452.23252.27252.205factor Effect-0.68750.1675-0.45250.02250.3525-0.0125-0.0675123A1B1C122.413001002.942.94y12.944.7193.745A1B2C222.413821602.282.28y22.081.851.818A2B1C222.713001601.791.79y33.034.2583.323A2B2C222.713821601.901.90y42.281.9221.9591.811.781.7591.791.7611.743effect of A-0.7652.081.9111.581effect of B0.0551.91.8221.843effect of C-0.3852.96122.7(0.40mm)13821001.871.851.971.881.981.971.872.031.831.86222.713821602.411.831.831.831.821.831.821.811.811.811.83322.713001002.111.931.761.761.761.741.881.731.731.771.74422.713001601.711.671681.721.711.691.931.721.811.731.95522.4(0.49mm)13821001.813.14.34.53.883.894.153.953.567.623.63622.413821601.841.991.961.911.91.931.91.891.961.881.9722.413001001.94.758.938.134.834.334.363.053.043.252.52822.413001601.861.821.851.861.861.841.881.851.861.82Test-1Hammering Load (screw length in mm)nicrome wire resistance/mtrButt welding current2.96122.413001001.94.7194.758.938.134.834.334.363.053.043.252.520.49222.413001601.851.861.821.851.861.861.841.881.851.861.82322.413821001.814.2583.14.34.53.883.894.153.953.567.623.63422.413821601.841.9221.991.961.911.91.931.91.891.961.881.9522.713001002.111.781.931.761.761.761.741.881.731.731.771.740.4622.713001601.711.7611.671.681.721.711.691.931.721.811.731.95722.713821001.9111.871.851.971.881.981.971.872.031.831.86822.713821602.411.8221.831.831.831.821.831.821.811.811.811.83122.713821001.951.741.721.91.071.751.841.021.840.98222.713821602.871.881.821.861.861.841.811.821.861.831.85322.713001001.751.731.881.751.751.741.781.721.741.75422.713001601.761.711.821.71.731.81.721.721.741.73522.413821003.033.395.593.343.22.932.93.742.582.872.69622.413821602.642.011.961.981.961.931.941.911.932.031.94722.413001002.762.823.692.95.426.953.532.853.223.31822.413001601.851.861.871.821.91.751.761.741.761.87Test-3Hammering Load (screw length in mm)nicrome wire resistance/mtrButt welding current122.413001003.7452.762.823.692.95.426.953.532.853.223.31222.413001601.8181.851.861.871.821.91.751.761.741.761.87322.413821003.033.3233.395.593.343.22.932.93.742.582.872.69422.413821602.641.9592.011.961.981.961.931.941.911.932.031.94522.713001001.7591.751.731.881.751.751.741.781.721.741.75622.713001601.7431.761.711.821.71.731.81.721.721.741.73722.713821001.5811.951.741.721.91.071.751.841.021.840.98822.713821602.871.8431.881.821.861.861.841.811.821.861.831.852.93Test-2Hammering Load (screw length in mm)nicrome wire resistance/mtrButt welding current122.713821401.8481.831.881.851.881.851.831.841.841.841.84222.413821402.3072.142.122.082.152.252.092.543.442.242.02322.713001401.7331.751.751.751.721.691.721.741.731.721.76422.413001402.0052.051.951.972.032.091.941.9921.982.05Test-4Hammering Load (screw length in mm)nicrome wire resistance/mtrButt welding current122.713821001.911.871.851.971.881.981.971.872.031.831.86222.713821101.881.91.921.821.81.941.951.881.871.871.88322.713821201.871.841.871.851.911.871.881.871.881.861.87422.713821301.851.851.841.881.861.91.811.911.831.841.82522.713821401.851.831.881.851.881.851.831.841.841.841.84622.713821501.871.921.891.881.831.851.861.891.851.881.89722.713821602.871.841.881.821.861.861.841.811.821.861.831.85Test-5Hammering Load (screw length in mm)nicrome wire resistance/mtrButt welding current122.7/0.40mm13001001.7591.751.731.881.751.751.741.781.721.741.75222.713001101.7281.771.71.731.741.721.731.721.721.731.72322.713001201.7111.751.741.71.731.741.71.661.71.711.68422.713001301.7121.731.681.691.741.731.71.731.691.721.71522.713001401.7331.751.751.751.721.691.721.741.731.721.76622.713001501.7121.731.691.741.711.71.71.711.71.741.7722.713001601.7431.761.711.821.71.731.81.721.721.741.73thickness(mm)nicrome wire resistance/mtrButt welding current10.2613821301.7871.891.791.81.811.781.761.751.781.761.7520.3313821301.7891.791.771.811.781.781.81.821.81.771.7730.3813821301.8331.861.821.831.81.81.831.851.811.861.8740.4113821301.9161.851.91.852.021.912.131.91.821.891.8950.4413821302.3052.12.232.232.222.262.592.232.562.452.1860.513821303.2972.654.552.552.433.772.247.82.32.312.37Experiment-1Trail