This document summarizes a quality control study on the production of 3-pole MCCBs at Havells India Ltd. The study found that the current process has low Cp and Cpk values, indicating high variation and rejection rates. The objectives were to analyze the production process, identify causes for low Cp and Cpk, and make improvements. Data was collected and analyzed using tools like control charts, fishbone diagrams, and Pareto charts. Improvements like fixing tooling issues and developing new springs increased Cp values but further work is needed to meet Cpk specifications. Recommendations include improving incoming material quality and using more in-house parts. The internship provided hands-on experience with quality control management systems and

1. QUALITY CONTROL
STUDY ON
3 – POLE MCCB
PRODUCTION
Under The Guidance Of
Mrs. Nisha Taank
Senior Manager ,QCD
Havells India Ltd, Sahibabad (U.P)
Presented by :
Akshay Nair (1527503)
Christ University Institute
of Management

2. PRODUCT
• MCCB –Moulded Case Circuit Breaker
• Project is limited to 3 pole MCCB
• Daily production of 200 to 250 No.s

3. PROBLEM STATEMENT
• The present state of product shows lower Cp and
Cpk (process capability) values in many of 3 pole
MCCB parameters which is less than the specified 1
and 1.33.
• By virtue of which company is facing high rejection
rate & low in customer specification.

4. PROJECT OBJECTIVE
• To study quality control measures by analysing the
3 pole MCCB production process.
• To analyse causes for low Cp and Cpk values.
• To address the issues and necessary improvement
required for increasing values of Cp and Cpk .

5. DATA COLLECTION
• After Understanding the production process , 30 random
samples of MCCB is picked up.
• DFSS data is collected for different parametres of MCCB
manuualy.
• Data is collected before & after improvements as well.
• Each time 30 random samples are selected.

6. CALCULATION OF CP & CPK
• The number of random samples taken
• Upper specification limit (USL)
• Lower specification limit(LSL)
• Cp = (USL – LSL) ÷ 6σ( Process Variation)
• Cpk = Minimum[(USL – X bar)/3σ;(X bar –LSL)/3σ]

7. RESULTS OF CP & CPK BEFORE
IMPROVEMENT
• DFSS ANALYSIS.xlsx
• It shows low Cp & Cpk Values much below the
specified 1 & 1.33.
• Many samples were showing high variations.
• Fishbone Diagram & Pareto Analysis used to find out
the diff causes for low Cp & Cpk.

8. FISHBONE DIAGRAM & PARETO
ANALYSIS
G frame TP
METHOD MAN
MATERIAL
Fitment not
proper
DFS cover
Unskilled Man Power
Problem in Trip Bar
Extra filing in DFS base
Trip bar filing
Delatch
Push button slot
dimension
MACHINE
NC

9. PARETO ANALYSIS
0.0
20.0
40.0
60.0
80.0
100.0
120.0
10 5 5 3 2 1 0
DL NC DEF BASE DEF COVER OTHERS PBNT OTHERS
PERCENTAGE
DEFECTS

10. IMPROVEMENTS TAKEN FOR
INCREASING CP & CPK
Step 1 : Cover slot depth in the breakers was less
than the required
Action Taken: The Tool has been rectified with
specified slot.
Step 2: Another observation in Push to trip spring
Action Taken: New springs has been developed from
special springs and the results shown good result.

11. RESULTS AFTER IMPROVEMENT
• improved data.xlsx
• All the parametres show Cp >1.
• Cpk values also increased significantly but still short of
specified limit.
• Much more improvement is going on from R&D team to
improve Cpk.

12. QUALITY IMPROVEMENT THROUGH 7 QC
TOOLS
S.N
o
Quality Control
Tool
Existin
g
Purpose Suggestion
s
1 Control Charts P-
Chart
Being used at all the stages
and used to calculate the
defect rate of the components
as well as process and it is
being updated daily
Using
Excel
template
for
P-Chart
instead of
manual
filling of
data
2 Flow Charts Present Indicate the flow of process
3 Check Sheet Present It is used while collecting the
data from the production
process.
4 Pareto Chart Present When analyzing data about
12

13. 5 Fish Bone
Diagram(Cause
and Effect
Diagram)
Not
Existing
Chart which enables to
find out the root cause of
the problem by analysing
each and every possible
opportunity for defect
6 Histogram Not
Existing
When seeing whether a
process change has
occurred from one
time period to another.
7 Scatter Diagram Not
Existing
The scatter diagram
graphs pairs of numerical
data, with one variable on
each axis, to look for a
relationship between
them.
Can be used
to find the
correlation
between
Defect rate
and various
causes for
defects
Quality Improvement through 7 QC Tools
Contd..

14. RECOMMENDATIONS
• Since the defects observed are mainly component
defects there is a necessity for a proper inspection
of Incoming materials by Internal Quality Control
(IQC) Department.
• Raw material should be in proper parameters, it may
give law cost and with minimum error’s.
• More number of In-house parts are preferable over
vendor.
• Usage of Cpk in control charts to understand the
variation in the product parameters.

15. HAVELLS EXPERIENCE
• Bridge the gap between theoretical knowledge we possess with
the real time hands-on practical experience at Havells.
• Huge importance of “Quality Control Management system”.
• Patience to gather the right information, how to organize that
data and use the necessary tools to make the data speak for
itself.
• Importance of Customer Satisfaction, Customer Retention,
Customer Loyalty.

16. THANK YOU