Project on Reducing TAT of Maintaince Equipment by Advance Innovation Group

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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 Reducing TAT of maintenance equipment,submitted for Six Sigma Certification.

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Published in: Education, Technology, Business

Project on Reducing TAT of Maintaince Equipment by Advance Innovation Group

  1. 1. Voice of the Customer-VOC (Internal Customer)2Customer Comments Critical to Quality-CTQ’sPM (Internal Customer) The breakdown time of failure isgreater than target time as per lastthree months data and it has beenimpacting company as theorganization will have to pay hugepenalties to MInfra.Increase TAT of breakdownmaintenanceMaintenance Manager Onward rectify time of non criticalfailure of AFC machines isimpacting on going maintenancedue to high maintenance cost i.e.large penalty amount.Increase TAT of breakdownmaintenance/PenaltydDEFINE
  2. 2. Voice of the Customer-VOC (External Customer)3Customer Comments Critical to Quality-CTQ’sHead (MIL) •Staff is too less for site•Single skilled technician•Low moral and motivation•Non availability of spares•Preventive maintenance is notgood.Increase TAT of breakdownmaintenancedDEFINE
  3. 3. Project CharterABC India PVT ltd, It was established in 1982, it is repudiatedmutibranded AFC system organisation which is being operated inmore than 110 countries. It provides services of design, supply,installation ,testing and commissioning of Automatic fare collectionticketing systems. AFC system reduces the ticket checking staff andit helps the prevent fraud .PQR is one of the clients to ABC, PQR is one of the biggestinfrastructure organization 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 .Ithas been clearly mentioned in AFC contract if the failures rectify timeof AFC equipments would be greater than one hundred twentyminutes in critical and non critical conditions then the service providerwill be paying the penalty of 3.5 lkh per hour. At BB ABC, It has beenobserved that failures rectify time of AFC equipments is greater thanone hundred twenty minutes in last three months data (July 2011 – sep2011) by prescribed the target in contract Consequently this is hugeimpact on project by maintenance penalty amount Rs 4,10,37500.TeamVice President: PKManaging director: MHProject Manager: RRMaintenance manager: GSBB: RSGB: RK,LS,AVMember: Maintenance TeamFinancial controller: Mr GoelProblem Statement:Last 3 month penalty of breakdown the AFC machines Jul , Aug &sep is respectively (15732500), (13206667) & (12098333) . The deficit oftotal revenue in last 3 months is four million ten lakh thirty seventhousand five hundred.This resulted probable delay of expansion plan of business &exposure to aggressive competitors in near future.Goal Statement :To achieve the TAT of breakdown maintenance is 120 minutes by the end of March2012.In Scope : Maintenance ,Hardware & software developmentdepartment.Out Scope : All other department other than Maintenance ,Hardware &software department.Milestones Target Date Actual DateD 15thNov 11 30thNov 11M 1stDec 11 15thDec 11A 16thDec 11 30thJan 12I 1stfeb 12 28thfeb 12C 1stMarch 12 15thMarch 12dDEFINE
  4. 4. RASICdDEFINE
  5. 5. CTQ TreeIncrease TAT ofbreakdown maintenanceCTQsTotal time taken rectify eachfailure on breakdown machineagainst 120 minutes targettime.(operational definition)Quarterly rectify time of noncritical failure is greater than120 minutes .(Defect Description)One hundred twenty minutes(critical & non critical failures)(Performance standard)Quarterly(Opportunity)dDEFINE
  6. 6. SIPOCDAMPELDAMPEL 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. 7. Data Collection PlanmMEASUREKPI Operational Definition Defect Def Performance StdSpecification LimitOpportunityLSL USLIncrease TAT ofbreakdownmaintenanceTotal time taken in rectifying each failure onbreakdown machine against 120 minutes targettime.Quarterly Rectifytime of non criticalfailure is greater than120 minutes.DAYNA wants to achieve therectifying time of non criticalfailure is 120 minutes by themarch 2012.NA 120 minutes QuarterlyKPI Data TypeData ItemsNeededFormula to beusedUnitPlan 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?Increase TAT ofbreakdownmaintenance ContinuousAFC FailureReportPenalty time =Total time taken-TATminutes Excel Existing NA NA NA
  8. 8. Validate Measurement System Gage R&RAnnova MethodmMEASUREGage R&RA) %ContributionSource VarComp (of VarComp)Total Gage R&R 27.91 2.69Repeatability 1.24 0.12Reproducibility 26.68 2.57Operator 20.86 2.01Operator*Part 5.82 0.56Part-To-Part 1009.80 97.31Total Variation 1037.71 100.00Process tolerance = 120B) Study Var %Study Var %ToleranceSource StdDev (SD) (6 * SD) (%SV) (SV/Toler)Total Gage R&R 5.2834 31.700 16.40 26.42Repeatability 1.1127 6.676 3.45 5.56Reproducibility 5.1649 30.989 16.03 25.82Operator 4.5670 27.402 14.18 22.83Operator*Part 2.4123 14.474 7.49 12.06Part-To-Part 31.7773 190.664 98.65 158.89Total Variation 32.2135 193.281 100.00 161.07C) Number of Distinct Categories = 8Hence, Three rule of Gauge R & R are pass (MSA is correct)
  9. 9. Validation Measurement System –Process CapabilitymMEASUREDenominator ValuesMean 111.75Std Dev 36.54Target 12000.00%Zusl 0.225DPO 4.13e-001DPMO 413000Hence, Total defects is four lakh thirteen thousand in one million opportunity
  10. 10. Probability PlotmMEASURESince, P value < 0.05,hence the data is not normal
  11. 11. Data Stability AnalysisaAnalyzeThe RUN chart shows that mixture, oscillation and trends exists in the data while there are noClustering .This evidently shows that the data is not stable.……bb
  12. 12. Data Distribution Analysis (centering)There is too much centering problem in my process .Our USL is 120 minutes but our 45% team isabove the 120 minutes in third quartile and maximum up to 176 minutes.aAnalyseAny data isgreater than120 minutesthis is defect
  13. 13. Box Plot analysis on TAT14The Box plot shows that more than 55 % team is achieving the TAT target and 45% team is not achievingthe TAT TargetaAnalyse
  14. 14. Spare Availability wise box plot analysis for TAT15Box plot for spare availability shows that there is significant impact of the spare availability (X) on theTAT (Y).aAnalyse
  15. 15. Marital status wise box plot analysis for TAT16Box plot for Marital status shows that there is no significant impact of the marital status (X) on the TAT(Y).aAnalyse
  16. 16. Maintenance team wise Box plot analysis for TAT17Box plot for Maintenance team shows that there is no significant impact of the maintenance team (X) onthe TAT (Y).aAnalyse
