2. Team Arjun
Parsons Nutritionals Pvt Ltd-Sahibabad 2
SN Team
Name of Quality circle
team
1 Virender Singh Section Incharge Production-NHC
2 Amar Supervisior Production-NHC
3 Sumit Singh IPQI Production-NHC
4 Amit Kumar Lab attendent Laminate sampling
5 Vinod Singh Foreman Production-NHC
6 Vinod Kumar Operator Production-NHC
7 Pankaj Chaubey Operator Production-NHC
8 Ram Dayal Operator Production-NHC
9 Bablu Helper Production-NHC
10 Gudiya Helper Production-NHC
11 Farha Helper Weightment
12 Tara Wati Helper Production-NHC
13 Pradeep Devidi Helper Production-NHC
3. Introduction to Quality Circle-
Name of the Quality Circle : Arjuna
Department : Manufacturing
Circle Starting Date : April’ 2014
Meeting day : Every Monday
Meetings : 13
Average Attendance : 90%
Parsons Nutritionals Pvt Ltd-Sahibabad 3
4. 4
1. Problem
Identification
2. Selection of problem
3. Define of problem
4. Analysis of the problem
5. Identification of cause
6. Find the root cause
8. Development of
solution
7. Data analysis
9.Foreseeing probable
resistance
10. Trail implementation
11. Regular
implementation
12. Review
DR. JURAN
12 Step Problem Solving Method-
Parsons Nutritionals Pvt Ltd-Sahibabad
6. String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage
test.
Paper Shifting On Each Machine.
Increased Laminate Wastage Due To Delimitation Of Roll From Inside.
Increased Laminate Wastage Due To Damaged Core Of The Roll.
Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting
Of The Roll.
Increased Laminate Wastage At The Time Of Roll Change Time.
Increased Laminate Wastage Machine Setting.
Increased Laminate Wastage After Change Over/ Wet Cleaning.
Noise Of Vibrators.
Increased Laminate Wastage Seal Powder, Leakage.
Unclosed Cover Of Wraptech Machine.
Holes In A.C Duct.
Open Hole On The Wraptech Machine.
Required Stands For The Tray.
Unproper Wiring Of The Panel.
Spillded Ink On The Nichrome Machine.
Cover On The Wraptech Machine Wiring Tray.
7. Water Leakage From The Air cylinder Of The Wraptech Machine.
Need To repaire The fioor of taping room.
Uncontrolled Oven Temperature.
Required Tube Light In QA Lab.
Display Board Have To Be Repaired.
Insided Transformer Of The Nichrome Machine Should Be Coverd.
Required Door Mat At The Entrance Of Sechet Section & Filling Room.
Adjoining Wire Of The Packing Table & Conveyer Should Be Covered.
Flat Body Of The Metal Detector.
Stopped Working Of The Emergency Stop OF The Wraptech Machine.
Even In The Low Air Pressure Machine Don’t Stop Working.
Wraptech Machine’s Farmer 'hole Have To Be Closed.
Broken Light Cover Of The Sechet Packing Hall.
Intercom Wire Should Be Placed In Pipe.
Broken Light Cover Of The Filling Room & Taping Machine Room.
The Problem Of Torned Laminate Roll In Running Machine.
Untidy Cleaning Bay.
Increased Laminate Wastage Due To Printing Cutting.
Due To The Wrinkle At The Corner Of The Laminate Roll the Machine’s Photo Sensor Can’t
Work That’s Why Increased Laminate Wastage.
Need To Repair The Refrigerator Of Micro Lab.
Broken Water Tap Pipe In Lab.
10. SELECTION OF PROBLEMS ( A,B,C CATEGORY)
S.NO Problem Category
1 String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage test. C
2 Paper Shifting On Each Machine A
3 Increased Laminate Wastage Due To Delamination Of Roll From Inside. B
4 Increased Laminate Wastage Due To Damaged Core Of The Roll. B
5 Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting Of The
Roll.
