Reduce warranty complains in pix 36 ( greenbelt project )

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It was a GreenBelt Six Sigma project for Company benefit. The Project was To reduce the warranty complaints in PIX-36 from 47% to 20% by 2009 end.

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Reduce warranty complains in pix 36 ( greenbelt project )

  1. 1. AIS - VADODARA
  2. 2. Reduce Warranty Complains in PIX-36 Action Leader : Sudip Dutta I-Nexus ID : 8999 AIS - VADODARA
  3. 3. Project Definition Sheet D M A I C BU/PL/UNIT: Products/PDS/VAIS Lever: Process Efficiency iNexus ID: 8999 ACTION TITLE: To reduce the warranty complain in PIX-36 from 47% to Y% by 2009 end. Business Problem: status before change Action objective: Status after change The warranty complain in PIX-36 is now 47% of the total dishpatched job till date leading to increase of cost of non quality & customer dissatisfaction. Key Indicator Definition (must be Not Financial) %Warranty Complaints = (Cumulative Number of warranty complaints for 18 months) / Cumulative number of recruitment for 18 months) X 100 47.00% Indicator Baseline: Quality, Cost & Delivery SQCD Impact: Contributing sites: Business Impact KINR Savings/Benefits Implementation Costs Net action impact on a 12 month basis Sales COI 436 435.8 Milestones x DEFINE x MEASURE CE To reduce the warranty complaints in PIX-36 by 15% from existing 47% 2009 end. In and out of Scope In scope: PIX-36 MANUFACTURING Out of scope: , HVX, HWX,HWX-C,PIX-12 <40% Indicator Target: Valuation Methodology Validation (by/when/signature) Finance validation by Debasish SQCD % warranty cost before & Chakraborty after the project Amol Phatak Sponsor: Action Leader: Sudip Dutta R. Karthikeyan/Rajan Pothi Coach (if applicable) DMAIC Methodology Team Members: Ugrasena,Ranjit Mallick,Saibal,Subhajit etc Deliverables Target Date x Problem Definition, Project scope, Project Charter, SIPOC, CTQ, Target improvement value, Benefit estimation, Project Owner 15.07.09 Detailed process mapping, Data collection, x ANALYSE x Prioritization, FMEA, Sigma level, Yield 16.08.09 x Data analysis, Root cause identification & validation Brainstorm on X’s, Identification of X’s affects Y 20.09.09 Solution identification, Piloting solutions, Risk assessment, Implementation of the improvement action plan. 15.10.09 x IMPROVE x x CONTROL x Auditing Standardization, Fool-proofing, Inspection, AIS 30.12.09 VADODARA
  4. 4. SIPOC D M A I C SUPPLIER INPUT TDC/ R&D/COMPETENCY DESIGN BOM END CUSTOMER CUSTOMER NEED, CORE ENGINEERING OUTPUT S2K BOM CUSTOMER PRODUCT DETAILS CENTRE PROCESS Assembled PIX 36 Panels APPLICATION ENGG S2K BOM, SAP BOM APPLICATION ENGG SAP BOM, DRAWINGS, PURCHASE MATERIAL REQUIRED PRODUCTION TESTING , QUALITY CORE CORE ENGINEERING ENGINEERING PROCESS PROCESS PIX-36 MANUFACTURING END CUSTOMER PROCESS PIX-36 READY PANELS Test Reports W/O SHORTAGES TESTED TAGGED PANELS APPLICATION APPLICATION ENGINEERING ENGINEERING PROCESS PROCESS PURCHASE PURCHASE PROCESS PROCESS PRODUCTION PRODUCTION PROCESS PROCESS TESTING & TESTING & QUALITY CHECK QUALITY PROCESS PROCESS PACKING & PACKING & DISHPATCH DISHPATCH PROCESS PROCESS AIS - VADODARA
  5. 5. VOC Tree D M A I C NEED DRIVER CORE CORE ENGINEERING ENGINEERING PROCESS PROCESS CTQ Proper Master BOM for Proper Master BOM for Pix-36 & in all variant. Pix-36 & in all variant. APPLICATION APPLICATION Meet Customer Meet Customer ENGGINEERING ENGGINEERING specifications specifications REDUCE WARRANTY COMPLAIN METRICS No of warranty complains No of warranty complains due to non-availability of due to non-availability of Material in S2K BOM. Material in S2K BOM. No of warranty complains No of warranty complains due to fault in SAP BOM & due to fault in SAP BOM & Appl Engg output. Appl Engg output. No of warranty complains No of warranty complains PRODUCTION PRODUCTION Quality of products Quality of products Related to manufacturing Related to manufacturing Fault. Fault. IN PIX-36 QUALITY & QUALITY & Faith in incoming Faith TESTING TESTING Checked Materials Checked Materials CHECKING CHECKING & final tagging. LOOSE LOOSE MATERIAL MATERIAL ARRENGEMENT ARRENGEMENT PACKAGING & PACKAGING & TRANSPORT TRANSPORT PROCESS PROCESS No of errors in Testing No of errors Reliability in arranged Reliability in arranged No of errors in loose No of errors Loose material box Loose material box Material arranging Material Standard Packaging & safe transportation. safe transportation. No of warranty complains No of warranty complains due to packaging & due to packaging & Transportation process Transportation process AIS - VADODARA