  17. 17. Age wise box plot analysis for TAT18Box plot for Age shows that there is significant impact of the Age (X) on the TAT (Y).aAnalyse
  18. 18. Qualification wise box plot analysis for TAT19Box plot for Qualification shows that there is no significant impact of the qualification (X) on the TAT(Y).aAnalyse
  19. 19. Subject Specialization wise box plot analysis for TAT20Box plot for subject specialization shows that there is no significant impact of the specialization(X) onthe TAT (Y).aAnalyse
  20. 20. Company Payroll wise box plot analysis for TAT21Box plot for company payroll shows that there is no significant impact of the payroll (X) on the TAT (Y).aAnalyse
  21. 21. Technical Rating wise box plot analysis for TAT22Box plot for Technical rating shows that there is no significant impact of the technical rating (X) on theTAT (Y).aAnalyse
  22. 22. Designation wise box plot analysis for TAT23Box plot for designation shows that there is no significant impact of the designation (X) on the TAT (Y).aAnalyse
  23. 23. Training wise box plot analysis for TAT24Box plot for training shows that there is no significant impact of the training (X) on the TAT (Y).aAnalyse
  24. 24. Monthly reimbursement wise box plot analysis for TAT25Box plot for monthly claims shows that there is no significant impact of the monthly reimbursement (X)on the TAT (Y).aAnalyse
  25. 25. Tenure wise box plot analysis for TAT26Box plot for tenure shows that there is no significant impact of the tenure (X) on the TAT (Y).aAnalyse
  26. 26. Monthly Salary wise box plot analysis for TAT27Box plot for monthly salary shows that there is no significant impact of the monthly salary (X) on the TAT(Y).aAnalyse
  27. 27. Appraisal wise box plot analysis for TAT28Box plot for appraisal shows that there is no significant impact of the appraisal (X) on the TAT (Y).aAnalyse
  28. 28. Experience wise box plot analysis for TAT29Box plot for experience shows that there is significant impact of the experience (X) on the TAT (Y).aAnalyse
  29. 29. TAT Target wise box plot analysis for TAT30Box plot for TAT target shows that there is significant impact of the TAT Target (X) on the TAT (Y).aAnalyse
  30. 30. Shift wise box plot analysis for TAT31Box plot for shift shows that there is no significant impact of the shift (X) on the TAT (Y).aAnalyse
  31. 31. Location wise box plot analysis for TAT32Box plot for location shows that there is significant impact of the location (X) on the TAT (Y).aAnalyse
  32. 32. Gender wise box plot analysis for TAT33Box plot for gender shows that there is no significant impact of the gender (X) on the TAT (Y).aAnalyse
  33. 33. Preventive Maintenance wise box plot analysis for TAT34Box plot for Preventive Maintenance shows that there is significant impact of the PreventiveMaintenance (X) on the TAT (Y).aAnalyse
  34. 34. One sample T test for data Centring AnalysisaAnalyzeOne sample T test shows thatsince the P-Value is 0.000, & TATUSL is 120 minutes. It means theTAT has shifted from the centrepoint towards right side. we needto improve the TAT for come tothe centre point.Variable N Mean StDev SE Mean 95% CI TTAT 554 111.75 36.54 1.55 (108.70, 114.80) -5.31Variable PTAT (Breakdown Maintainace 0.000
  35. 35. Proposed tests according to problem and factor’s centeringdata typeaAnalyzeS No.X PotentialCauseOperational Definition Y Data TypeX DataTypeTest of beperformed1 Spare Availability Availability of spare inventory in warehouse for doing project. Continuous Discrete Mood’s Median2 Marital status Married or un married. Continuous Discrete Mood’s Median3 Maintenance TeamA group of people with a full set of complementary skills required to complete a task ,job, or project.Continuous Discrete Mood’s Median4 Age The number of years an individual associate is old in his / her span of life Continuous ContinuousRegressioncorrelation5 QualificationIt’s capacity, knowledge and skill which represents the eligibility criteria of person forenter the any field and position e.g. (technical or non technical.).Continuous Discrete Mood’s Median6 Subject specialization This defines the knowledge of interest in particular subject. Continuous Discrete Mood’s Median7 Company Payroll This represents you are company employee or third company employee. Continuous Discrete Mood’s Median8 Technical Rating This is method to evaluate the technical ability of person. Continuous Discrete Mood’s Median9 Designation To select and set aside for a duty. Continuous Discrete Mood’s Median10 TrainingIt is the learning process for development skill, knowledge, ability to perform a job forgrowth of company.Continuous Discrete Mood’s Median11 Reimbursement Reimbursement means to Pay back the money against the expenses by an employer. Continuous Discrete Mood’s Median12 TenureThe time in months / years which an individual associate has spent in the particularprocess.Continuous Discrete Mood’s Median13 Monthly SalarySalary is a fixed amount of money or compensation paid to an employee by an employerin return for work performedContinuous DiscreteMood’s Median14 AppraisalIt is the process of obtaining , analyzing and work effectiveness recording informationabout the relative worth of an employee.Continuous Discrete Mood’s Median15 Experience The total work experience of an individual in present company. Continuous ContinuousRegressioncorrelation16 TAT Target It means Our target is met or not met. Continuous Discrete Mood’s Median17 Shift Shift refers to a job work schedule for employee . Continuous Discrete Mood’s Median18 LocationThis is a place on where maintenance team goes for attending the failures for AFCequipments.Continuous Discrete Mood’s Median19 Gender Gender is a range of characteristics used to distinguish between males and females Continuous Discrete Mood’s Median20PreventiveMaintenancePreventive maintenance is a schedule of planned maintenance actions aimed at theprevention of breakdowns and failures. Continuous Discrete Mood’s Median
  36. 36. 37Mood’s median test between TAT & Spare AvailabilityaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus Spare AvailabilityMood median test for TAT (Breakdown Maintenance)Chi-Square = 4.58 DF = 1 P = 0.032Spare Individual 95.0% CIsAvailability N<= N> Median Q3-Q1 -----+---------+---------+---------+-Available 51 71 141.0 63.0 (--------------------------*)Not Available 228 204 108.0 73.0 (----*--------)-----+---------+---------+---------+-108 120 132 144Overall median = 109.0A 95.0% CI for median(Available) - median(Not Available): (1.0,38.0)The mood’s median test shows that since the p- value is 0.032 , spare availability (X) has significantimpact on TAT (Y).
