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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 Variation of breakdown of Maintenance Equipment

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) 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. 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. Project CharterABC PVT Ltd, is repudiated mutibranded AFC system organisationwhich is being operated in more than 100 countries. It providesservices of design, supply, installation ,testing and commissioning ofAutomatic fare collection ticketing systems. AFC system reduces theticket checking staff and it helps the prevent fraud .XXX is one of the clients to ABC, XXX 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 organization willbe 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: LMManaging director MOProject Manager: RRMaintenance manager: GSBB: SBGB: RP ,MA, RLMember: Maintenance TeamFinancial controller: RGProblem Statement:Last 3 month penalty of breakdown the AFC machines Jul , Aug &sep is respectively (15732500), (13206667) & (1209833) cr. The deficitof total revenue in last 3 months is Two million seventy eight lakheighty three thousand three hundred thirty three.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 and reduce thevariation in my process by the end of March 2012.In Scope : Maintenance ,Hardware & software developmentdepartment.Out Scope : All other department other than Maintenance ,Hardware &software department.Milestones Target Date Actual DateD 15thMarch 11 30thMarch 11M 1stApril11 15thNov’11A 16thNov’11 30thNov’11I 1stdec’11 6thDec’11C 6thDec’11 15thDec’11dDEFINE
- 4. RASICdDEFINE
- 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. 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. 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. 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. 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. Probability PlotmMEASURESince, P value < 0.05,hence the data is not normal
- 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. Data Distribution Analysis for VariationThere is too much variation problem in my process .Our USL is 120 minutes but our 55% team isbelow the 120 minutes (upto minimum 55 minutes) in first quartile and 45% team is above the 120minutes (maximum upto 176 minutes).aAnalyseMinimum TAT is 55 andmaximum TAT is 176 itis huge variation in myprocess and our targetis 120 minute
- 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 Target.aAnalyse
- 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. Proposed tests according to problem and factor’s variationdata typeaAnalyzeS No.X PotentialCauseOperational DefinitionY DataTypeX DataTypeTest of beperformed1 Spare Availability Availability of spare inventory in warehouse for doing project. Continuous Discrete Test for equal variance2 Marital status Married or un married. Continuous Discrete Test for equal variance3 Maintenance TeamA group of people with a full set of complementary skills required to complete a task , job, orproject.Continuous Discrete Test for equal variance4 Age The number of years an individual associate is old in his / her span of life Continuous Continuous Test for equal variance5 QualificationIt’s capacity, knowledge and skill which represents the eligibility criteria of person for enterthe any field and position e.g. (technical or non technical.).Continuous Discrete Test for equal variance6SubjectspecializationThis defines the knowledge of interest in particular subject. Continuous Discrete Test for equal variance7 Company Payroll This represents you are company employee or third company employee. Continuous Discrete Test for equal variance8 Technical Rating This is method to evaluate the technical ability of person. Continuous Discrete Test for equal variance9 Designation To select and set aside for a duty. Continuous Discrete Test for equal variance10 TrainingIt is the learning process for development skill, knowledge, ability to perform a job forgrowth of company.Continuous Discrete Test for equal variance11 Reimbursement Reimbursement means to Pay back the money against the expenses by an employer. Continuous Discrete Test for equal variance12 TenureThe time in months / years which an individual associate has spent in the particularprocess.Continuous Discrete Test for equal variance13 Monthly SalarySalary is a fixed amount of money or compensation paid to an employee by an employer inreturn for work performedContinuous Discrete Test for equal variance14 AppraisalIt is the process of obtaining , analyzing and work effectiveness recording informationabout the relative worth of an employee.Continuous