  6. 6. Defect Definition of CTQ D M A I C CTQ METRICS No of warranty complains due to non-availability of due to non-availability of Material in S2K BOM. Material in S2K BOM. No of warranty complains due to fault in SAP BOM & due to fault in SAP BOM & Appl Engg output. Appl Engg output. No of warranty complains Related to manufacturing Related to manufacturing Fault. Fault. DEFECT definition Any one or more components That are missed in S2K BOM Any required components that are Missed in SAP Bom & Engg output. Any fault remains in the offered Completed panels for tagging No of warranty complaints Any fault remains in inspected due to errors in Testing due to errors in Testing Materials & tagged Panel No of errors in loose No of errors in loose If any loose material component Material arranging Material arranging Missed to put in the BOX No of warranty complains due to packaging & due to packaging & Transportation process Transportation process Packaging is not as per AREVA spec & transportation practice is not good AIS - VADODARA
  7. 7. Measure Measure 7 AIS - VADODARA
  8. 8. Data Collection Plan D M A I C COLOR INDICATE PNL EXECUTED IN 2007 COLOR INDICATE PNL EXECUTED IN 2008 COLOR INDICATE PNL EXECUTED IN 2009 ALL THE DATAS ARE FOUND AFTER DISSCUSSION WITH Mr. Amit pyne , Mr Amol phatak The Service team-Kotambi & me. SL NO SO NO PNL QTY CUSTOMER 1 2 3 4 5 6 7 8 9 10 11 12 127 3106700638 3106700638/02/01 3106700638/01/01 3106700638/01/02 3106700240/02/01 3106700463/01/01 3106700463/01/02 3106700463/01/03 3106700240/03/01 3106700647/01/01 3106700616/01/02 3106700616/01/03 3106700616/01/04 3107700221/01/01 1 1 1 1 1 1 1 1 1 1 1 1 1 VENKATESH ELECTRICALS VENKATESH ELECTRICALS VENKATESH ELECTRICALS JOYPRAKASH ASSOCIATES MARUTI CLEAN COAL & POWER MARUTI CLEAN COAL & POWER MARUTI CLEAN COAL & POWER JOYPRAKASH ASSOCIATES POWER & INSTRUMATION LTD ESSAR CONSTRUCTION LTD ESSAR CONSTRUCTION LTD ESSAR CONSTRUCTION LTD R.R. ISPAT LTD 3107700221/01/02 3107700221/01/03 3107700397/01/01 3107700397/01/01 3107700336/01/01 3107700336/01/02 3107700336/01/03 3107700336/02/01 3107700336/02/01 3107700484/01/01 3107700470/01/01 3107700470/01/02 3107700470/01/03 3108710001/099/02 3108710001/099/03 3108710001/099/04 3108710001/099/05 3108710001/099/06 3108710001/099/08 3108710001/099/12 3108710001/099/16 3508701551/01/01 3508701551/01/02 3508701551/01/03 3108700138/01/01 3108700138/01/02 3108700138/01/03 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 R.R. ISPAT LTD R.R. ISPAT LTD POWERLINE CABLE POWERLINE CABLE GOVINRAJ - POWER DRIVE GOVINRAJ - POWER DRIVE GOVINRAJ - POWER DRIVE GOVINRAJ - POWER DRIVE GOVINRAJ - POWER DRIVE VENKATESH ELECTRICLAS-AAI AURANGABAD AJITA TRADING AJITA TRADING AJITA TRADING JSPL JSPL JSPL JSPL JSPL JSPL JSPL JSPL ATIBIR ATIBIR ATIBIR LARSEN & TOUBRO LTD LARSEN & TOUBRO LTD LARSEN & TOUBRO LTD 128 129 130 131 132 133 134 135 136 137 138 139 140 397 398 399 400 401 402 403 404 405 406 407 408 409 410 3106700240 3106700463 3106700240 3106700647 3106700616 3107700221 3107700397 3107700336 3107700484 3107700470 3508701551 3108700138 1 1 1 SITE COMPLAINT RECEIVED YES YES NOT KNOWN YES YES YES YES YES NOT KNOWN YES NOT KNOWN NOT KNOWN NO SOURCE YEAR MONTH TAG DATE AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW 2007 2007 2007 2007 2007 2007 2007 2007 2007 2007 2007 2007 2008 FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY MARCH MARCH MARCH FEBRUARY 01.02.2007 02.02.2007 05.02.2007 08.02.2007 09.02.2006 09.02.2006 10.02.2006 15.02.2007 27.02.2007 22.03.2007 22.03.2007 23.03.2007 13.02.2008 AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW AEIW SLW SLW SLW 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2008 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 2009 FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY FEBRUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY JANUARY VADU VADU VADU 2009 2009 2009 JANUARY JANUARY JANUARY 13.02.2008 13.02.2008 14.02.2008 14.02.2008 19.02.2008 19.02.2008 19.02.2008 20.02.2008 20.02.2008 22.02.2008 28.02.2008 28.02.2008 28.02.2008 30.01.2009 30.01.2009 30.01.2009 30.01.2009 30.01.2009 30.01.2009 30.01.2009 30.01.2009 29.01.2009 29.01.2009 29.01.2009 18/01/2009 18/01/2009 18/01/2009 TOTAL NO OF DEFECTED(CUSTOMER COMPLAINED) ORDERS DATASHEET AIS - VADODARA