  37. 37. 38Mood’s median test between TAT & Marital StatusaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus MaritalstatusMood median test for TAT (Breakdown Maintenance)Chi-Square = 2.60 DF = 1 P = 0.107Marital Individual 95.0% CIsstatus N<= N> Median Q3-Q1 --------+---------+---------+--------Married 128 145 121.0 63.0 (---------*--------------)unmarried 151 130 107.0 73.0 (-----*--------------)--------+---------+---------+--------108 120 132Overall median = 109.0A 95.0% CI for median(Married) - median(unmarried): (-6.0,35.0)The mood’s median test shows that since the p- value is 0.107,marital status (X) has no significantimpact on TAT (Y).
  38. 38. 39Mood’s median test between TAT & Maintenance TeamaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus Maintenance TeamMood median test for TAT (Breakdown Maintenance)Chi-Square = 4.35 DF = 5 P = 0.501Maintenance Individual 95.0% CIsTeam N<= N> Median Q3-Q1 -----+---------+---------+---------+-Ankush 42 43 130.0 83.0 (----------------*------)Pradeep 50 42 94.0 85.0 (-*----------------)Rajesh 51 43 100.0 80.0 *----------------------)Rajni 39 55 118.0 66.3 (---*----------------)Rita 50 45 108.0 74.0 *--------------------)Suresh 47 47 113.0 77.3 (----*----------------)-----+---------+---------+---------+-100 120 140 160Overall median = 109.0The mood’s median test shows since the p- value is 0.501 , maintenance team (X) has no significantimpact on TAT (Y).
  39. 39. 40Regression Correlation test between TAT & AGEaAnalyzeRegression Analysis: TAT (Breakdown Maintenance) versus AgeThe regression equation isTAT (Breakdown Maintenance) = 61.3 + 1.74 AgePredictor Coef SE Coef T PConstant 61.30 14.33 4.28 0.000Age 1.7398 0.4915 3.54 0.000S = 36.1669 R-Sq = 2.2% R-Sq(adj) = 2.0%Analysis of VarianceSource DF SS MS F PRegression 1 16392 16392 12.53 0.000Residual Error 552 722041 1308Total 553 738432The regression correlation shows that since the p- value is 0.000 , age (X) has significant impact onTAT (Y).
  40. 40. 41Mood’s median test between TAT & QualificationaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus QualificationMood median test for TAT (Breakdown Maintenance)Chi-Square = 4.29 DF = 3 P = 0.232Individual 95.0% CIsQualification N<= N> Median Q3-Q1 -----+---------+---------+---------+-B.tech 89 90 121.0 74.0 (---------*----------)Btech,CCNA 50 42 94.0 85.0 (-*----------------)Diploma 101 88 108.0 74.0 (---*-------------)I.T.I 39 55 118.0 66.3 (---*----------------)-----+---------+---------+---------+-100 120 140 160Overall median = 109.0The mood’s median test shows that since the p- value is 0.232 , qualification (X) has no significantimpact on TAT (Y).
  41. 41. 42Mood’s median test between TAT & Subject specializationaAnalyzeMood Median Test: TAT (Breakdown Maintainance) versus specializationMood median test for TAT (Breakdown Maintainance)Chi-Square = 0.36 DF = 1 P = 0.549Individual 95.0% CIsspecialisation N<= N> Median Q3-Q1 --------+---------+---------+--------CS 97 89 105.0 72.5 (--*-----------------------)E & C 182 186 110.0 71.0 (-*----------------------)--------+---------+---------+--------110 120 130Overall median = 109.0A 95.0% CI for median(CS) - median(E & C): (-23.4,19.4)The mood’s median test shows that since the p- value is 0.549 ,specialization (X) has no significantimpact on TAT (Y).
  42. 42. 43Mood’s median test between TAT & Company PayrollaAnalyzeMood Median Test: TAT (Breakdown Maintainance) versus PayrollMood median test for TAT (Breakdown Maintainance)Chi-Square = 2.43 DF = 1 P = 0.119Individual 95.0% CIsPayroll N<= N> Median Q3-Q1 ----+---------+---------+---------+--OFFROLE 193 173 107.0 79.0 (----*-------------)ONROLE 86 102 115.5 66.0 (---*--------------------)----+---------+---------+---------+--105 120 135 150Overall median = 109.0A 95.0% CI for median(OFFROLE) - median(ONROLE): (-39.4,4.2)The mood’s median test shows that since the p- value is 0.119 ,payroll (X) has no significant impact onTAT (Y).
  43. 43. 44Mood’s median test between TAT & Technical RatingaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus Technical ratingMood median test for TAT (Breakdown Maintenance)Chi-Square = 1.10 DF = 3 P = 0.778Technical Individual 95.0% CIsExpertise N<= N> Median Q3-Q1 ----+---------+---------+---------+--4 90 98 110.0 66.0 (-----*-----------------)5 92 88 108.0 69.0 (*-------------------)6 50 42 94.0 85.0 (--*---------------------)7 47 47 113.0 77.3 (----*--------------------)----+---------+---------+---------+--96 112 128 144Overall median = 109.0The mood’s median test shows that since the p- value is 0.778 ,Technical rating (X) has no significantimpact on TAT (Y).
  44. 44. 45Mood’s median test between TAT & DesignationaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus DesignationMood median test for TAT (Breakdown Maintenance)Chi-Square = 3.99 DF = 3 P = 0.263Designation N<= N> Median Q3-Q1Support Engineer 51 43 100.0 80.0Technical Supervisor 42 43 130.0 83.0Technical support Executive 147 134 108.0 75.0Technician 39 55 118.0 66.3Individual 95.0% CIsDesignation ------+---------+---------+---------+Support Engineer (*-----------------------------)Technical Supervisor (----------------------*-------)Technical support Executive (-*-------------)Technician (-----*---------------------)------+---------+---------+---------+105 120 135 150Overall median = 109.0The mood’s median test shows that since the p- value is 0.263 ,Designation(X) has no significant impacton TAT (Y).
  45. 45. 46Mood’s median test between TAT & Maintenance TrainingaAnalyzeMood Median Test: TAT (Breakdown M versus Maintenance TrainingMood median test for TAT (Breakdown Maintenance)Chi-Square = 0.27 DF = 1 P = 0.604Maintenance Individual 95.0% CIsTraining N<= N> Median Q3-Q1 --+---------+---------+---------+----NO 186 189 110.0 68.0 (--*------------------)Yes 93 86 100.0 79.0 (-*---------------------------------)--+---------+---------+---------+----100 110 120 130Overall median = 109.0A 95.0% CI for median(NO) - median(Yes): (-25.0,24.0)The mood’s median test shows that since the p- value is 0.604 ,Training (X) has no significant impact onTAT (Y).