Discrete Test for equal variance15 Experience The total work experience of an individual in present company. Continuous Continuous Test for equal variance16 TAT Target It means Our target is met or not met. Continuous Discrete Test for equal variance17 Shift Shift refers to a job work schedule for employee . Continuous Discrete Test for equal variance18 LocationThis is a place on where maintenance team goes for attending the failures for AFCequipments.Continuous Discrete Test for equal variance19 Gender Gender is a range of characteristics used to distinguish between males and females Continuous Discrete Test for equal variance20PreventiveMaintenancePreventive maintenance is a schedule of planned maintenance actions aimed at theprevention of breakdowns and failures. Continuous Discrete Test for equal variance
- 35. 36Test for equal variance between TAT & Spare AvailabilityaAnalyzeThe test for equal variance shows that since the p- value is 0.000 , spare availability (X) has significantimpact on TAT (Y).Test for Equal Variances:TAT(Breakdown M versus Spare Availability,Sub system)Bartletts Test (Normal Distribution)Test statistic = 213.01, p-value = 0.000Levenes Test (Any Continuous Distribution)Test statistic = 13.65, p-value = 0.000
- 36. 37Test for equal variance between TAT & Marital StatusaAnalyzeThe test for equal variance test shows that since the p- value is 0.455,marital status (X) has nosignificant impact on TAT (Y).Test for Equal Variances:TAT (Breakdown versus Marital status,Maintenance)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any Continuous Distribution)Test statistic
- 37. 38Test for equal variance between TAT & Maintenance TeamaAnalyzeThe test for equal variance shows since the p- value is 0.455 , maintenance team (X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance) versusMaintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 38. 39Test for equal variance between TAT & AGEaAnalyzeThe test for equal variance shows that since the p- value is 0.455 , age (X) has no significant impact onTAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance versusAge, Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 39. 40Test for equal variance between TAT & QualificationaAnalyzeThe test for equal variance shows that since the p- value is 0.455 , qualification (X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance versusQualification, Maintenance)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 40. 41Test for equal variance between TAT & Company PayrollaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,payroll (X) has no significant impacton TAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance versusPayroll, Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 41. 42Test for equal variance between TAT & Technical RatingaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,Technical rating (X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance versusTechnical Ex, Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 42. 43Test for equal variance between TAT & DesignationaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,Designation(X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown M versus Designation,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 43. 44Test for equal variance between TAT & Maintenance TrainingaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,Training (X) has no significant impacton TAT (Y).Test for Equal Variances:TAT (Breakdown versus Maintenance ,Maintenance)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 44. 45Test for equal variance between TAT & Monthly claimsaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,monthly claims (X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown versus Monthly Claim,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 45. 46Test for equal variance between TAT & TenureaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,Tenure (X) has no significant impacton TAT (Y).Test for Equal Variances:TAT (Breakdown M versus Tenure,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 46. 47Test for equal variance between TAT & Monthly SalaryaAnalyzeThe test for equal variance shows that since the p- value is 0.843 ,Monthly salary (X) has no significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown versus Monthly Salary,Maintenance)Bartletts Test (Normal Distribution)Test statistic = 6.43, p-value = 0.843Levenes Test (Any ContinuousDistribution)Test statistic = 1.01, p-value = 0.435