  9. 9. D M A I C Data Collection Plan CCH S NO CU S TO MER SO CO MPL A I N S O U RCE DIS P D ATE COM PL A IN D A TE CO MM EN TS M A TERIA L A FFECTED CO MPL A I N TYPE 1 SYAD-0003 power & instrumenation 3106700647 CCHS 27.02.2007 18/04/2007 Bkr on-off sticker reversely sticked Breaker Mechanical 2 NDAS-0273 Essar Power limited 3106700616 CCHS 12/07/2007 Rack in-out handle not engaging. Breaker Mechanical 3 NDAS-0273 Essar Power limited 3106700616 CCHS 12/07/2007 Shutters are not operating properly Shutter Mechanical 12/07/2007 PNL Interlock are not functioning Interlock Mechanical 12/07/2007 E.Switch aslly disturbed EarthSwitch Mechanical 12/07/2007 Faulty Transducer Transducer Electrical 12/07/2007 Busber sleeve (Raychem) scratched in transit Sleeving Mechanical SL 22.03.2007 22.03.2007 22.03.2007 4 NDAS-0273 Essar Power limited 3106700616 CCHS 5 NDAS-0273 Essar Power limited 3106700616 CCHS 22.03.2007 22.03.2007 6 NDAS-0273 Essar Power limited 3106700616 CCHS 22.03.2007 7 NDAS-0273 Essar Power limited 3106700616 CCHS 3106700281 CCHS 24.08.2007 28/10/2007 BKR stucked in Pnl Breaker Mechanical 3106700281 CCHS 24.08.2007 28/10/2007 Auxiliary Drive fault Breaker Mechanical 10 BHUTAN POWER CORPORATION DEVELOPMENT & CONSTRUCTION DEPT. NDAS-0277 BHUTAN POWER CORPORATION DEVELOPMENT & CONSTRUCTION DEPT. NDAS-0277 BHUTAN POWER CORPORATION DEVELOPMENT & CONSTRUCTION DEPT. NDAS-0277 3106700281 CCHS 24.08.2007 28/10/2007 Energy-meter defective Meter Electrical 11 VSAL-0001 DANCO ENTERPRISES 3107700110 CCHS 22.09.2007 11/10/2007 Emergency push-trip rod not entering Machining Items Mechanical 12 VSAL-0001 DANCO ENTERPRISES 3107700110 CCHS 22.09.2007 11/10/2007 BKR not getting off through rod Breaker Mechanical 13 VSAL-0001 DANCO ENTERPRISES 3107700110 CCHS 22.09.2007 11/10/2007 Control wiring broken LV Wiring Electrical 14 VSAL-0001 DANCO ENTERPRISES 3107700110 CCHS 22.09.2007 11/10/2007 BKR stucked in Pnl Breaker Mechanical 15 PBIJ-0028 larsen & toubro ltd, ecc division , chennai 3107700153 CCHS 30.11.2007 08/01/2008 Front door opening problem Pnl assly Mechanical 8 9 FROM DISPATCHED DATE & COMPLAIN RECEIVE DATE, THE CONCLUSION CAME THAT THE ALL COMPLAINTS ARE WITHIN EITHER 18 MONTH FROM DELIVERY OR 12 MONTH AFTER INSTALLATION . SO ALL THE CUSTOMER COMPLAIN FOR PIX-36 A/C WAS WARRANTY COMPLAINTS ORDER WISE COMPLAIN DETAILS DATASHEET AIS - VADODARA
  10. 10. 0 D M A I Summary of % Warranty Complaints - Before C Inferences Summar y f or % War r ant y compl ai nt s = ( Cumul at Status = 1 Before A nderson-Darling Normality Test A -Squared P-V alue Mean StDev V ariance Skew ness Kurtosis N 35 40 45 50 0.47 0.210 47.617 3.607 13.011 0.841807 -0.085621 13 Minimum 1st Q uartile Median 3rd Q uartile Maximum 55 42.727 45.119 46.602 49.765 54.545 95% Confidence I nterv al for Mean 45.437 49.797 95% Confidence I nterv al for Median 45.179 9 5 % Co n f i d e n ce I n t e r v a l s 2.587 Mean Median 45 46 47 48 49.432 95% Confidence I nterv al for StDev 49 5.954  Current level of % Warranty Complaints  The Mean warranty complaint % is 47%.  The Warranty Complaints % varies between 42.7% to54.5%  Majority of the values lie between 45.1% and 49.7%. 50 10
  11. 11. D M A I C Initial Process Sigma Calculation Determine number of defect opportunities/unit (O) Determine number of unit processed Determine number of total defected unit Calculate defects per opportunities 1 (N) 149 (D) 70 (DPO) Calculate Yield Dpmo=469798.6 5 0.46979865 53.9% Look up Sigma in the process sigma table (SIGMA) Determine Z value from Z bench 1.6 0.1 HERE UNITS CONSIDERS AS TOTAL NOS OF ORDERS EXECUTED AIS - VADODARA
  12. 12. 2 Summary of Measure Phase  Current level of % Warranty Complaints  The Mean warranty complaint % is 47%.  The Warranty Complaints % varies between 42.7% to54.5%  Majority of the values lie between 45.1% and 49.7%.  Warranty complaint process stands at 1.6 sigma 12
  13. 13. 3 Analyze Analyze 13
  14. 14. 4 D M A I C Deployment Process Flow 14 AIS - VADODARA
  15. 15. Problem Type D M A I C Par et o Char t of PROBLEM TYPE 80 Count 60 60 50 40 40 30 20 20 10 0 al ic an h ec M Count Percent Cum % ec El l ca tr i m Hu 20 22.5 80.9 52 58.4 58.4 an ce en ig gl Ne ow Kn e dg le 9 10.1 91.0 0 p Ga Per cent 80 70 PROBLEM TYPE Major Defect type to focus are 100 90 Mechanical Errors Electricial Errors Errors due to Human Negligence 8 9.0 100.0 PROBLEM TYPE Dot pl ot of SL of JOB Electrical Human Negligence Knowledge Gap Mechanical 0 12 24 36 48 SL 60 72 84 AIS - VADODARA