B
6 Increased Laminate Wastage At The Time Of Roll Change Time. A
7 Increased Laminate Wastage At The Time Of Machine Setting. A
8 Increased Laminate Wastage After Change Over/ Wet Cleaning. A
9 Noise Of Vibrators. C
10 .Increased Laminate Wastage Seal Powder, Leakage. A
11. S.NO PROBLEM CATAGORY
11 .Unclosed Cover Of Wraptech Machine. B
12 .Holes In A.C Duct. B
13 Open Hole On The Wraptech Machine. B
14 Unproper Wiring Of The Panel. B
15 Required Stands For The Tray. C
16 Spillded Ink On The Nichrome Machine. A
17 Cover On The Wraptech Machine Wiring Tray. B
18 Water Leakage From The Air cylinder Of The Wraptech Machine. A
19 Need To Prepare The Humidity Chamber In Lab. B
20 Uncontrolled Oven Temperature Of Lab B
SELECTION OF PROBLEMS ( A,B,C CATEGORY)
12. S.NO PROBLEM CATAGORY
21 .Required Tube Light In QA Lab. B
22 Display Board Have To Be Repaired In Packing Hall Of Sechet Section. B
23 .Inside Transformer Of The Nichrome Machine Should Be Coverd. B
24 Required Door Mat At The Entrance Of Sechet Section & Filling Room. B
25 Adjoining Wire Of The Packing Table & Conveyer Should Be Covered. B
26 Flat Body Of The Metal Detector. C
27 Stopped Working Of The Emergency Stop OF The Wraptech Machine. A
28 Even In The Low Air Pressure Machine Don’t Stop Working. B
29 Wraptech Machine’s Farmer 'hole Have To Be Closed. B
30 Broken Light Cover Of The Sechet Packing Hall. B
SELECTION OF PROBLEMS ( A,B,C CATEGORY)
13. S.NO PROBLEM CATAGORY
31 Intercom Wire Should Be Placed In Pipe. C
32 Broken Light Cover Of The Filling Room & Taping Machine Room. B
33 The Problem Of Torned Laminate Roll In Running Machine. A
34 Untidy Cleaning Bay. A
35 Increased Laminate Wastage Due To Printing Cutting. A
36 Due To The Wrinkle At The Corner Of The Laminate Roll the Machine’s Photo Sensor Can’t
Work
B
37 Need To Repair The Refrigerator Of Micro Lab. C
38 Broken Water Tap Pipe In Lab. B
SELECTION OF PROBLEMS ( A,B,C CATEGORY)
14. A B C ANALYSIS
A B C
Involvement of team
member
Involvement of Other
Department’s
Involvement of Higher
Management
12 21 06
15. SELECTION OF PROBLEMS ( A,B,C CATEGORY
31%
54%
15%
A -Involvement of team member
B -Involvement of Other Department’s
C -Involvement of Higher Management
16. Status of Problems
Problems Identified Problems Solved Problems Pending
NO OF PROBLEMS NO OF PROBLEMS NO OF PROBLEMS
38 20 18
17. SELECTION OF PROBLEM
PROBLEM SELECTION FROM “A” CATEGORY
S.NO PROBLEM IMPORTENCE
1 Paper Shifting On Each Machine M I
2 Increased Laminate Wastage At The Time Of Roll Change Time. M I
3 Increased Laminate Wastage At The Time Of Machine Setting. I
4 Increased Laminate Wastage After Change Over/ Wet Cleaning. I
5 .Increased Laminate Wastage Seal Powder, Leakage. I
6 Spillded Ink On The Nichrome Machine. LI
7 Water Leakage From The Air cylinder Of The Wraptech Machine. LI
8 . Stopped Working Of The Emergency Stop OF The Wraptech Machine. M I
9 The Problem Of Torned Laminate Roll In Running Machine. I
10 Untidy Cleaning Bay I
11 Increased Laminate Wastage Due To Printing Cutting M I
18. SELECTION OF PROBLEM
PROBLEM SELECTION FROM “A” CATEGORY
1 Increased Laminate Wastage Due To Printing Cutting..
2. Stopped Working Of The Emergency Stop OF The
Wraptec Machine.
3. Paper Shifting On Each Machine .
4. Increased Laminate Wastage At The Time Of Roll
Change.
19. SELECTION OF PROBLEM
DATA BASE ANALYSIS
S.NO PROBLEM Amar sumit vinod gudiya Pankaj TOTAL
1. 1. Paper Shifting
On Each Machine
.
12 12 11 10 12 57
2. . Increased
Laminate Wastage
At The Time Of
Roll Change.