  46. 46. 47Mood’s median test between TAT & Monthly claimsaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus MonthlyreimbursementMood median test for TAT (Breakdown Maintenance)Chi-Square = 2.43 DF = 1 P = 0.119Individual 95.0% CIsMonthly Claims N<= N> Median Q3-Q1 ----+---------+---------+---------+--Not Received 193 173 107.0 79.0 (----*-------------)Received 86 102 115.5 66.0 (---*--------------------)----+---------+---------+---------+--105 120 135 150Overall median = 109.0A 95.0% CI for median(Not Received) - median(Received): (-39.4,4.2)The mood’s median test shows that since the p- value is 0.119 ,monthly claims (X) has no significantimpact on TAT (Y).
  47. 47. 48Mood’s median test between TAT & TenureaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus TenureMood median test for TAT (Breakdown Maintenance)Chi-Square = 2.43 DF = 1 P = 0.119Individual 95.0% CIsTenure N<= N> Median Q3-Q1 ----+---------+---------+---------+--Contract 193 173 107.0 79.0 (----*-------------)Permanent 86 102 115.5 66.0 (---*--------------------)----+---------+---------+---------+--105 120 135 150Overall median = 109.0A 95.0% CI for median(Contract) - median(Permanent): (-39.4,4.2)The mood’s median test shows that since the p- value is 0.119 ,Tenure (X) has no significant impact onTAT (Y).
  48. 48. 49Mood’s median test between TAT & Monthly SalaryaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus Monthly SalaryMood median test for TAT (Breakdown Maintenance)Chi-Square = 2.05 DF = 1 P = 0.152Monthly Individual 95.0% CIsSalary N<= N> Median Q3-Q1 --+---------+---------+---------+----Delay 182 195 112.0 75.0 (----*---------------------)Ontime 97 80 107.0 70.5 (--------*----------------------)--+---------+---------+---------+----100 110 120 130Overall median = 109.0A 95.0% CI for median(Delay) - median(Ontime): (-19.0,28.0)The mood’s median test shows that since the p- value is 0.152 ,Monthly salary (X) has no significantimpact on TAT (Y).
  49. 49. 50Mood’s median test between TAT & AppraisalaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus AppraisalMood median test for TAT (Breakdown Maintenance)Chi-Square = 1.23 DF = 1 P = 0.268Individual 95.0% CIsAppraisal N<= N> Median Q3-Q1 ---------+---------+---------+-------NO 143 128 100.0 81.0 (-*------------------------)Yes 136 147 110.0 70.0 (-*----------------------)---------+---------+---------+-------108 120 132Overall median = 109.0A 95.0% CI for median(NO) - median(Yes): (-38.0,11.0)The mood’s median test shows that since the p- value is 0.268 ,Appraisal (X) has no significant impacton TAT (Y).
  50. 50. 51Mood’s median test between TAT & Present organization ExperienceaAnalyzeRegression Analysis: TAT (Breakdown M versus EPC)The regression equation isTAT (Breakdown Maintenance) = 94.4 + 6.52 Experiencepresent companyPredictor Coef SE Coef T PConstant 94.369 5.684 16.60 0.000Experience present company 6.523 2.053 3.18 0.002S = 36.2453 R-Sq = 1.8% R-Sq(adj) = 1.6%Analysis of VarianceSource DF SS MS F PRegression 1 13257 13257 10.09 0.002Residual Error 552 725175 1314Total 553 738432The mood’s median test shows that since the p- value is 0.000 ,Present Experience (X) has significantimpact on TAT (Y).
  51. 51. 52Mood’s median test between TAT & TAT TargetaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus TAT TargetMood median test for TAT (Breakdown Maintenance)Chi-Square = 504.31 DF = 1 P = 0.000Individual 95.0% CIsTAT Target N<= N> Median Q3-Q1 -+---------+---------+---------+-----met 279 13 75.0 37.0 (*-)Not met 0 262 147.0 7.3 (*-+---------+---------+---------+-----75 100 125 150Overall median = 109.0A 95.0% CI for median(met) - median(Not met): (-75.0,-66.0)The mood’s median test shows that since the p- value is 0.000 ,Present TAT Target (X) has significantimpact on TAT (Y).
  52. 52. 53Mood’s median test between TAT & ShiftsaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus ShiftsMood median test for TAT (Breakdown Maintenance)Chi-Square = 2.60 DF = 1 P = 0.107Individual 95.0% CIsShifts N<= N> Median Q3-Q1 --------+---------+---------+--------Evening 128 145 121.0 63.0 (---------*--------------)Morning 151 130 107.0 73.0 (-----*--------------)--------+---------+---------+--------108 120 132Overall median = 109.0A 95.0% CI for median(Evening) - median(Morning): (-6.0,35.0)The mood’s median test shows that since the p- value is 0.107,P shifts (X) has significant impact onTAT (Y).
  53. 53. 54Mood’s median test between TAT & LocationaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus LocationMood median test for TAT (Breakdown Maintenance)Chi-Square = 17.79 DF = 5 P = 0.003Individual 95.0% CIsLocation N<= N> Median Q3-Q1 -----+---------+---------+---------+-Airport 13 10 75.0 87.0 (----*-------------------------)Delhi Aerocity 38 64 142.0 50.3 (--------*)Dhaula kuan 50 27 100.0 66.0 (--*--)Dwarka sector-21 88 69 107.0 73.0 (--*------)New Delhi 43 45 110.0 77.5 (-----*---------)Shivaji stadium 47 60 141.0 75.0 (--------------*)-----+---------+---------+---------+-75 100 125 150Overall median = 109.0The mood’s median test shows that since the p- value is 0.003,P Gender (X) has significant impact onTAT (Y).
  54. 54. 55Mood’s median test between TAT & GenderaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versus GenderMood median test for TAT (Breakdown Maintenance)Chi-Square = 1.23 DF = 1 P = 0.268Individual 95.0% CIsGender N<= N> Median Q3-Q1 ---+---------+---------+---------+---Female 89 100 110.0 70.0 *-------------------------)Male 190 175 105.0 79.0 (--*---------------)---+---------+---------+---------+---105 120 135 150Overall median = 109.0A 95.0% CI for median(Female) - median(Male): (-10.0,37.0)The mood’s median test shows that since the p- value is 0.268,P Gender (X) has significant impact onTAT (Y).