  16. 16. Material Affected by Problem Type D M A I C PROBLEM TYPE MECHANICAL MAJOR AFFECTED Breaker,Pnl Assly MATERIAL Earth Switch PROBLEM TYPE Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE ELECTRICAL PROBLEM TYPE = Mechanical 60 20 40 10 20 0 0 Count Percent Cum % l T T e r ly h s s r T k r ke ss i tc m m t t e P ria P C enc rloc t he ea l a Sw It e r It e hu Bus at e O g te i S Br Pn t h ing e m gl I n ar hin Oth ne se E c o g in a Lo M gg a lt na Fi Per cent 80 30 MATERIAL AFFECTED 100 40 Count 50 20 7 5 3 3 3 2 2 2 1 1 1 2 38 13 10 6 6 6 4 4 4 2 2 2 4 38 52 62 67 73 79 83 87 90 92 94 96 100 Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE PROBLEM TYPE = Electrical MAJOR AFFECTED LV Wiring,CT,PT,Relay 50 MATERIAL Count 30 20 10 MATERIAL AFFECTED 0 r ng CT ac k PT ealy m p it ch CB et e ir i p R La Sw M M W er n w io i t LV Po at im ic L d In Count 3 2 2 2 2 1 1 1 1 Percent 15 10 10 10 10 5 5 5 5 Cum % 15 25 35 45 55 60 65 70 75 r PT alay elay i tch t he Re R c sw O Tn 100 80 60 40 20 0 Powerpack Per cent 40 1 1 1 1 1 5 5 5 5 5 80 85 90 95 100 AIS - VADODARA
  17. 17. Material Affected by Problem Type D M A I C PROBLEM TYPE KNOWLEDGE GAP 50 MAJOR AFFECTED Pnl Handling 40 MATERIAL Transport Damage PROBLEM TYPE HUMAN NEGLIGENSE Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE Per cent PROBLEM TYPE = Knowledge Gap Count 30 20 10 MATERIAL AFFECTED 0 g e in ag dl am an h tD el or an sp P an Tr Count 4 2 Percent 50.0 25.0 Cum % 50.0 75.0 s Bu PT r be us B 1 12.5 87.5 er th O 1 12.5 100.0 100 80 60 40 20 0 0 0.0 100.0 Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE PROBLEM TYPE = Human Negligence MAJOR AFFECTED 50 MATERIAL Per cent Count 40 30 20 10 0 MATERIAL AFFECTED Count Percent Cum % Loose Material Loose material 8 88.9 88.9 Packaging 1 11.1 100.0 Other 0 0.0 100.0 100 80 60 40 20 0 AIS - VADODARA
  18. 18. Material Affected D M A I C PARETO CHART of MATERI AL AFFECTED 100 90 80 Count 60 60 50 40 40 30 20 20 10 MATERI AL AFFECTED 0 l er ri a sly ch ng ak te as wi t dli e a l Br m Pn th S han r l se Ea n e oo L Pa Count Percent Cum % Per cent 80 70 T T T g s s r k k y e r e p h h B r g T y r P P C r in em em tte oc ac eal ag b e nc m i tc itc C et e in P al a th e s i t t u rl p s e a M M ag e W g I r I Sh te er R am Bu lig n L Sw Sw R O Bu k e n w D g io it i t V in th I o ac t e t im im L in P n a P or O g ic L L ch sp n nd a gi I M an Tr l t ag a n Fi 20 10 7 5 4 4 3 3 3 3 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4 22 11 8 6 4 4 3 3 3 3 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4 22 33 41 47 51 56 59 62 66 69 72 76 78 80 82 84 86 87 88 89 90 91 92 93 94 96100 0 It is clearly visible that the majority of the items affected are Breaker(20%),loose Material(11%),Pnl assly(8%) & EarthSwitch(6%) as these contributes 47 % of total affected material . AIS - VADODARA
  19. 19. Fishbone – Breaker Issues D M A I C MATERIAL MATERIAL MACHINE MACHINE MECHANICA L MAN MAN ISSUE A TRIPPING CLOSING COIL MISMATCH POLE CENTERE TO CENTRE DISTANCE UNEVEN FAULTY BREAKER ISOLATING LIMIT SWITCH CONTACT LOOSE INTERLOCKING PIN SECONDARY SOCKET QC STICKER NMISSING PIN BROKEN RATING STICKER MISSING CLUTCH WIRE MALFUNCTION ELECTRICAL PROBLEM TEST & SERVICE STICKER MISSING MECHANICAL PROBLEM FABRICATION SECONDARY SOCKET MISTAKE STOPBOLT LENGTH MISHMATCH WIRE MISSING SHUTTER PIN HOLDING BRACKET MALFUNCTION ON OFF INDICATION REVERSE AUXILIARY DRIVE TEST SERVICE INTERLOCKING LINK FAULT BREAKER (MVIA00055-01) FAULTY OPERATION ISSUE LAND ALTITUDE EXPOSURE TO RAIN SITE LOCATION BUS PT SURFACE & SHUTTER WRONG BRASS BUSS ROLLER CENTER TO CENTRE DISTANCE PIN RUBBING WRONG PROCESS FOR BUSPT TRUCK INSERTION LACK OF KNOWLEDGE BREAKER INSERTION IMPROPER SCRAP EARTH SUPPORT SLOT NO CONTROL OVER COMMISSIONING PEOPLE MISALIGNMENT WRONG HANDLING AT SITE SITE CLIMATE CONDITION IMPROPER RACK IN-OUT SLOT ON THE FACIA PLATE NO GUIDELINES AVAILABLE TOTAL NO OF CAUSE : 26 TOTAL MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD CONTROLLABLE CAUSE : 22 CONTROLLABLE CAUSE : 22 NONCONTROLLABLE CAUSE : 4 NONCONTROLLABLE 4 AIS - VADODARA
  20. 20. Fishbone – Panel Assembly Issues D M A I C MATERIAL MATERIAL MACHINE MACHINE MAN MAN PRODUCTION BOM NOT IN PROCESS CT CHAMBER EARTHING CAGE NUT FALLING MECHANICA L ISSUE B IMPROPER HARDWARE USED SHUTTER FOULING WITH SPOUT INSULATOR FIXING CHANEL MVIB00162-01, MVIB00162-02 WRONG POSITION SHORTAGES OF FABRICATION FROM SUPPLIER END BUSBAR CHAMBER TOP BLOW OFF COVER MVIB00112-01 HOLE NOT MATCH WITH TOP COVER (MVIB00143-01 ) HOLE NO STANDARD HARDWARE LIST IMPROPER SUPER MARKET ARRENGEMENT (2 BIN) NO SYSTEMATIC PROCESS BRK GUIDE CHANNELMVIB0005901/ MVIB00050-02 OPPOSIT BEND IMPROPER LIMIT SWITCH OPERATION RED-YELLOW SHUTTER POSITION OPPOSITE LOOSE TITGHTENING OF FASTENERS SIDE SHEET BULGING CT CH DOOR CLOSING PROBLEM INSULATOR, DROPPER CONN LOSSE ASSEMBLED IMPROPER GASKETTING SHUTTER SLIDING BRACKET MVIB00O97-01/98-01 SLOTE NOTFILED LV DOOR ISSUE PANEL ASSLY ISSUE BAD UNEVEN FLOOR BAD QUALITY SEMIFINISHED PNL FROM SUPPLIER END INSULATOR, DROPPER CONN LOSSE ASSEMBLED WORKSHOP CONDITION NO INCOMING INSPECTION FOR PANEL FRO SUB-CONTRACTORS IMPROPER PROCESS NO QUALITY CHECK FROM SUPPLIER END IMPROPER PANEL ASSLY LACK OF KNOWLEDGE BREAKER CHAMBER DOOR PROBLEM POOR QUALITY BENDING. WRONG PAINT THICKNESS RUST COMES IN PANEL Since all causes for the PANEL Since all causes ASSLY ISSUES are very minute ASSLY ISSUES are very minute MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD so whole panel assly considered so whole panel assly considered as 1 controllable cause as 1 controllable cause AIS - VADODARA