11 9 10 12 10 52
3. Stopped
Working Of The
Emergency Stop
OF The
Wrapetech
Machine
.
10 11 9 9 11 49
4. . Increased
Laminate Wastage
Due To Printing
Cutting
4 7 12 11 9 43
20. SELECTION OF PROBLEM
SELECTION OF MAJOR PROBLEM
(Pareto Analysis)
0
50
100
150
200
250
0
10
20
30
40
50
60
4. Increased Laminate
Wastage Due To Printing
Cutting
3. Stopped Working Of The
Emergency Stop OF The
Wrapetec Mavchine
2.Increased Laminate
Wastage At The Time Of Roll
change
1. Paper Shifting On Each
Machine
Total No
Percentage
cumilative No
28%
55%
79%
100%
22. DEFINE THE PROBLEM
STEP 3
OBSERVATION
PROCESS FLOW DIAGRAM
UN-PROPER
SETTING OF
ROLL
CODING
OUT
PHOTO CELL
OUT
ROLL
CHANGE
CODING+LENGTH-OUT
+OUT-CUTTING POUCH
23. DEFINE THE PROBLEM
Increased Laminate Wastage At The Time Of Roll Change Due To Paper Shifting
IMPACTS OF THE PROBLEM:-
Degradation of Pouch Quality
Dissatisfaction of customer.
High Laminate and Insert losses.
Wastage of time in repeated adjustments
24. DEFINE THE PROBLEM
OBJECTIVES
To Eliminate The Losses.
To Improve Product Quality.
To Improve Packing Quality.
Ensure Customer Satisfaction.
To Improve Working Environment.
Step .3
25. Mile Stone Chart
Mile Stone Chart
Sl.N
o Activity April.14 May.14 June.14 July.14 Aug-14
Week
-1
Week
-2
Week
-3
Week
-4
Week
-5
Week
-1
Week
-2
Week
-3
Week
-4
Week
-1
Week
-2
Week
-3
Week
-4
Week
-1
Week
-2
Week
-3
Week
-4
Week
-5
Week
-1
Week
-2
1
Identify
problem
2
Selection of
Problem
3
Define the
Problem
4
Analysis of
Problem
5
Identify
Causes
6
Identify Root
Causes
7 Data Analysis
8
Development
Solution
9
Forseen
Resistance
10
Trail
Implement
11
Regular
Implement
12
Followup and
Review
Continuous Process
30. IDENTIFICATION OF CAUSES
CAUSE & EFFECT DIAGRAM
LAMINATE WASTAGE
MAN
MATERIAL
MAN
METHOD
MACHINE
PAPER SHIFFTING ON MACHINE
CODING OUT
PHOTO CELL OUT
STEP 5
32. S.No Cause Description Analysis Validation
1
IMPROPER SETTING OF THE
LAMINATE ROLL
PHYSICALLY CHECKED
LAMINATE ROLL WAS
PROPERLY SET
2
PAPER SHIFFTING ON
MACHINE
PHYSICALLY
CHECKED THAT ROLL
WAS SHIFTING ON THE
ROLLER CAUSE OF
VIBRATION OF
RUNNING MACHINE
3
CODING OUT ON THE
MACHINE
PHYSICALLY CHECKED
CODING WAS O.K ON
THE POUCH
4
PHOTO CELL OUT ON THE
MACHINE
PHYSICALLY
CHECKED PHOTO CELL
FOUND O.K .
5
WRONG CUTTING OF
LAMINATE AT THE
STARTING OF THE ROLL
PHYSICALLY CHECKED
THAT OPRATOR WAS
CUTTING THE ROLL IN
WRONG MANNER AT
THE STARTING
NOTE:- Gemba analysis done for validation of causes.
