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Project for minimizing Machine failure by Advance Innovation Group

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(http://advanceinnovationgroup.com) …

(http://advanceinnovationgroup.com)

This Lean Six Sigma Project done by student from Advance Innovation group which is posted to provide for benchmarking and best practices sharing purposes.

This is a Student project on Minimizing Machine Failure.

Additionally, it is advisable that you also visit and subscribe Advance Innovation Group Blog (http://advanceinnovationgroup.com/blog) for more Lean Six Sigma Project, Case Studies on Lean Six Sigma, Lean Six Sigma Videos, Lean Six Sigma Discussions, Lean Six Sigma Jobs etc.

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  • 1. Voice of the Customer-VOC (Internal Customer)2Customer Comments Critical to Quality-CTQ’sPM (Internal Customer) No of failures of AFC system is goingto upward due to its direct impact onRAM (Reliability ,Availability &Maintainability).Maximizing FailuresMaintenance Manager Due to upward failure , AFCsystem’s reliability is going to down ifwe didn’t control the upward failurethen Dayna will have to pay hugepenalty to Minfra in the end of year2012.Maximizing Failures/PenaltydDEFINE
  • 2. Voice of the Customer-VOC (External Customer)3Customer Comments Critical to Quality-CTQ’sHead (MIL) •Rising Hardware issue•Rising Software issues•Preventive maintenance is not goodMaximizing failuredDEFINE
  • 3. Project CharterBUP PVT ltd, It was established in XXX , it is an AFC system organisationwhich is being operated in more than 110 countries. It provides servicesof design, supply, installation ,testing and commissioning of Automaticfare collection ticketing systems. AFC system reduces the ticketchecking staff and it helps the prevent fraud .XYZ is one of the clients to BUP, MIL is one of the biggest infrastructureorganization for developing the Metros in India.It deals with the Minfra for 5 years warranty services in maintenance ofAFC equipments for six metro stations .The organization will start thewarranty period of maintenance from starting day of metro station .A oneclause add in BUP AFC contract regarding RAM .RAM is reliability,maintainability and availability .BUP systems reliability target is one lakhcycle per month, maintainability TAT is thirty minutes and availabilityshould be ninety nine percent .In AFC contract mentioned if BUP will notachieve the twelve lakh cycle with respecting of minimum failures in theend of December 2012 then it will pay four lakh to Minfra. At BB BUP hasbeen observed that In month of Jan to March AFC systems is not able toachieve the reliability due to upward failures.TeamVice President: PKLManaging director: LKOProject Manager: JNLMaintenance manager: TGJBB: RS KGB: RKG,MIS, AVPMember: Maintenance TeamFinancial controller: GKLProblem Statement:First two months RAM reliability is (100000 in Nov 2011 & 100000 cyclesin Dec 2011) with respect to minimum failure but in (Jan to March 2012)RAM reliability is less than one lakh cycle due to increasing failures. Thisresulted probable delay of expansion plan of business & exposure toaggressive competitors in near future.Goal Statement :To achieve the reliability growth of AFC equipment by minimize the failures in the endof June 2012.In Scope : Maintenance ,Hardware & software development department.Out Scope : All other department other than Maintenance ,Hardware &software department.Milestones Target Date Actual DateD 1stApril 2012 15thApril 2012M 16thApril 2012 30thApril 2012A 1stMay 2012 16thMay 2012I 17thMay 2012 31stMay 2012C 1stJune 2012 30thJune 2012dDEFINE
  • 4. RASICdDEFINE
  • 5. CTQ TreeMaximizing Failure ofAFCCTQsEquipment failure attributable tosome defect in a circuit (looseconnection or insulation failureor short circuit etc.)(operational definition)Failure is occurs on of AFCsystem(Defect Description)Cycles(Opportunity)dDEFINE