  21. 21. Fishbone –Earth Switch Issues D M A I C MATERIAL MATERIAL MACHINE MACHINE ISSUE DESIGN ISSUE EARTHSWITCH INDICATION IMPROPER NO DESIGN LLI INSULATOR WIRING ISSUE INSULATOR OF LLI EARTH SWITCH HV FAILED MECHANICA L MAN MAN C EARTHSWITCH STICKER MISSING MVIB00373-01 , MVIB00375-01 ASSEMBLY BROKE WRONG TYPE OF EARTH SWITCH FITTED LINK IN S/E EARTH SWITCH FOULING WITH EARTHING CONN CONFUSION BELWEEN LLI & NORMAL EARTHWITCH CONTACT LOOSE LOOSE FITTING OF BOLT & NUT IN CONTACT WRONG CALL IN BOIM KNOWLEDGE GAP EARTH-SWITCH ISSUE THE HOLE OF CAM LEVER(MVIB0036901AND MVIB0035001) NOT PROPER EXTERNAL THREAD OF ESW INTERLINK MVIB00530-01 AND MVIB00353-01 NOT PROPER THE CAM ASSEMBLY MVIB00350-01 FOULED WITH B/B CHAMBER SIDE SHEET DURING MOVEMENT BECAUSE THE SLOT OF SIDE SHEET ARE SMALL THE CAM LEVER(MVIB00350-01) FIXING HOLE AT ESW ROD(MVIB00356-04) NOT MATCHED. WRONG USING AT CUSTOMER END WRONG HANDLING PROECSS THE M6 SCREW LENGTH ARE SMALL WHICH IS FIXED WITH ESW ARMS. KNOWLEDGE GAP IMPROPER MANPOWER Since all causes for the EARTH Since SWITCH ISSUES are very minute SWITCH ISSUES are very minute MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD so whole panel assly considered so whole panel assly considered as 1 controllable cause as 1 AIS - VADODARA
  22. 22. Fishbone –LV Wiring Issues D M A I C ELECTRICAL MATERIAL MATERIAL MACHINE MACHINE SWITCH DEFECTIVE WIRE MISSING,LOOP OPEN APPL ENGG MISTAKE LV CHAMBER FABRICATION PROBLEM SWITCH LABEL WRONG BTB,MTB,DTB & OTHER WIRING PROBLEM SUPPLIER’S MISTAKE WIRE DUCT COVER OPENED OPERATOR’S MISTAKE ANNUNCIATOR LABEL MISSING WRONG COLOR INDICATION LAMP APPL ENGG MISTAKE A WRONG ISSUE OF RELAY/METER/ANNUNCIATOR/MCB ETC DISCONNECTOR TERMINAL BLOCK MISSING APPL ENGG MISTAKE ISSUE MAN MAN OPERATOR’S MISTAKE SECONDARY PLUG WIRE MISSING , WIRE OPEN, WRONG FERRULING, SOCET BROKEN EARTHING FLEX MISSING RELAY POWER SUPPLY CARD BLOWN OUT WIRE MISSING,LOOP OPEN POOR QUALITY WIRE DRESSING SWITCH HANDLE MISSING RELAY / METER / ANNUNCIATOR ETC DEFCTIVE WRONG FERRULING,LUG INSRTUMENT STICKER MISSING LV WIRING ISSUE LAND ALTITUDE SOFTWARE PROBLEM OF RELAYS EXPOSURE TO RAIN TRANSIT DAMAGE WRONG PACKAGING PALLAVARAM ISSUE TESTING ENGG ISSUE SITE LOCATION WRONG SETTING OF INSTRUMENTS SITE CLIMATE CONDITION WRONG HANDLINHG IN SITE NO GUIDELINE AVAILABLE CARELESSNESS KNOWLEDGE GAP NO CONTROL OVER SITE PEOPLE INADQUATE TRAINING TOTAL NO OF CAUSE : 28 TOTAL MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD CONTROLLABLE CAUSE : 14 CONTROLLABLE CAUSE : 14 NONCONTROLLABLE CAUSE : 14 NONCONTROLLABLE CAUSE : 14 AIS - VADODARA
  23. 23. D M A I C Fishbone –CT, PT, Meter, Relay, Power pack Issues ELECTRICAL MATERIAL MATERIAL MACHINE MACHINE ISSUE MAN MAN WRONG LABELING OF MODEL NO B PT FUSE MISSING PALLAVARAM ISSUE POWER PACK FUSE MISSING RELAY , METER DISPLAY OUT CT RATIO WRONG RELAY,METER LEG MISSING RELAY CASING, SCREW INSERT BROKEN WRONG PROCUREMENT OF RELAY, METERS TRANSPORT DAMAGE PALLAVARAM QUALITY ISSUE WRONG TYPE ELECTRO MAGNETIC RELAY OPERATING COIL WRONG CALL IN BOM PROCUREMENT WRONG CT,PT,METER PT RACK IN IMPROPER RELAY,POWER LAND ALTITUDE WRONG RATIO METERS EXPOSURE TO RAIN APPL ENGG MISTAKE SITE LOCATION OPERATOR’S MISTAKE PACK ISSUE WRONG PACKAGING POOR QUALITY MATERIAL NO QUALITY CHENK FOR ELECTRICAL MATERIALS SITE CLIMATE CONDITION TRANSIT DAMAGE WRONG SETTING OF INSTRUMENTS WRONG HANDLINHG IN SITE NO GUIDELINE AVAILABLE NO CONTROL OVER SITE PEOPLE CARELESSNESS KNOWLEDGE GAP TOTAL NO OF CAUSE : 17 TOTAL INADQUATE TRAINING MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD CONTROLLABLE CAUSE : 12 CONTROLLABLE CAUSE : 12 NONCONTROLLABLE CAUSE : 5 NONCONTROLLABLE 5 AIS - VADODARA
  24. 24. Fishbone –Earth Switch Issues D M A I C MATERIAL MATERIAL MACHINE MACHINE HUMAN MAN MAN NEGLIGENSE A LOOSE MATERIAL BOX BROKEN PT RACK IN HANDLE NOT IN THE BOX BUS-COUPLER TO BUSRISER CONN MISSING IN LM BOX MISMATCH ITEMS IN BOX & THE ITEMS MENTIONED IN ATTACHED LIST NOT IN SAP LOOSE MATERIAL BOM CARELESSNESS SPRING CHARGE HANDLE MISSING FAULTY SAP BOM MISMATCH ITEMS IN LM BOX SHORTAGE OF MATERIAL IN LM BOX LOOSE MATERIAL ISSUE IMPROPER LOOSE MATERIAL BOM NO PROPER CROSSCHECK TOTAL NO OF CAUSE : 10 TOTAL MOTHER NATURE MOTHER NATURE MEASUREMENT MEASUREMENT METHOD METHOD CONTROLLABLE CAUSE : 10 CONTROLLABLE CAUSE : 10 NONCONTROLLABLE CAUSE : 0 NONCONTROLLABLE 0 AIS - VADODARA