  55. 55. 56Mood’s Median test between TAT & Preventive MaintenanceaAnalyzeMood Median Test: TAT (Breakdown Maintenance) versusPM StationsMood median test for TAT (Breakdown Maintenance)Chi-Square = 25.52 DF = 10 P = 0.004PM Stations N<= N> Median Q3-Q1Airport Not Done 25 35 142.0 73.8Delhi Aerocity Done 10 19 141.0 61.5Delhi Aerocity Not Done 25 33 139.5 63.0Dhaula Kuan Done 16 16 109.5 81.0Dhaula Kuan Not Done 34 30 106.0 74.0Dwarka sector -21 Not Done 36 27 102.0 83.0Dwarka sector -21Not Done 14 6 85.0 71.0New Delhi Station Done 10 18 142.0 52.0New Delhi Station Not Done 21 35 141.0 56.5Shivaji stadium Done 25 23 109.0 67.5Shivaji stadium Not Done 63 33 100.0 73.0Individual 95.0% CIsThe mood’s median test shows that since the p- value is 0.004,P location (X) has significant impact onTAT (Y).PM Stations -+---------+---------+---------+-----Airport Not Done (--------------*)Delhi Aerocity Done (------------*-)Delhi Aerocity Not Done (--------------*)Dhaula Kuan Done (-------------*-----------)Dhaula Kuan Not Done (---*-------------)Dwarka sector -21 Not Done (-----------*----------)Dwarka sector -21Not Done (----*------------------)New Delhi Station Done (---------------*-)New Delhi Station Not Done (------------*)Shivaji stadium Done (----*------------)Shivaji stadium Not Done (---*--)-+---------+---------+---------+-----75 100 125 150Overall median = 109.0
  56. 56. 57Vital X’s that are impacting the TATaAnalyzeS No.X PotentialCauseOperational Definition Y Data Type X Data TypeTest of beperformed1 Spare Availability Availability of spare inventory in warehouse for doing project. Continuous Discrete 0.0322 Age The number of years an individual associate is old in his / her span of life Continuous Continuous 0.0003 Experience The total work experience of an individual in present company. Continuous Continuous 0.0004 TAT Target It means Our target is met or not met. Continuous Discrete 0.0005 LocationThis is a place on where maintenance team goes for attending thefailures for AFC equipments.Continuous Discrete 0.0036PreventiveMaintenancePreventive maintenance is a schedule of planned maintenance actionsaimed at the prevention of breakdowns and failures.Continuous Discrete 0.004
  57. 57. 58IImproveQFDMicrosoft OfficeExcel WorksheetActionable Items Responsibility Start Date Close DateChecked monthly RAM/Failure Report Maintenance Manager 2-Jan-2012 7-Jan-2012Increase quantity of Repaired Material stock Head of LAB 2-Jan-2012 14-Jan-2012Increased quantity of advance tool and machines Head of LAB 2-Jan-2012 21-Jan-2012Maintained all stock of Laboratory Head of LAB 2-Jan-2012 21-Jan-2012Increased quantity of Spare Availability Store Manager 9-Jan-2012 18-Feb-2012Recruited employee 28 to 35 years HR Manager 2-Jan-2012 14-Jan-2012Find Weakness and strong point of Team and workout Maintenance Manager 9-Jan-2012 21-Jan-2012Prepared Innovation and plan for Team motivation, Trainings, PM, Shifts Maintenance Manager 2-Jan-2012 31-Jan-2012Approval for preventive and testing for identify the common cause Maintenance Manager 2-Feb-2012 29-Feb-2012Reconsider shift for M Team members Maintenance Manager 2-Jan-2012 7-Jan-2012Test the technical expertise of whole team Maintenance Manager 2-Jan-2012 14-Jan-2012Increase the availability Transportation Maintenance Manager 2-Jan-2012 21-Jan-2012Start prcedure of monthly Inspection for Warehouse Store Manager 2-Jan-2012 29-Feb-2012Increaseing % of Annual Performance Appraisal Maintenance Manager 2-Jan-2012 29-Feb-2012Increaseing Technical Training Maintenance Manager 21-Jan-2012 29-Feb-2012Checked and Maintained Stock Report Store Manager 2-Jan-2012 28-Jan-2012Purchased branded Cleaning Kit Maintenance Manager 2-Jan-2012 7-Jan-2012Purchase Rack assembly for Storage Store Manager 2-Feb-2012 29-Feb-2012Increasing quantity of PM technician Maintenance Manager 2-Jan-2012 31-Jan-2012Generate SAP for keeping record for improve the store layout by newtechnologyStore Manager 2-Jan-2012 2-Feb-2012
  58. 58. 59IImproveImplementation Road Map
  59. 59. 60IImproveFailure mode effect analysisDefined "X"s Items Failure Mode Effect on EDR Severity Occurrence Detection RPN RMS RTP ResponsibilitySPARE AVAILABILITYWarehouseInappropriate Location Time and money would be consume for transportation 10 2 10 200 Avoid Consult to client Bid mangerUnsufficient space material could be damage and broken. 10 2 10 200 Avoid Consult to client Bid mangerStorageUnsufficient resources for covering and housing Dust and water leakage could be spoil our inventory 10 2 10 200 Avoid Consult to client store managerLack of raw material for organised the inventory.% of searching time would be greater to find out the inventory for separatedepartments.10 5 10 500 Reduce Take Approval for process manager store managerStock Report Incomplete Stock reportQuantity could be mismatch and store incharge can not easily diagnose shortageand requirement of inventory.8 5 10 400 Reduce ask complete spare list to vendor store managerAvailability of no of spare Adequate of inventoryService quality of equipment could be affected .TAT would be increase and penaltycharge will be too high.10 5 10 500 ReduceApproval for process manager to purchasethe itemsstore managerstorage TechnologyNo implementation of SAP Chances of data accuracy would be minimum.data could be loss. 8 5 10 400 Transfer Request mail to SAP department store managerUnavailability of Fire protection element% of safety protection would be negligible for inventory & employee inuncertanity situations.8 2 10 160 AvoidApproval for process manager to purchasethe fire protection devicestore managerAGE Recruited Employees between 28 to 35 Years Freshers & unexperience employeeMaintenance service time would be greater and chances of penalty amount couldbe raised.8 4 10 320 Avoidmail to HR for recruiting to experiencedpeopleMaintenance ManagerEXPERIENCE Performance AppraisalInappropriate salary structure(unclear bonus) chances of attrition would be high. 8 2 10 160 Avoid Mail to HR Recruiter Maintenance ManagerExperienced employee in third party chances of attrition would be high. 8 5 10 400 Reduce Mail to HR Recruiter Maintenance Managerunfair appraisal chances of attrition would be high. 8 5 10 400 Avoid Mail to HR Recruiter Maintenance ManagerTAT TargetTeam Less employee If no of employee is adequate then service quality could be low. 8 5 10 400 Reduce Mail to HR Recruiter Maintenance ManagerLaboratory Lack of maintenance LABservice quality would be out of control,quantity of repaired items will benegligible.Impossible equipment testing.8 2 10 160 Avoid Mail to maintenance Manager Head of LABRepaired Material stock Lack of specification and maintenance documents% of troubleshooting the fault will be difficult.Quantity of scrap would be greater.itcan affect the cost of project.8 5 10 400 Reduce Mail to maintenance Manager Head of LABTechnical Expertise % of non technical employee is greater TAT of breakdown maintenance wolud be high. 8 5 10 400 Reduce Mail to project Manager Maintenance ManagerTechnical Training Lack of maintenance trainingTeam knowlede would be little about equipment .Difficult to identify and rectifythe faults of equipments.8 4 10 320 Reduce Mail to trainer Maintenance ManagerAdvanced tool and Machines Lack of proper tool and machines % of rejection would be high and maintainace would be difficult. 