noHammering Load (screw length in mm)nicrome wire resistance/mtrButt welding currentResistance123122.413001002.942.944.7193.745222.413001602.082.081.851.818322.413821003.033.034.2583.323422.413821602.282.281.9221.959522.713001001.811.811.781.759622.713001601.791.791.7611.743722.713821002.082.081.9111.581822.713821601.91.91.8221.843Experiment-2Trail noHammering Load (screw length in mm)nicrome wire resistance/mtrButt welding currentResistance122.713821001.911222.713821101.883322.713821201.87422.713821301.854522.713821401.848622.713821501.874722.713821602.871.843822.713001001.759922.713001101.7281022.713001201.7111122.713001301.7121222.713001401.7331322.713001501.7121422.713001601.743Experiment-3122.713821401.848222.413821402.307322.713001401.733422.413001402.005Experiment-4thickness(mm)nicrome wire resistance/mtrButt welding currentResistance10.2613821301.78720.3313821301.78930.3813821301.83340.4113821301.91650.4413821302.30560.513821303.29770.4913001302.942.9480.413001301.7121.881.81.871.671.832.11.81.961.921.861.651.751.82.111.761.951.91.961.821.681.811.91.841.741.891.841.921.82.021.81.791.781.861.661.881.91.831.991.71.751.621.791.631.761.781.881.921.781.671.76gageaiaglinearity studyPartOperatorresponsepartmasterresponse112.0511.51.51112.0711.51.5211.8511.51.51211.8511.51.5311.7811.51.5311.7711.51.49411.8711.51.5411.9211.51.5511.9811.51.5151211.51.5611.9311.51.5611.9311.51.5711.9421.81.82711.9821.81.82811.921.81.82811.9221.81.81912.1321.81.82912.1221.81.811011.8221.81.811011.8321.81.81122.1721.81.81122.1621.81.81221.9321.81.81221.9521.81.81PartOperatorresponse321.79322.11111.82321.79322.11111.89422322.12111.9422322.11212.02522.01322.1212.07522.05322.11212.07621.91322.12312.48621.91322.11312.54721.99322.11312.64721.99322.11121.94821.93322.11121.96821.93322.11121.96922.1642.22.22222.1922.1542.22.22222.021021.8242.22.22222.11021.8242.22.22322.54132.242.22.22322.76132.242.22.22323.23231.9642.22.21131.99231.9442.22.22132.07331.842.22.22132.09331.8142.22.22232.1443242.22.23232.2143242.22.22232.17532.0452.42.42332.66532.0452.42.42332.55631.9152.42.42332.91631.952.42.42731.9952.42.4273252.42.41831.9452.42.42831.9552.42.42932.1652.42.42932.1652.42.421031.8352.42.421031.8252.42.42GAUGE R-R STUDYpart12345678910operatorno.observationA12.051.851.781.871.981.931.941.92.131.820.104559225222.071.851.771.9221.931.981.922.121.83B12.171.931.7922.011.911.991.932.161.820.12079125122.161.951.7922.051.911.991.932.151.82C12.21.961.822.041.911.991.942.161.830.124641591422.21.941.8122.041.921.952.161.820.1166640225GAUGE LINEARITY STUDYpartmaster valueresponsepartmaster valueresponsepartmaster valueresponsepartmaster valueresponsepartmaster valueresponse11.51.5121.81.82322.1142.22.2252.42.4211.51.521.81.82322.1142.22.2252.42.4211.51.5121.81.82322.1242.22.2252.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.521.81.82322.142.22.2252.42.4211.51.4921.81.81322.1142.22.2252.42.4111.51.521.81.81322.1242.22.2152.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.5121.81.81322.1142.22.2252.42.4211.51.521.81.81322.1142.22.2252.42.4211.51.521.81.81322.1142.22.2352.42.4211.51.521.81.81322.1142.22.2252.42.42Chart11.561.971.531.521.532.72.031.51.531.571.611.831.572.21.631.541.711.711.5301.431.921.581.541.51.5301.51.311.581.571.661.511.541.871.71.541.751.5401.521.571.541.591.521.731.691.581.61.51.561.591.561.571.6601.542.121.51.581.641.551.8201.561.531.681.5901.571.621.581.891.571.691.541.612.041.641.561.591.61.581.551.621.581.651.5901.571.621.581.891.5701.691.5401.612.04PARETOSl.noNo.of samples inspectedNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxWire shortBends1302081703230211013043303171702430505160453060138126308011803730603180383041195109307191102103010122061130401276112301304121013302012313143070415131530403144516303022203173020221141830207182119301307901203050520002130501012212230200280023303022401243010325012530509150130263020820003027308012001302830601280430293010151400303030208150530313020818023032301022223303330130980030343020519043035306041910303630401213013037302071902303830304220130393030121500304030301970130Total120019142856192378% of rejection15.91666666670.333333333323.7551.58333333331.91666666676.5100nos%Nil Resistance19115.9166666667Low Resistnce40.3333333333High Resistance28523.75short231.9166666667Bends786.5Good items in rejection box61951.58333333333PARETOGood items in rejection box0.5158333333High Resistance0.7533333333Nil Resistance0.9125Bends0.9775short0.9966666667Low Resistnce11111DataParetoSamplesDataPercentPareto Analysis619285191782341300rejection1.561.971.531.521.532.72.031.51.531.571.611.831.572.21.631.541.711.711.5301.431.921.581.541.51.5301.51.311.581.571.661.511.541.871.71.541.751.5401.521.571.541.591.521.731.691.581.61.51.561.591.561.571.6601.542.121.51.581.641.551.8201.561.531.681.5901.571.621.581.891.571.691.541.612.041.641.561.591.61.581.551.621.581.651.5901.571.621.581.891.5701.691.5401.612.041300measure dataDatem/c noProductionrejectionNo. samples inspected from rejectionNil ResistanceLow ResistnceHigh ResistanceGood items in rejection boxshortbendsmeasuement (sample taken from rejection)15-May136856350030208170330237192350030211013043033678035003031717023016-May19594750305051604301.741.712.831.981.731.821.891.921.721.722.4501.71.71.71.4201.701.811.861.741.992.531.632.3504.032.30294351000306013812302.3302.361.685.443.262.672.532.672.292.3502.952.642.392.373.072.882.432.6702.294.5702.3003.172.047.5339521800308011803301.681.744.462.392.6902.372.532.756.0702.422.612.373.311.7302.451.932.5601.83001.632.3504.032.3017-May1181282000306031803300001.862.622.342.332.51.921.851.72.322.031.742.411.842.3401.791.861.891.942.392.341.7301.7101.711.742187281500304119510302.453.0602.332.813.04002.994.212.623.32.385.422.014.022.862.902.662.441.572.442.912.342.412.72.325.223.7139326800307191102302.572.672.5101.8601.674.4102.48002.571.961.662.421.691.672.382.451.7101.782.461.791.771.891.3601.744924810003010122063019-May218624150030401276130318654150030130412103041865416003020123133020-May118801500307041513302962060030403144530318610150030302220330B219045100030202211430318681150030207182130C11916312003013079013031885615003050520003021-May130501012213023020028003033030224013043010325013023-May30509150130302082000303080120013024-May306012804303010151400303020815053026-May3020818023030102222330301309800303020519043027-May306041910303040121301303020719023028-May303042201303030121500303030197013012001914285619237812003565953175015.920.3323.7551.581.926.50100.001.742.331.6801.7101.7402.832.364.4601.981.682.391.861.823.2602.341.735.442.692.621.892.672.372.331.922.532.532.51.722.296.071.851.722.672.751.922.452.3501.7002.422.321.72.952.612.031.72.642.371.741.72.393.312.411.422.3504.032.302.37003.172.047.531.732.3504.032.301.8401.7101.711.7403.0702.341.72.882.4501.994.5702.391.812.672.561.861.742.291.831.9402.431.931.792.53002.341.86001.891.632.31.631.73base dataDIPPING OPERATIONAUTO SORTINGMONTHGross ProductionRejection% of rejectionGross ProductionRejection% of rejection12.243total rejectionAPRIL-08MARCH-083908520590921.512363052238960010.731239199212.243448692FEBRUARY-083367980452661.344318689035833011.243877259612.588403596JANUARY-082505184245740.98138482733421008.8897019529.871366674DECEMBER-074915350553081.12545555883673008.06262550529.188422608NOVEMBER-074879710494781.014504597154610010.82249580911.836595578OCTOBER-074469148330750.740433082573920017.068341482317.808772275245980692742630Monthrejection%productionrejectionDPUDPMOsigmalevel1March-0810.7336305223896000.10726828.09799802893.452Feb-0811.2431868903583300.11228109.69314912033.523Jan-088.8938482733421000.08922224.25488004623.54Dec-078.0645555883673000.08120156.56376300933.655nov-0710.8250459715461000.10827056.23952258153.46Oct-0717.0743308257392000.17142670.85370570273.2MONTHMARCH-08FEBRUARY-08JANUARY-08DECEMBER-07NOVEMBER-07OCTOBER-07PRODUCTION363052231868903848273455558850459714330825REJECTION389600358330342100367300546100739200DPU0.1070.1120.0890.0810.1080.171DPMO26828.128109.722224.320156.627056.242670.9SIGMA