  25. 25. Controllable & Non-Controllable Causes D M A I C Total No of Causes : 83 Mechanical : 28 Electrical : 45 Loose Material : 10 Total No of Controllable Causes : 60 Mechanical : 24 Electrical : 26 Loose Material : 10 Total No of Non-Controllable Causes : 23 Mechanical : 4 Electrical : 19 Loose Material : 0 CONTROLLABLE CAUSES REF DETAILS: REF DETAILS M-A M-B M-C E-A Mechanical Issue- Breaker E-B HN-A Mechanical Issues- Pnl Assly Mechanical Issues- Earth Switch Electrical Issues- LV Wiring Electrical Issues- CT,PT,Meter, Relay,Powerpack Human Negligence Loose material issue AIS - VADODARA
  26. 26. Prioritizations Matrix for Controllable Causes D M A I C • Mechanical M-A-2 M-A-3 M-A-4 M-A-5 M-A-6 M-A-7 M-A-8 IMPACT ON ROOT CAUSE WEIGHT M-A-1 6 4 6 3 6 2 2 3 4 4 5 3 2 7 4 4 6 3 2 2 4 6 9 8 7 FINANCIAL BENEFIT 5 3 7 4 5 3 3 4 4 2 5 1 5 5 6 3 2 4 5 4 3 6 7 7 8 QUALITY OF PRODUCT 4 5 8 2 4 3 7 5 5 5 4 3 7 6 5 2 6 4 3 7 8 6 8 8 5 CUSTOMER SATISFACTION 3 5 5 6 6 4 5 6 7 4 6 6 7 6 4 6 4 6 8 4 6 3 8 6 4 MANAGEMENT ACCEPTANCE 2 4 6 5 4 6 7 7 7 5 4 6 8 9 5 7 4 6 7 9 4 5 6 9 8 SIDE EFFECT ON OTHER CTQ 1 5 3 6 6 6 7 3 5 6 7 8 8 4 6 6 7 7 5 5 5 9 6 6 5 87 133 80 109 69 91 93 104 82 104 73 110 131 102 85 97 91 92 95 102 118 163 157 135 E-A-2 E-A-3 E-A-4 E-A-5 E-A-6 E-A-7 E-A-8 E-A-9 TOTAL • Electrical : WEIGHT E-A-1 M-A-9 M-A-10 M-A-11 M-A-12 M-A-13 M-A-14 M-A-15 M-A-16 M-A-17 M-A-18 M-A-19 M-A-20 M-A-21 M-A-22 M-B-1 M-C-1 • Top five are : M-A-22 , M-B-1 , M-C-1 , M-A-2 , M-A-13 E-A-10 E-A-11 E-A-12 E-A-13 E-A-14 E-B-1 E-B-2 E-B-3 E-B-4 E-B-5 E-B-6 E-B-7 E-B-8 E-B-9 E-B-10 E-B-11 E-B-12 IMPACT ON ROOT CAUSE 6 4 6 3 6 2 7 3 4 4 5 3 2 7 4 4 6 3 2 8 8 6 8 8 4 6 4 FINANCIAL BENEFIT 5 3 7 4 5 3 5 4 4 2 5 1 5 5 6 3 2 4 5 6 6 6 8 7 8 7 5 QUALITY OF PRODUCT 4 5 8 2 4 3 7 5 5 5 4 3 7 6 5 2 6 4 3 8 8 6 8 0 3 5 5 CUSTOMER SATISFACTION 3 5 0 6 6 4 5 6 7 4 6 6 7 6 4 6 4 6 8 8 8 3 5 6 4 6 6 MANAGEMENT ACCEPTANCE 2 4 0 5 4 6 4 7 7 5 4 6 8 9 5 7 4 6 7 6 6 5 4 0 8 3 5 SIDE EFFECT ON OTHER CTQ 1 5 3 6 6 6 7 3 5 6 7 8 8 4 6 6 7 7 5 5 5 9 6 6 5 5 5 87 106 80 109 69 125 93 104 82 104 73 110 131 102 85 97 91 92 109 120 102 TOTAL • Loose material : 151 151 118 149 107 • Top Six are : E-B-5 , E-B-6 , E-B-8 , E-A-13 , E-A-6 , E-B-11 WEIGHT HN-A-1 HN-A-2 HN-A-3 HN-A-4 HN-A-5 HN-A-6 HN-A-7 HN-A-8 HN-A-9 HN-A-10 IMPACT ON ROOT CAUSE 6 5 6 3 9 7 5 8 4 4 7 FINANCIAL BENEFIT 5 3 5 4 7 5 5 8 4 2 5 QUALITY OF PRODUCT 4 6 7 2 5 5 7 5 5 5 7 CUSTOMER SATISFACTION 3 5 4 6 9 8 5 7 7 4 5 MANAGEMENT ACCEPTANCE 2 5 3 5 9 6 4 7 7 5 4 SIDE EFFECT ON OTHER CTQ 1 5 3 6 7 6 7 6 5 6 7 99 110 80 161 129 113 149 104 82 125 TOTAL • Top five are : HN-A-4 , HN-A-7 , HN-A-5 , HN-A-10 , HN-A-6 AIS - VADODARA
  27. 27. 7 Root-cause Validation D M A I C SL CAUSES VALIDATION PLAN METHOD ROOT CAUSE 1 BREAKER INSERTION No of Warranty Complains happened due to Breaker Inertion YES 2 PANEL ASSLY ISSUE Warranty Complain Warranty Complain & Gemba Investication No of Warranty Complains happened due to Panel Assly issue & Gemba Investication carried out in POPULAR(Subcontractor) YES 3 EARTH-SWITCH ISSUE 4 No of Warranty Complains happened due to Earth Switch issues YES ISOLATING CONTACT LOOSE(BKR) Warranty Complain Warranty Complain & Gemba Investication No of Warranty Complains happened due to loose isolating contact of breaker & Gemba Investication carried out in Components YES 5 TRIPPING CLOSING COIL MISMATCH (BKR) Warranty Complain No of Warranty Complains happened due to Tripping,Closing Coil mismatch YES 6 PT FUSE MISSING Warranty Complain No of Warranty Complains happened due to PT fuse missing YES 7 POWER PACK FUSE MISSING Warranty Complain No of Warranty Complains happened due to Powerpack fuse missing YES 8 WRONG PROCUREMENT OF RELAY, METERS No of Warranty Complains happened due to wrong fitted Relay & meters YES No of Warranty Complains happened due to Improper wire dressing & Gemba investication carried out in RNG (Wiring Subcontractor) YES No of Warranty Complains happened due to wrong issue of Realy,meter & Gemba investication carried out in wiring dept. YES No of Warranty Complains happened due to Poor qulaity of material & Gemba investication carried out at Incoming rejections. YES 11 POOR QUALITY MATERIAL Warranty Complain Warranty Complain & Gemba Investication Warranty Complain & Gemba Investication Warranty Complain & Gemba Investication 12 MISMATCH ITEMS IN LM BOX Warranty Complain No of Warranty Complains happened due to Mismatch items in LM BOX YES Warranty Complain No of Warranty Complains happened due to mismatch items in lm box & the items mentioned in attached list. YES Warranty Complain No of Warranty Complains happened due to Bus-Coupler to Bus-Riser conn missing in the LM BOM YES 9 POOR QUALITY WIRE DRESSING WRONG ISSUE OF RELAY/METER /ANNUNCIATOR/MCB ETC 10 MISMATCH ITEMS IN BOX & THE ITEMS MENTIONED IN ATTACHED LIST 13 BUS-COUPLER TO BUS-RISER CONN MISSING IN LM BOX 14 15 IMPROPER LOOSE MATERIAL BOM Warranty Complain No of Warranty Complains happened due to wrong Loose material BOM. YES 16 SHORTAGE OF MATERIAL IN LM BOX Warranty Complain No of Warranty Complains happened due to shortage of material in LM Box. YES 27 AIS - VADODARA