  • 6. SIPOCMINFRAMINFRA Elevator/LiftElevator/LiftDesired routeDesired routeFare listFare listPost machine with assistancedevicesPost machine with assistancedevicesDesired routeDesired routeEntry in SHIVAJI STADIUM stationEntry in SHIVAJI STADIUM stationGo to the ticket counterGo to the ticket counterSee Fare table from shivaji to dwarkaSee Fare table from shivaji to dwarkaissued the token by CUCissued the token by CUCPurchased the journey ticket from ticketcounterPurchased the journey ticket from ticketcounterTravel for journeyTravel for journeyEnquiry for fareEnquiry for fareFare finalizationFare finalizationissuedissuedReceived Ticket(Token/smart card)Received Ticket(Token/smart card)PassengersPassengersMoneyMoneyGo to the unpaid area of AFC gateGo to the unpaid area of AFC gate Arrived platformArrived platformToken/smart cardToken/smart card Touch the ticket with AFC Gate in unpaidareaTouch the ticket with AFC Gate in unpaidareaShow fare amount intoken/smart cardShow fare amount intoken/smart cardFlap opened for entryFlap opened for entry EntryEntryAFC MachineAFC MachineLift/ElevatorLift/Elevator Go to arrival platformGo to arrival platform For pick the metroFor pick the metroMetroMetro Reached departure stationReached departure station Arrived dwarka sec-21Arrived dwarka sec-21Desired routeDesired route Go to unpaid area of AFC gateGo to unpaid area of AFC gate ArrivedArrivedToken/smart card & AFC machineToken/smart card & AFC machine Touch the ticket in AFC Gate in paid areaor flap opened for exitTouch the ticket in AFC Gate in paid areaor flap opened for exitDeduct fare amount intoken /card & ExitDeduct fare amount intoken /card & ExitdDEFINE
  • 7. Data Collection PlanmMEASUREKPI Operational Definition Defect Def OpportunityReduce the failure ofAFC systemEquipment failure attributable to some defect in a circuit (looseconnection or insulation failure or short circuit etc.).Failure is occurs on of AFCsystemcyclesKPI Data TypeData ItemsNeededFormula to be used UnitPlan to collect DataPlan tosampleWhat Databaseor Containerwill be used torecord thisdata?Is this anexistingdatabaseor new?If new, Whenwill thedatabase beready for use?When is theplanned startdate for datacollection?Reduce thefailure of AFCsystem Discrete RAM Report NA Count Excel Existing 1-01-12 31-03-12 NA
  • 8. Validate Measurement Data Effectiveness &EfficiencymMEASUREEffectiveness at 98.92% with 93 sample is good enough ,and we conclude that the measurementsystem is adequate.To serve the purpose of data validation last 3 month of the data been collected with the helpof the data been collected with the help of maintenance manager in maintenance department.On re verification , it’s been confirmed that a single data point was mismatched with thecollected data .Effectiveness% = Number of sample where both measurement were similarTotal number of sample were consideredEffectiveness% = 92 *100/93Effectiveness% = 98.92%
  • 9. mMEASUREDenominator ValuesTotal Defect (Total Failure) 190Total opportunity (Total cycles) 1598110DPO 1.18890DPMO 118.89Sigma Level 5.18Validation Measurement System – Before improve
  • 10. Graphical Summary For Daily failureThe graphical representation of data shows that the data is non Random.aAnalyse
  • 11. Probability Plot for Daily FailuresaAnalyzeSince p value is less than 0.05, the data is not normal.
  • 12. Run chart for Daily FailuresaAnalyzeThere is Trends , mixture is no existing the p value and clustering & oscillation exists ,the process is non Random.
  • 13. Run chart for Daily FailuresaAnalyzeThere is Trends , mixture is no existing the p value and clustering & oscillation exists ,the process is non Random.
  • 14. Reliability chart – Before improveaAnalyzeMonthSAF (ServiceAffecting Failure)CyclesReliability (TotalCycle/SAFJanuary 60 800000 13333.33February 65 900000 13846.15March 65 1000000 15384.62
  • 15. Potential Xs’ and Tests Chosen to test their Significance effect16aAnalyseYPotentialXOperational Defination Data Type XData subType XData TypeYTestChosenMaximizingAFCFailuresAG Automatic Gate is used for entry and exit.Categorical Count DiscreteGoodnessof fit andParetoTIMTicket Issuing Machine is used for sale and reload the cardand tokens.RVCTRemaining Value check in Ticket machine is used for checkthe balance and validity of cards.POSTPoint of Sale Terminal is used for sale, Reload and refund thecard and tokens.SC Station Computer is used to integrate the AFC systemPTDPortable Ticket Detector is used for sale ,reload and refundthe card and tokens.CIDCard Initializing Device is used for initializing the card andtokens.