LEVEL3.453.43.53.553.413.2resistance1.7901.781.881.674.612.632.011.781.771.911.761.811.774.713.121.741.841.6801.751.822.811.761.831.811.921.871.781.791.681.812.42.811.791.82.52.134.652.262.321.981.891.862.262.031.91.771.952.42.391.92.171.9202.091.761.941.91.952.081.771.91.981.762.381.843.371.971.871.781.781.771.951.771.771.771.791.781.811.772.062.42.354.31.981.921.834.711.781.842.32.41.881.971.911.91.751.92.05base data000000no.of monthsrejection rate% OF REJECTIONRR STUDY1no.of samplesresistancefuse head resistanceR-R STUDY DATAlineaty studyPartOperatorResponsepatrReferanceresponse111.7611.61.59111.7511.61.66212.2411.61.81212.2311.61.74312.2311.61.59312.2111.61.61412.1611.61.61412.1911.61.6511.7511.61.61511.7511.61.65613.3111.61.63613.3111.61.62711.8521.81.8711.8421.81.881021.82.0681021.81.97911.7821.81.9911.7821.81.831012.0321.81.841012.0421.81.81121.7521.81.79121.7521.81.81222.2321.81.81222.2321.81.8322.22322.11322.22322.13422.19322.12422.19322.11521.75322.13521.75322.12623.31322.13623.3322.1721.84322.1721.84322.13820322.13820322.09921.7842.22.21921.7742.22.211022.0342.22.241022.0342.22.22131.7642.22.25131.7642.22.26232.2442.22.23232.2342.22.28332.2242.22.26332.2142.22.23432.1942.22.35432.1942.22.3531.7552.42.42531.7652.42.41633.3152.42.43633.352.42.46731.8552.42.41731.8452.42.4483052.42.4183052.42.47931.7852.42.46931.7852.42.41032.0452.42.411032.0352.42.41LINEARITYPatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponsePatrReferanceResponseReferanceResponseReferanceResponseReferanceResponseReferanceResponseReferanceResponse11.61.5921.81.8322.1142.22.2152.42.421.61.591.81.822.112.22.212.42.4211.61.6621.81.8322.1342.22.2152.42.411.61.661.81.822.132.22.212.42.4111.61.8121.82.06322.1242.22.2452.42.431.61.811.82.0622.122.22.242.42.4311.61.7421.81.97322.1142.22.2252.42.461.61.741.81.9722.112.22.222.42.4611.61.5921.81.9322.1342.22.2552.42.411.61.591.81.922.132.22.252.42.4111.61.6121.81.83322.1242.22.2652.42.441.61.611.81.8322.122.22.262.42.4411.61.6121.81.84322.1342.22.2352.42.411.61.611.81.8422.132.22.232.42.4111.61.621.81.81322.142.22.2852.42.471.61.61.81.8122.12.22.282.42.4711.61.6121.81.79322.142.22.2652.42.461.61.611.81.7922.12.22.262.42.4611.61.6521.81.81322.1342.22.2352.42.41.61.651.81.8122.132.22.232.42.411.61.6321.81.81322.1342.22.3552.42.411.61.631.81.8122.132.22.352.42.4111.61.6221.81.8322.0942.22.352.42.411.61.621.81.822.092.22.32.42.41R-R STUDYPart12345678910operatorobservationA11.762.242.232.161.753.311.8501.782.0421.752.232.212.191.753.311.8401.782.03B11.752.232.222.191.753.311.8401.782.0321.752.232.222.191.753.31.8401.772.03C11.762.242.222.191.753.311.8501.782.0421.762.232.212.191.763.31.8401.782.03

1)Improper tin coating on brass strip.

Nichrome wire resistance.Hammering load.Butt welding current.Online comb cutting.wrong segregation of Auto sorting machine.

Identified Significant reasons for rejection

ACTIONS TAKEN ON THE ISSUES

Improper tin coating on brass strip.

Cleaning blade sharpness increased and fixed in correct position.

Action taken.

One clutch bearing wheel was provided to avoid looseness of strip while cleaning and unwinding of brass strip.

Action taken.

2)Nichrome wire resistance.

Nichrome wire resistance specification changed from 1425-1450 /m

to 135025 /m.Action taken.

3)Hammering load.

To control hammering load, load sensor to be provided

Action not taken.

Butt welding current.

Butt w