  28. 28. 8 Improve Improve 28
  29. 29. Action Plan 01 of 02 BREAKER INSERTION 2) Start checking & functionality of MVIA0008501,Clutch wire & MVIA00150/151-01 before receiving the Breaker. 2 PANEL ASSLY ISSUE 1)The slot of the MVIB00012-01(LV Ch) to be increased to ensure the proper locking of LV BOX. 2)Viewing window's position changed in MVIB00236-01 CT ch door to ensure the proper locking. 3) Three through hole requied to fix bolt in MVIB00029-01, MVIB00027-01,MVIB00196-01to solve the shutter-spout foluing. CONCERNED DEPT CONCERNED PEOPLE TARGET STATUS Component Mr.Rajib Marwa 25.12.09 In progress 01.08.09 Done 01.08.09 Done 01.08.09 Done 01.08.09 Done PIX-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta 4) Removal of unwanted teeth in Internal arc angle to protrct Done TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta 01.08.09 Done 6) In MVIB00236-01 bottomside 3mm cutting required to ensure the free movement of CT Ch doors TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta 25.09.09 Done 7) CT access cover & Division plate holes should be alligned to for proper fitment TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta 25.09.09 Done 8)Long fishplate to be introduced in the end pnl of BD for proper earthing fitment. TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta 25.09.09 Done 9) Small size of PIN for shutter sliding bearing to be introduced for PNL with BUS-PT Truck . EARTH-SWITCH ISSUE 01.08.09 5) In Reinforcement(left & right)(MVIB000595-01) CSK holes to be implemented for fitment of CSK Rivet. 3 TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta TDC & Mr.Debasish Mahapatra Pix-36 Manufacturing Sudip Dutta Pix-36 Manufacturing Sudip Dutta & Quality Subhajit Das Pix-36 Manufacturing Sudip Dutta & Subhada Ind Mrs. Kalpana 25.12.09 In progress 25.12.09 In progress 25.09.09 Done 25.09.09 Done 25.12.09 ACT 1 ACTION PLAN 1)Master testing jig to be improved/ A sample pnl can be used for BKR insertion testing. DO ROOT CAUSES CHECK SL PLAN 9 D M A I C In progress 1) Proper EarthSwitch On-Off indication should be introduced 2)MVIB00373-01 , MVIB00375-01 Welding required to resist Stress & stop breaking. 4) Before Closing/tagging panel start physical checking of Earth-Switch arm & contacts tightness. 6) The Length of M6 bolt of the arm to be increased. 29 AIS - VADODARA
  30. 30. 0 D M A I C Action Plan 02 of 02 4 ISOLATING CONTACT LOOSE(BKR) 1)Start Checking the proper tightening of Isolating Contact at Bkr premises & check Micro-ohm in panel premises before receiving the Breaker. 5 TRIPPING CLOSING COIL MISMATCH (BKR) 1) Re-Functional test required after changing of faulty coil 6 PT FUSE MISSING 1) Before Closing/tagging panel start physical checking. 7 POWER PACK FUSE MISSING 8 WRONG PROCUREMENT OF RELAY, METERS 9 POOR QUALITY WIRE DRESSING WRONG ISSUE OF RELAY/METER /ANNUNCIATOR/MCB ETC 10 11 12 POOR QUALITY MATERIAL MISMATCH ITEMS IN LM BOX MISMATCH ITEMS IN BOX & THE ITEMS MENTIONED IN ATTACHED LIST 13 BUS-COUPLER TO BUS-RISER CONN MISSING IN LM BOX 14 15 16 IMPROPER LOOSE MATERIAL BOM SHORTAGE OF MATERIAL IN LM BOX 1) Before Closing/tagging panel start physical checking. 1) Start re-checking of ordered relay ,meters (model no,spec) from Engg Drg of each Job prior to material delivery. 