8 5 10 400 Reduce Mail to maintenance Manager Head of LABInnovation and plan Lack of planning Difficult to take time estimation for any process. 8 5 10 400 Avoid Plaaned to all activities Maintenance ManagerLOCATIONReconsider shifts Lack of Muster rollTeam shift will not properly organised and workload can be greater to individualteam members.7 5 10 350 Reduce Prepared report and distribute the team Maintenance ManagerTransportation Lack of conveyance Delay the service of DLP.it would be direct impact on customer service. 7 5 10 350 Reduce Take Approal to project Manager Maintenance ManagerPREVENTIVE MAINTENANCEApproval Lack of approavlAfter handover we need permission to client without (PTW approval) permission towork.our company will have to paid to as per our contract clauses.8 5 10 400 Avoid Take Approal to client Maintenance ManagerIncrease no of technician Less TechnicianPreventive time would be greater for every station and it would be direct impacton equipment failure TAT.8 4 10 320 Avoid send mail to HR recruiter Maintenance ManagerStation RAM/Failure Report Non availability of reportWithout Failure report it would be very difficult to diagnose the RAM cycles andsystem stability.7 4 10 280 Reducesend mail to team for daily activity failurereportMaintenance ManagerCleaning Kit Non availability of kit50% failures occoured by dust if we will not use proper cleaning kit and devices itwould be direct impact on our RAM .7 5 10 350 Reduce send mail to maintenance manger Head of LABMicrosoft OfficeExcel 97-2003 Worksheet
  60. 60. 61cControlX-bar S Chart on TAT and spare availabilityTest Results for Xbar S Chart of TAT (BreakdownMaintenance) :TEST 1. One point more than 3.00 standarddeviations from center line.Test Failed at points: 44, 95AFTER IMPROVEMENTBEFORE IMPROVEMENTThere is no special cause variation.
  61. 61. 62cControltTTTest Results for S Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side ofcenter line.Test Failed at points: 110, 111, 113, 131TEST – 2 AbnormalityBEFORE IMPROVEMENT AFTER IMPROVEMENTThere is no special cause variation.
  62. 62. 63cControlTEST – 3 AbnormalityThis process is not special cause but variation ismore & need to improve it.BEFORE IMPROVEMENT AFTER IMPROVEMENTThere is no special cause variation.
  63. 63. 64TEST- 4 AbnormalitycControltTTTEST 4. 14 points in a row alternating up anddown.Test Failed at points: 108, 109, 110, 111, 112,113, 114, 115, 116, 117, 118,119, 120, 121, 122,123, 124, 125, 126, 127, 128, 129,143, 144There is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  64. 64. 65cControltTTTest Results for Xbar Chart of TAT(Breakdown Maintenance)TEST 5. 2 out of 3 points more than 2standard deviations from centres line (onone side of CL).Test Failed at points: 95, 127, 142TEST – 5 AbnormalityThere is no special cause variation.AFTER IMPROVEMENTBEFORE IMPROVEMENT
  65. 65. 66cControltTTTest Results for X bar Chart of TAT(Breakdown Maintenance)TEST 6. 4 out of 5 points more than 1standard deviation from centre line (on oneside of CL).Test Failed at points: 27, 46TEST – 6 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  66. 66. 67cControltTTTEST -7 AbnormalityThis process is not special cause but variation ismore & need to improve it.There is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  67. 67. 68TEST -8 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 8. 8 points in a row more than 1 standarddeviation from centre line (above and below CL).Test Failed at points: 105, 106, 141, 142, 143Process is under control & system is stable.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  68. 68. 69X bar- S chart TAT with AGEcControltTTThis process is not special cause. but variationis more.This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  69. 69. 70TEST – 2 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side of centerline.Test Failed at points: 10, 11, 103Test Results for S Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side of centerline.Test Failed at points: 22BEFORE IMPROVEMENT AFTER IMPROVEMENT
  70. 70. 71TEST – 3 AbnormalitycControltTTTest Results for S Chart of TAT (BreakdownMaintenance)TEST 3. 6 points in a row all increasing or alldecreasing.Test Failed at points: 145, 147There is no special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  71. 71. 72TEST – 4 AbnormalitycControltTTThere is no special cause. variations are more. Test Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 4. 14 points in a row alternating up anddown.Test Failed at points: 138, 139BEFORE IMPROVEMENT AFTER IMPROVEMENT
  72. 72. 73TEST – 5 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 5. 2 out of 3 points more than 2 standarddeviations from center line (on one side of CL).Test Failed at points: 121, 180, 182This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  73. 73. 74TEST – 6 AbnormalitycControltTTTest Results for X bar s Chart of TAT (BreakdownMaintenance)TEST 6. 4 out of 5 points more than 1 standarddeviation from centre line (On one side of CL).Test Failed at points: 41, 124BEFORE IMPROVEMENTThere is no special cause.AFTER IMPROVEMENT
  74. 74. 75TEST – 7 AbnormalitycControltTTThere is no special cause . Variation is more.BEFORE IMPROVEMENTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 7. 15 points within 1 standard deviation ofcenter line (above and below CL).Test Failed at points: 80AFTER IMPROVEMENT
  75. 75. 76TEST – 8 AbnormalitycControltTTThere is no special cause but variation is more.Need to reduce the variation.BEFORE IMPROVEMENTThere is no special cause.AFTER IMPROVEMENT