  • 16. Pareto Test of Quarterly Failures17Pareto Test is showing AG,TIM ,POST generate the highest failure from last three months incomparatively to other SC,PTD,CID. We need to improve to those issues.aAnalyseAFC System DescriptionNo ofFailuresAutomatic Gate (AG) 86Ticket Issuing Machine (TIM) 53Remaining Value Checking Ticket(RVCT)5Point of sale Terminal (POST) 40Station Computer (SC) 1Portable Ticket Decoder (PTD) 4Card Initialization Device (CID) 1
  • 17. Failure chart with Automatic Gate Machine18aAnalyse
  • 18. Pareto Analysis of Failure with AG19AG Pareto chart is showing that application restart ,hang & CSC not detected problems are majorfailures to others then we need to work out in these issues.aAnalyseMonthAG FailuredescriptionNo of failureJan - March Flap not working 6Jan –MarchApplication Restartautomatically 25Jan - March Application Hanged 25Jan - MarchCSC Card notdetected 10Jan - MarchAutomatically displayshift 10Jan - March Hardware Error 10
  • 19. Failure chart with Ticket Issuing Machine20aAnalyse
  • 20. Pareto Analysis of Failure with TIM21TIM pareto chart is showing coin stucked in hopper 5 & 10 & revenue mismatch problems are majorfailures to other then we need to work out in these issuesaAnalyseMonthTIM FailuredescriptionNo offailureJan –MarchBNA is notaccepting Rs 5 note10Jan - MarchCoin stuck in Rs 5Hopper15Jan - MarchCoin stuck in Rs 10Hopper13Jan - March Revenue Mismatch 8Jan - March Hardware Issue 7
  • 21. Failure Chart with Point of sale Terminal machine22aAnalyse
  • 22. Pareto Analysis of Failure with Post23Post pareto chart is showing that the application hang problem is major failure to others and we needto improve this issues.aAnalyseMonthPOST FailuredescriptionNo offailureJan - MarchApplication hanged afterone hour10Jan - March Shift close error 10Jan - MarchCash drawer is not openautomatically10Jan - MarchCSC/CST not detectederror10
  • 23. Goodness of fit test with AFC system Before Improve24Goodness of fit test of AFC system is showing AFC system failure is greater and p value is 0.000 it means we need to improve the failure of thesesystems.aAnalyzeN DF Chi-sq P-Value179 14 38.2905 0.000AFCDeviceCategory Observed Proportion ExpectedContribution tochi squareAG Flap not working 6 0.0666667 11.9333 2.9501AG Application Restart automatically 25 0.0666667 11.9333 14.3076AG Application Hanged 25 0.0666667 11.9333 14.3076AG CSC Card not detected 10 0.0666667 11.9333 0.3132AG Automatically display shift 10 0.0666667 11.9333 0.3132AG Hardware Error 10 0.0666667 11.9333 0.3132TIM BNA is not accepting Rs 5 note 10 0.0666667 11.9333 0.3132TIM Coin stuck in Rs 5 Hopper 15 0.0666667 11.9333 0.7881TIM Coin stuck in Rs 10 Hopper 13 0.0666667 11.9333 0.0953TIM Revenue Mismatch 8 0.0666667 11.9333 1.2965TIM Hardware Issue 7 0.0666667 11.9333 2.0395POST Application hanged after one hour 10 0.0666667 11.9333 0.3132POST Shift close error 10 0.0666667 11.9333 0.3132POST Cash drawer is not open automatically 10 0.0666667 11.9333 0.3132POST CSC/CST not detected error 10 0.0666667 11.9333 0.3132
  • 24. Vital X’s and Significance effect25aAnalyseY Vital X’s Operational DefinationTest to beperformedSignificanceImpactMaximizingAFCFailuresAG Automatic Gate is used for entry and exit.Goodnessof fit andPareto0.000TIMTicket Issuing Machine is used for sale and reload the cardand tokens.POSTPoint of Sale Terminal is used for sale, Reload and refundthe card and tokens.
  • 25. 26iImproveQuality Function DeploymentQuality FumctionDeployment
  • 26. 27iImproveFailure Effect Mode Analysis (FMEA)FMEA(Maximizing Failure)Defined "X"s Process Step Identification of Failure Mode Effect on EDR Severity Occurrence Detection RPN (sxoxd)RMS (RiskManagement system)RTP (Risk treatment Plan) ResponsibilityAFC Automatic Gate,Ticket Issuing Machine, Point of saleTerminalDiagnose the mode of failure Without diagnose the type of failure we cant categorize it as like(hardware error , software error) Maximizing Failure ,reliabilitywould be less10 2 10 200 AvoidMail and meeting to serviceProviderMaintenance ManagerChecked RMA Report Without RAM Report we cant analyze the Reliability , Maintainabilityand avialability of AFC machines.RAM measurment would bedifficult10 2 10 200 AvoidMail and meeting to serviceProviderSoftware ManagerFind Highest Failure Without this factor we cant find which module create highestfailure ratio we cant work on actual error. Failure Ratio would be Higher 10 2 10 200 AvoidMail and meeting to serviceProviderSoftware ManagerSearch Reason of Failure Without searching the reason of failure we cant find actual rootcause as like voltage fluctuation, excess voltage,other designproblem. Failure Ratio would be Higher 10 2 10 200 AvoidMail and meeting to serviceProviderSoftware Manager &Maintenance ManagerNon critical Hardware Failure Without find out hardware failure ratio we cant check reliability ofindividual equipment. Due to less reliability wouldbe cancellation of futureproject8 2 10 160 