1) Several Visit require to supplier's end & verify the process wiring set up,quality of the LV Wiring 1) Separate BOM with Long description of each instruments to be given to all Wiremen(In-house+Out-side) for respective LV BOX to visuallly varify all the materials before mounting in Low Voltage/Instrument chamber 1) Sampling inspection with ordered copy of the Electrical items to be Started by Incoming Inspection 1) Strict Verification required for each & everything items qty. 1) One standard list should be prepared for each varity of panels board & that list only to be circulated in LM BOX & with invoice. PIX-36 Manufacturing, Testing Sudip Dutta Mr. Saibal Boxi 20.07.09 Done Component Pix-36 Manufacturing & Quality Pix-36 Manufacturing & Quality Mr. Vivek patil Sudip Dutta Subhajit Das Sudip Dutta Subhajit Das Mr.Satyabreta Manna Ms. Darshana patel Mr. Naresh Kumar Subhajit Das 01.12.09 In progress 01.10.09 Done 01.10.09 Done 30.12.09 In progress 01.07.09 Done PIX-36 WIRING Incomin Inspection Quality Quality Mr. Naresh Kumar 30.12.09 In progress Mr. Indranil Indu Mr. Indranil Indu 30.12.09 In progress Done Quality Mr. Indranil Indu 01.11.09 Done Sudip dutta Mr. Aditya Kota Respective Engg Mr.Indranil Indu Sudip Dutta 01.11.09 Done 30.12.09 In progress 01.11.09 Done Purchase PIX-36 Wiring Supplier-Quality 1) The Connection should be incorporated in LM Bom of Space 2k Though we are managing entering it in SAP Lm BOM. PIX-36 Manufacturing Core Engg Appl Engg 1) Correct Sap bom to be uploaded in Space2k & sap . Quality PIX-36 Manufacturing 2)1) Strict Verification required for each & everything items qty. 30 AIS - VADODARA
  31. 31. 1 D M A I C Improvements BEFORE AFTER Gap reduced Holes are incorporated in DRG 31 AIS - VADODARA
  32. 32. 2 D M A I C Improvements BEFORE CSK holes required Create rusting in MVIB00236-01 AFTER CSK holes added The teeth was obsoluted in DRG 32 AIS - VADODARA
  33. 33. 3 D M A I C Improvement results Boxpl ot of % War r ant y compl ai nt s = ( Cumul at % War r ant y complaint s = ( Cumulat 55 50 45 40 35 1 Before St at us 2 After Two-Sample T-Test and CI: %Warranty complaints = (Cumulat, Status Two-sample T for %Warranty complaints = (Cumulat Status N Mean StDev SE Mean 1 Before 13 47.62 3.61 1.0 2 After 1.5 4 40.46 3.08 Difference = mu (1 Before) - mu (2 After) Estimate for difference: 7.16 95% CI for difference: (2.88, 11.43) T-Test of difference = 0 (vs not =): T-Value = 3.57 P-Value = 0.003 DF = 15 33 AIS - VADODARA
  34. 34. D M A I C Process Sigma Calculation-(JULY,09-OCT,09) Determine number of defect opportunities/unit (O) 1 Determine number of unit processed (N) 23 (D) 2 Determine number of total defected unit Calculate defects per opportunities (DPO) Calculate Yield Dpmo=86956.52 0.08695652 91.2% Look up Sigma in the process sigma table (SIGMA) Determine Z value from Z bench 2.9 1.4 HERE UNITS CONSIDERS AS TOTAL NOS OF ORDERS EXECUTED AIS - VADODARA
  35. 35. 5 Benefit Calculation D M A I C As per the AREVA Standards we consider the followings, RE O EF B • Avg 1 no of PIX-36 pnl cost : 700 KINR • Avg 1 no of warranty complain attend time: 5 days • Hotel rent allocated for Service people (Non-metro City) : 3000 Rs / day • Food cost allowable (Non-metro City) : 750 Rs / day • Ticket (AIR/TRAIN) cost is not considered as the places may vary. DURATION FEB-07 TO JUNE-09 TOTAL NO NO OF FREE REPLACEMENT (KINR) MONTH OF PNL COMPLAIN SALE (KINR) 29 565 69 395500 114.66 COST INCURRED BY TOTAL COST COST OF SERVICE PERSON FOR WARRANTY WARRANTY/MONTH (KINR) CLAIM (KINR) (KINR) 1293.75 1408.41 48.56586207 Percentage warranty cost = [{(cost of warranty/month) / (sales/month)} x 100] = [{(48.57) / (395500/29)} x100] R TE AF = 0.36 DURATION JULY-09 TO OCTOBER-09 TOTAL NO NO OF FREE REPLACEMENT (KINR) MONTH OF PNL COMPLAIN SALE (KINR) 4 158 2 110600 11.49 COST INCURRED BY TOTAL COST COST OF SERVICE PERSON FOR WARRANTY WARRANTY/MONTH (KINR) CLAIM (KINR) (KINR) 37.5 48.99 12.2475 Percentage warranty cost = [{(cost of warranty/month) / (sales/month)} x 100] = [{(12.25) / (110600/4)} x100] = 0.04 SO TOTAL SAVE / ANNUM WILL BE = {(cost of warranty/month BEFORE-cost of warranty/month AFTER) X 12} ={(48.56-12.24) X 12} = 435.8 KINR 35
  36. 36. 6 D M A I C Financial Validation LY AL CI D AN ATE N FI LID VA The savings due to this project is financially validated 36
  37. 37. 7 Control Control 37
  38. 38. 8 Warranty Complaints – Current Status D M A I C I Char t of % War r ant y compl ai nt s by St at us 55 1 Before 1 2 After 1 I ndiv idual Value 50 UCL= 47.01 45 _ X= 40.46 1 40 35 LCL= 33.92 1 3 5 7 9 11 Obser v at ion 13 15 17 38 AIS - VADODARA
  39. 39. 9 D M A I C Process Standardization Process checklists introduced to control & maintain the improvement 39
  40. 40. 0 D M A I C Key learning’s & Further Scope • Fundamentals of DMAIC Methodology & how to apply the same to improve any kind of process. • Main Key understanding during this project : • How important is DATA to evaluate & improve any present process. • Statistically presentation of any process & evaluate the same . • Minitab Statistical tool . • The major points of PIX-36 panels where improvement required . • Further Scope : • Next greenbelt can be taken on other products (HWX,PCOB,BREAKER etc) 40
  41. 41. 1 Thank you 41

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