  76. 76. 77X Bar-S chart TAT with ExperiencecControltTTThis process is not special cause but variationis more and need to improve it.This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  77. 77. 78TEST -2 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side of centerline.Test Failed at points: 10, 11, 103Test Results for S Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side ofcenter line.Test Failed at points: 46, 47, 48BEFORE IMPROVEMENT AFTER IMPROVEMENT
  78. 78. 79TEST- 3 AbnormalitycControltTTTest Results for S Chart of TAT (BreakdownMaintenance)TEST 3. 6 points in a row all increasing or alldecreasing.Test Failed at points: 145, 147This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  79. 79. 80TEST- 4 AbnormalitycControltTTThis process is not special cause. but variationis more.Test Results for S Chart of TAT (BreakdownMaintenance)TEST 4. 14 points in a row alternating up anddown.Test Failed at points: 17, 18, 19BEFORE IMPROVEMENT AFTER IMPROVEMENT
  80. 80. 81TEST- 5 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 5. 2 out of 3 points more than 2 standarddeviations from center line (on one side of CL).Test Failed at points: 121, 180, 182This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  81. 81. 82TEST- 6 AbnormalitycControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 6. 4 out of 5 points more than 1 standarddeviation from center line (on one side of CL).Test Failed at points: 41, 124This process is not special causeBEFORE IMPROVEMENT AFTER IMPROVEMENT
  82. 82. 83TEST- 7 AbnormalitycControltTTThis process is not special cause and variationsin data points are more.Test Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 7. 15 points within 1 standard deviation ofcenter line (above and below CL).Test Failed at points: 92, 93, 94, 95BEFORE IMPROVEMENT AFTER IMPROVEMENT
  83. 83. 84TEST- 8 AbnormalitycControltTTThis process is not special cause. variation ismore.This process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  84. 84. 85cControltTTTest Results for Xbar Chart of TAT (Breakdown Maintenance)TEST 1. One point more than 3.00 standard deviations fromcenter line.Test Failed at points: 1, 2, 3, 4, 5, 6, 8, 12, 16, 18, 19, 20, 21,22, 23,24, 28, 29, 30, 32, 33, 34, 35, 36, 37, 38, 39, 41,44,46, 48,49, 50, 51, 53, 54, 56, 58, 60, 61, 64, 65, 66,67, 68, 69, 70, 71, 72,74, 75, 76, 7782, 83, 84, 85,87, 89, 90, 92, 94, 98, 99, 101, 103,104, 106, 107,109, 111, 114, 117, 118, 119, 121, 126, 127, 128,130,131, 132, 133, 135, 136, 138, 140, 142, 143, 145, 146,147,148, 150, 152, 154, 155, 158, 159, 160, 161, 163,164, 165, 166,167, 168, 172, 173, 176, 177, 179, 181,182, 183, 184, 185, 187,189, 192, 195, 196, 197, 199,201, 207, 210, 211, 212, 213, 215,216, 218, 220, 222,223, 226, 228, 229, 230, 231, 232, 233, 234,236, 237, 238, 239, 241, 242, 243X bar – s chart TAT with TAT TargetThis process is not special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  85. 85. 86cControltTTThis Process is not special cause. but variation is more.TEST – 2 AbnormalityBEFORE IMPROVEMENT AFTER IMPROVEMENTThere is no special cause variation.
  86. 86. 87cControltTTThis process is not special cause but variationis more.TEST – 3 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  87. 87. 88cControltTTXbar-S Chart of TAT (Breakdown Maintenance)Test Results for Xbar Chart of TAT (Breakdown Maintenance)TEST 4. 14 points in a row alternating up and down.Test Failed at points:15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35,36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56,57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77,78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98,99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114,115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129,130,131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144, 145,146,147, 148, 149, 150, 151, 152, 153, 154, 155, 156, 157, 158, 159, 160, 161,162,163, 164, 165, 166, 167, 168, 169, 170, 171, 172, 173, 174, 175, 176, 177,178,179, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193,194,195, 196, 197, 198, 199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 209,210,211, 212, 213, 214, 215, 216, 217, 218, 219, 220, 221, 222, 223, 224, 225,226,227, 228, 229, 230, 231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241,242, 243, 244TEST – 4 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  88. 88. 89cControltTTTest Results for Xbar Chart of TAT (Breakdown Maintenance)TEST 5. 2 out of 3 points more than 2 standard deviations from centerline (on one side of CL).Test Failed at points: 3, 4, 5, 6, 8, 10, 12, 14, 16, 18, 19, 20, 21, 22, 23,24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36 37, 38, 39, 40, 41, 46, 48,50, 51, 53, 56, 58, 60, 62, 64, 66, 67, 68, 69, 70, 71, 72, 74, 76, 77, 79, 82,84, 85, 86, 87, 89, 92, 94, 96, 98, 100, 101, 102, 103, 104,105, 106, 107,108, 109, 110, 111, 112, 114, 117, 119, 120, 121, 122, 123, 128, 130, 132,133, 134, 135, 136, 138, 140, 142, 144, 145, 146, 147, 148, 149, 150, 151,152, 153, 154, 155, 156, 158, 160, 161, 162, 163, 164, 165, 166, 167, 168,170, 172, 174, 176, 178, 179, 180, 181, 182, 183, 184, 185, 186, 187, 188,189, 190, 192, 195, 197, 198, 199, 200, 201, 206, 208, 210, 212, 213,215,218, 220, 222, 224, 225, 226, 227, 228, 229, 230, 231, 232, 233, 234, 235,236, 237, 238, 239, 240, 241, 242, 243, 244TEST – 5 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  89. 89. 90cControltTTThis Process is not special cause butvariation is more & need to improve it.TEST – 6 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  90. 90. 91cControltTTThis process is not special cause butvariation is more & need to improve it.TEST – 7 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  91. 91. 92cControltTTXbar-S Chart of TAT (Breakdown Maintenance)Test Results for Xbar Chart of TAT (Breakdown Maintenance)TEST 8. 8 points in a row more than 1 standard deviation fromcenter line (above and below CL).Test Failed at points: 8, 9, 10, 23, 24, 25, 26, 27, 28, 29, 30, 31,32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 65, 66, 67, 68, 69, 70, 71,72, 105, 106, 107, 108,109,110, 111, 112, 113, 114, 115, 116, 117,118, 119,120, 121, 122, 123,124, 133, 134, 135, 136, 137, 138,149, 150, 151, 152, 153, 154, 155,156, 165, 166, 167, 168, 177,178, 179, 180, 181, 182, 183, 184, 185,186, 187, 188, 189,190,199, 200, 201, 202, 203, 204, 205, 206, 207, 208, 229, 230,231, 232, 233, 234, 235, 236, 237, 238, 239, 240, 241, 242, 243,244TEST – 8 AbnormalityThere is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENT
  92. 92. 93cControltTTThis process is not special cause but variation ismore ,need to improve it.This process is not special causeBEFORE IMPROVEMENT AFTER IMPROVEMENTXbar-S chart TAT with location
  93. 93. 94cControltTTTest Results for S Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side of center line.Test Failed at points: 69Test Results for S Chart of TAT (BreakdownMaintenance)TEST 2. 9 points in a row on same side of centerline.Test Failed at points: 92, 103, 108, 113, 118, 131,136BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 2 Abnormality
  94. 94. 95cControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 3. 6 points in a row all increasing or alldecreasing.Test Failed at points: 201This process is not special cause .BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 3 Abnormality
  95. 95. 96cControltTTThere is no special cause but variation is more. There is no special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST - 4 Abnormality
  96. 96. 97cControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 5. 2 out of 3 points more than 2 standarddeviations from center line (on one side of CL).Test Failed at points: 308There is no special cause .BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST - 5 Abnormality
  97. 97. 98cControltTTTEST 6. 4 out of 5 points more than 1 standard deviationfrom centre line (on one side of CL).Test Failed at points: 11, 26, 27, 28, 30, 46, 113, 122, 123,124, 130, 148, 172, 175, 196, 262, 277, 291, 318, 319, 320,321, 322, 335, 428, 454, 466, 468, 469, 470, 471There is no special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST - 6 Abnormality
  98. 98. 99cControltTTVariation is more. There is no special cause.BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST - 7 Abnormality
  99. 99. 100cControltTTTest Results for Xbar Chart of TAT (BreakdownMaintenance)TEST 8. 8 points in a row more than 1 standard deviationfrom center line (above and below CL).Test Failed at points: 11, 264, 471There is no special cause variation.BEFORE IMPROVEMENT AFTER IMPROVEMENTTEST - 8 Abnormality
  100. 100. 101cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTX bar –s chart TAT with PMThere is no special cause but variation is more. There is no special cause variation.
  101. 101. 102cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 2 AbnormalityThere is no special cause but variation is more. There is no special cause variation.
  102. 102. 103cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 3 AbnormalityVariations are more. There is no special cause variation.
  103. 103. 104cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 4 AbnormalityVariations are more. There is no special cause variation.
  104. 104. 105cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 5 AbnormalityVariations are more. There is no special cause variation.
  105. 105. 106cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 6 AbnormalityVariations are more. There is no special cause variation.
  106. 106. 107cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 7 AbnormalityVariations are more. There is no special cause variation.
  107. 107. 108cControltTTBEFORE IMPROVEMENT AFTER IMPROVEMENTTEST – 8 AbnormalityVariations are less The system is stable.
  108. 108. 109tTTcControlPre & Post Project Process Control Analysis
  109. 109. 110tTTcControlPre TAT: Test Results for I Chart of C2 by SubscriptsTEST 1. One point more than 3.00 standard deviationsfrom center line.Test Failed at points: 151TEST 3. 6 points in a row all increasing or all decreasing.Test Failed at points: 362, 363TEST 5. 2 out of 3 points more than 2 standard deviationsfrom center line (on one side of CL).Test Failed at points: 140, 345TEST 6. 4 out of 5 points more than 1 standard deviationfrom center line (on one side of CL).Test Failed at points: 8, 12, 30, 31, 32, 34, 51, 117, 118,129, 138, 139,140, 141, 145, 147, 156, 196, 199, 205, 207,220, 221,300, 301, 318, 319, 321, 322, 323, 327, 329, 338, 345,359,368, 374, 375, 389, 401, 402, 403, 405, 479, 491,502, 517,543, 549TEST 8. 8 points in a row more than 1 standard deviationfrom center line (above and below CL).Test Failed at points: 11, 12, 89, 118, 119, 120, 144, 145,146, 147, 165, 299, 300, 301, 302, 303, 328, 329, 378, 379,380, 452,478, 479, 526, 527Post TAT: There is no special cause variation.
  110. 110. 111tTTBox plot of TAT shows that after improve the vital x TAT shifted the side of centering (176minutes to 120 minutes).cControlBox plot of TAT after implementation of improvement plan
  111. 111. 112tTTBox plot of TAT shows that after increasing the spare, TAT has been shifted 17.cControlSpare availability wise box plot of TAT after improvement
  112. 112. 113tTTBox plot of TAT shows that after recruited the 27 to 30 age group employee, TAT has beenshifted a side to target and able to achieve the target.cControlAGE wise box plot of TAT after improvement
  113. 113. 114tTTBox plot of TAT shows that after manipulating the other resources, Team member is able toreduce the TAT.cControlTAT Target wise box plot of TAT after improvement
  114. 114. 115tTTBox plot of TAT shows that after recruited the experienced employee, Team member is ableto reduce the TATcControlExperience wise box plot of TAT after improvement
  115. 115. 116tTTBox plot of TAT shows that after changing team member shifts & increase the availability ofspare in nearest warehouse it is direct impact on location, TAT has been reduced and cometo the target .cControlLocation wise box plot of TAT after improvement
  116. 116. 117tTTBox plot of TAT shows that after done the preventive maintenance in all station TAT hasbeen reduced and shifted the centre point.cControlPM wise box plot of TAT after improvement
  117. 117. 118tTTThis Data Distribution chart shows that stages of Pre TAT and post TAT . The pre stage of TAT wasshowing, team was taking maximum time up to 176 minutes for (BM) and too much centering problemwhile our TAT target was 120 minutes after improvement TAT time was reduced and it reached up to 120minutes Now All maintenance team is able to reduce the TAT.Difference between Pre & Post TAT of breakdown maintenance(centering)cControl
  118. 118. 119tTTThis chart shows the comparison of both ‘Improved TAT and Pre-project TAT’. In Pre-Project TATthe mean was of 111.749% and post project the mean is 17.671%.Difference between Pre & Post TAT of breakdown maintenance cControl
  119. 119. 120tTTTHANK YOU

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