- 47. 48Test for equal variance between TAT & AppraisalaAnalyzeThe test for equal variance shows that since the p- value is 0.455 ,Appraisal (X) has no significant impacton TAT (Y).Test for Equal Variances:TAT (Breakdown M versus Appraisal,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 48. 49Test for equal variance between TAT & Present organization ExperienceaAnalyzeThe test for equal variance shows that since the p- value is 0.000 ,Present Experience (X) has nosignificant impact on TAT (Y).Test for Equal Variances:TAT (Breakdown versus Experience ,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 49. 50Test for equal variance between TAT & TAT TargetaAnalyzeThe test for equal variance shows that since the p- value is 0.000 ,Present TAT Target (X) has significantimpact on TAT (Y).Test for Equal Variances:TAT (Breakdown M versus TAT Target,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 148.51, p-value = 0.000Levenes Test (Any ContinuousDistribution)Test statistic = 7.38, p-value = 0.000
- 50. 51Test for equal variance between TAT & ShiftsaAnalyzeThe test for equal variance shows that since the p- value is 0.107,P shifts (X) has significant impact onTAT (Y).Test for Equal Variances:TAT (Breakdown M versus Shifts,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.98, p-value = 0.418Levenes Test (Any ContinuousDistribution)Test statistic = 1.52, p-value = 0.183
- 51. 52Test for equal variance between TAT & LocationaAnalyzeThe Test for equal variance shows that since the p- value is 0.000 Gender (X) has significant impact onTAT (Y).Test for Equal Variances:TAT (Breakdown Maintenance versusLocation, TAT TargetBartletts Test (Normal Distribution)Test statistic = 141.57, p-value = 0.000Levenes Test (Any ContinuousDistribution)Test statistic = 16.03, p-value = 0.000
- 52. 53Test for equal variance between TAT & GenderaAnalyzeThe test for equal variance shows that since the p- value is 0.455 Gender (X) has no significant impacton TAT (Y).Test for Equal Variances:TAT (Breakdown M versus Gender,Maintenance Team)Bartletts Test (Normal Distribution)Test statistic = 4.69, p-value = 0.455Levenes Test (Any ContinuousDistribution)Test statistic = 1.33, p-value = 0.250
- 53. 54Test for equal variance between TAT & Preventive MaintenanceaAnalyzeThe test for equal variance shows that since the p- value is 0.895,P location (X) has significant impact onTAT (Y).Test for Equal Variances:TAT (Breakdown versus PM Work Allow,PM Stations, ...Bartletts Test (Normal Distribution)Test statistic = 5.66, p-value = 0.895Levenes Test (Any ContinuousDistribution)Test statistic = 0.92, p-value = 0.518
- 54. 55Vital 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 TAT Target It means Our target is met or not met. Continuous Discrete 0.0003 LocationThis is a place on where maintenance team goes for attending thefailures for AFC equipments.Continuous Discrete 0.003
- 55. 56IImproveQFDActionable Items Responsibility Start Date Close DateChecked monthly RAM/Failure Report Maintenance Manager 2-Jan-12 7-Jan-12Increase quantity of Repaired Material stock Head of LAB 2-Jan-12 14-Jan-12Increased quantity of advance tool and machines Head of LAB 2-Jan-12 21-Jan-12Maintained all stock of Laboratory Head of LAB 2-Jan-12 21-Jan-12Increased quantity of Spare Availability Store Manager 9-Jan-12 18-Feb-12Find Weakness and strong point of Team and workout Maintenance Manager 9-Jan-12 21-Jan-12Innovation and plan Maintenance Manager 2-Jan-12 31-Jan-12Reconsider shift for M Team members Maintenance Manager 2-Jan-12 7-Jan-12Test the technical expertise of whole team Maintenance Manager 2-Jan-12 14-Jan-12Increase the availability Transportation Maintenance Manager 2-Jan-12 21-Jan-12Start procedure of monthly Inspection for store Store Manager 2-Jan-12 29-Feb-12Increasing % of Annual Performance Appraisal Maintenance Manager 2-Jan-12 29-Feb-12Increasing Technical Training Maintenance Manager 21-Jan-12 29-Feb-12Checked and Maintained Stock Report Store Manager 2-Jan-12 28-Jan-12Purchase Rack assembly for Storage Store Manager 2-Feb-12 29-Feb-12Generate SAP for keeping record in Storage Technology Store Manager 2-Jan-12 2-Feb-12
- 56. 57IImproveImplementation Road MapQFD