AvoidMail and meeting to serviceProviderSoftware ManagerNon critical software failure Without find of software bug we cant improve the efficiency ofequipmet . Due to less Reliability Penaltycharge would be higher10 2 10 200 AvoidMail and meeting to serviceProviderMaintenance ManagerContact to service provider according to nature of fault Without coordinate the service provider we cant remove the failureratio. Failure Ratio would be Higher 8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance ManagerHardware Error Then check Reliabilty in contract Without check reliability of equipment we cant claim to serviceprovider regarding unhappening errors. Due to less Reliability Penaltycharge would be higher 8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance ManagerNot meet the reliability then contact to service provider regardingHardware related issueWithout any reliability agreement, if Service low then serviceprovider can refuse for replacement thats why agreement ismandatory.Due to less Reliability Penaltycharge would be higher 8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance ManagerIf other hardware error then send logs to hardware team Without send hardware logs hardware team cant find actual partwhich is affecting the DLP service .Failure Ratio would be Higher 8 2 10 160 AvoidMail and meeting to serviceProviderSoftware ManagerAfter receive solution of hardware Error apply modification to allsystemWithout apply the Improvement souces which is send by serviceprovider we cant check "the percentage of error have been reducedor not".Failure Ratio would be Higher 8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance ManagerSoftware error then contact to software team If we cant tell to software team regarding software related errorsthen system would not be stable. Failure Ratio would be Higher 8 2 10 160 AvoidMail and meeting to serviceProviderSoftware ManagerSend Logs after creating Failure Without send software logs to software team We cant find actualpart which is affecting the System stability . Failure Ratio would be Higher 8 2 10 160 AvoidMail and meeting to serviceProviderSoftware ManagerAfter receive solution of software error then apply modification toall systemWithout install latest firmware version of application which isprovided by service provider after complaint the customer we cantcheck "the percentage of error have been reduced or not". Due to less Reliability Penaltycharge would be higher 8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance ManagerAfter updation in both case hardware and sotware we analyzepercentage of reducing failureWithout modification of hardware and software versions we cantcheck reilability growth. Failure Ratio would beHigher/Dayna will have to paypenalty8 2 10 160 AvoidMail and meeting to serviceProviderMaintenance Manager &Software Manager
  • 27. 28iImproveGantt ChartImplementationRoad Map
  • 28. 29tTTiImproveQuarterly Failure Chart Before & After Improve
  • 29. 30tTTiImproveFailure Table Before & After ImproveItem Failure Description No. of Failure (Jan -Mar)No. of Failure(April - June)AGFlap not working 6 5Application Restartautomatically25 5Application Hanged 25 5CSC Card not detected 10 8Automatically display shift 10 6Hardware Error 10 5TIMBNA is not accepting Rs 5 note 10 6Coin stuck in Rs 5 Hopper 15 5Coin stuck in Rs 10 Hopper 13 6Revenue Mismatch 8 6Hardware Issue 7 6POSTApplication hanged after onehour10 7Shift close error 10 6Cash drawer is not openautomatically10 6CSC/CST not detected error 10 8
  • 30. 31tTTiImproveGoodness of fit test with AFC system After ImproveCategory ObservedProportionExpectedContributionto chi squareAG Flap not working 5 0.0666667 6 0.166667AGApplication Restart automatically5 0.0666667 6 0.166667AG Application Hanged 5 0.0666667 6 0.166667AGCSC Card not detected8 0.0666667 6 0.666667AG Automatically display shift 6 0.0666667 6 0AG Hardware Error 5 0.0666667 6 0.166667TIMBNA is not accepting Rs 5 note6 0.0666667 6 0TIMCoin stuck in Rs 5 Hopper5 0.0666667 6 0.166667TIMCoin stuck in Rs 10 Hopper6 0.0666667 6 0TIM Revenue Mismatch 6 0.0666667 6 0TIM Hardware Issue 6 0.0666667 6 0POSTApplication hanged after one hour7 0.0666667 6 0.166667POST Shift close error 6 0.0666667 6 0POST Cash drawer is not openN DF Chi-sq P-Value179 14 2.33333 1.000
  • 31. 32cControlPre and Post Failure Control ChartPre Stage Special Cause Post Stage Special CauseTEST 1. One point more than3.00 standard deviations fromcentre line.TEST 2. 9 points in a row onsame side of center line.Test Failed at points: 2, 3 Test Failed at points: 26
  • 32. 33cControlReliability Chart After ControlMonthSAF (ServiceAffecting Failure)CyclesReliability (TotalCycle/SAFApril 35 1200000 34285.71May 35 1250000 35714.29June 30 1300000 43333.33
  • 33. 34cControlValidation Measurement system - After ControlDenominator ValuesTotal Defect (Total Failure) 90Total opportunity (Total cycles) 1602110DPO 5.617DPMO 56.175Sigma Level 5.36
  • 34. 35FFinishTHANKS