- 57. 58IImproveFMEADefined "X"s Items Failure Mode Effect on EDR Severity Occurrence Detection RPN RMS RTP ResponsibilitySPARE AVAILABILITYStoreInapt Location Time and money would be consumed for transportation 10 2 10 200 Avoid Consult to client Bid mangerUnsatisfactory space material could be damage and broken. 10 2 10 200 Avoid Consult to client Bid mangerStorageInadequate resources for casing and housing Dust and water leakage could be spoil our inventory 10 2 10 200 Avoid Consult to client store managerDefeciency of raw material for organised the inventory.% of searching time would be greater to find out the inventory for separatedepartments.10 5 10 500 ReduceTake Approval forprocess managerstore managerStock Report Imperfect Stock reportQuantity could be mismatch and store incharge can not easily diagnoseshortage and requirement of inventory.8 5 10 400 Reduceask complete spare listto vendorstore managerAvailability of no of spare Inadequate of inventoryService quality of equipment could be affected .TAT would be increase andpenalty charge will be too high.10 5 10 500 ReduceApproval for processmanager to purchasethe itemsstore managerstorage TechnologyNo implementation of SAP Chances of data accuracy would be minimum.data could be loss. 8 5 10 400 TransferRequest mail to SAPdepartmentstore managerUnavailability of Fire protection element% of safety protection would be negligible for inventory & employee inuncertanity situations.8 2 10 160 AvoidApproval for processmanager to purchasethe fire protectiondevicestore managerTAT TargetTeam If quantity of employee is less 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 AvoidMail to maintenanceManagerHead of LABRepaired Material stock Lack of specification and maintenance documents% of troubleshooting the fault will be difficult.Quantity of scrap would begreater.it can affect the cost of project.8 5 10 400 ReduceMail to maintenanceManagerHead of LABTechnical Expertise % of non technical employee is greater TAT of breakdown maintenance wolud be high. 8 5 10 400 ReduceMail to projectManagerMaintenance ManagerTechnical Training Maintenance training is too shortTeam knowlede would be little about equipment .Difficult to identify andrectify the faults of equipments.8 4 10 320 Reduce Mail to trainer Maintenance ManagerAdvanced tool and Machines Using Imperfect tool and machines % of rejection would be high and maintainace would be difficult. 8 5 10 400 ReduceMail to maintenanceManagerHead of LABApproval Delay in approval It will direct impact on our services and PM 8 5 10 400 Avoid Take Approal to client Maintenance ManagerStation RAM/Failure Report Non availability of reportWithout Failure report it would be very difficult to diagnose the RAM cyclesand equipment stability.7 4 10 280 Reducesend mail to team fordaily activity failurereportMaintenance ManagerInnovation and plan Weak planning Difficult to take time estimation for any process. 8 5 10 400 Avoid Plaaned to all activities Maintenance ManagerLOCATIONReconsider shifts Deficiency of Muster rollTeam shift will not properly organised and workload can be greater toindividual team members.7 5 10 350 ReducePrepared report anddistribute the teamMaintenance ManagerWare house Inavailability of warehousewe dont have warehouse then we cant put repaired material near by station.waiting time of spare availability would be increase and TAT will increase.8 2 10 160 Avoidconsult to projectmanagerMaintenance ManagerTransportation Lack of conveyance Delay the service of DLP.it would be direct impact on customer service. 7 5 10 350 ReduceTake Approal toproject ManagerMaintenance ManagerFailure Mode effect Analysis
- 58. 59cControlI-MR Chart Pre and Post TAT
- 59. 60cControlPre TAT: Test Results for I Chart of C2 by SubscriptsTEST 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: Test Results for MR Chart of C2 by SubscriptsTEST 1. One point more than 3.00 standard deviationsfrom center line.Test Failed at points: 151
- 60. 61tTTDifference in TAT between Pre and Post improvementThis graph shows the bell curve for ‘Pre-Project TAT ‘ v/s ‘Improved TAT’. The improvementis evident in both the bell-curvescControl
- 61. 62tTTBox plot of TAT shows that after improve the vital x TAT has been reduced.cControlBox plot of TAT after implementation of improvement plan
- 62. 63tTTBox plot of TAT shows that after increasing the spare, TAT has been reduced.cControlSpare availability wise box plot of TAT after improvement
- 63. 64tTTBox 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
- 64. 65tTTBox 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.cControlLocation wise box plot of TAT after improvement
- 65. 66tTTVariation: This Data Distribution chart shows that stages of Pre TAT and post TAT . The pre stage of TATwas showing, team was taking maximum time up to 176 minutes and minimum time was 55 minutes forBM).This is huge variation problem but after improvement Team was taking minimum time 10 minutes andmaximum time 28 minutes. The problem of variation and TAT has been resolved and team is able to achievethe target.Difference between Pre & Post TAT of breakdown maintenance(variation)cControl
- 66. 67tTTThis 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
- 67. 68tTTTHANK YOU

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