Step 6
VALIDATION OF CAUSES
ROOT CAUSE ANALYSIS
34. DATA ANALYSIS OF THE CAUSES
RANKING METHOD
S.R.NO Root causes SUDHIR SUMIT VINOD I VINOD II PARDEEP TOTAL % age
1. PAPER SHIFFTING ON
MACHINE 8 7 8 7 8 38 58%
2 WRONG CUTTING OF
LAMINATE AT THE
STARTING OF THE
ROLL 6 5 6 5 6 28 42%
(Rating 10 being the Highest, 0 being the lowest
Step .7
35. DATA ANALYSIS OF THE
CAUSES
42 42
42%
0
20
40
60
80
100
120
0
5
10
15
20
25
30
35
40
45
marks cumilative
marks
cumilative %
§WRONG CUTTING OF LAMINATE AT
THE STARTING OF THE ROLL
PAPER SHIFFTING ON MACHINE
42%
SELECTION OF VITAL CAUSE
(Pareto Analysis)
Step .7
36. DATA ANALYSIS OF THE CAUSES
MOST VITAL CAUSE IDENTIFIED
From pareto analysis in last slide team
members decided to eliminate all two root
causes
1 PAPER SHIFFTING ON MACHINE
ROOT CAUSE. 2 WRONG CUTTING OF LAMINATE
AT THE
STARTING OF THE ROLL
ROOT CAUSE.
38. Solutions from
Team member
Two operators will
Set the laminate roll
On the machine
Proper cutting
of the
Laminate at the
starting
Of the roll after
the roll
change
To inform the
vender
For the wrinkle
on the
Side of the roll
and for
The core band
Roller mark
must
Be fixed on roll
assembly
Roller mark must
Be fixed on roll
assembly
40. FORSEEN RESISTANCE
FORSEEING PROBABLE RESISTANCE
S.No. RESISTANCE SOLUTION RESPONSIBILTY TARGET
DATE
1 Oprator can do mistake to paste
The taplone guide
Foremem & incharge will guide
Operator to fix the taplone guide on
farmer
Vinod Singh/
Pankaj Choubey
15.07.14
2 Two Operator will set the laminate
roll on the machine
It will be scheduled properly to
avoid the problems
Sechet incharge 15.07.14
3 Proper cutting of the
Laminate at the starting
Of the roll after the roll
change
Operator will instruct before the
starting of each roll
Supervisior/forem
en
16.07.14
4 Roller mark must
Be fixed on roll
assembly
To check by the supervisior &
foremen that roller mark is fixed
properly
Amar Nath Singh/
Vinod Singh
16.07.14
5 To inform the vender
For the wrinkle on the
Side of the roll and for
The core band
It is physically checked before fixing
the laminate roll on machine
Vinod/Pankaj
chouby
29.04.14
HENCE NO RESISTENCE TO IMPLEMENT THE SOLUTIONSTEP 9
48. REGULAR
IMPLEMENTATION
TANGIBLE GAINS
1.50%
1.20% 1.20% 1.20%
0.00%
0.20%
0.40%
0.60%
0.80%
1.00%
1.20%
1.40%
1.60%
feb may june july
laminate wastage
before quality
circle
laminate wastage
after quality circle
laminate wastage
after quality circle
laminate wastage
after quality circle
Series1
Before Quality Circle in Feb 2014 Laminate Wastage Target = 1.51%
r After Quality Circle in May 2014 Laminate Wastage = 1.21%
After Quality Circle in jUNE 2014 Laminate Wastage = 0.99%
After Quality Circle in jULY 2014 Laminate Wastage = 1.44%
Approx Saving of Laminate Wastage per month = .29%
Its Worth Near About = 1,40000
51. PARSONS NUTRITIONALS PRIVATE LIMITED
NO OF PROBLEMS SOLVED
S. No Problem
1 String Should Be Hold For At least 3 Hours Which Is Taken For Water Leakage test.
2 Increased Laminate Wastage Due To Delimitation Of Roll From Inside.
3 Increased Laminate Wastage Due To Damaged Core Of The Roll.
4 5.Increased Laminate Wastage Due To Eccsassive Pasting Of Stickers' At Starting Of The Roll
5 Unclosed Cover Of Wraptech Machine.
6 Holes In A.C Duct.
7 Opon Hole On The Wraptech Machine.
8 Unproper Wiring Of The Panel.
9 Spillded Ink On The Nichrome Machine.
10 Water Leakage From The Air cylinder Of The Wraptech Machine.
11 Need To repaire The fioor of taping room
12 Uncontrolled Oven Temperature.
13 Required Tube Light In QA Lab
14 Display Board Have To Be Repaired.
15 Insided Transformer Of The Nichrome Machine Should Be Coverd.
52. PARSONS NUTRITIONALS PRIVATE LIMITED
NO OF PROBLEMS SOLVED
S. No Problem
16 .Required Door Mat At The Entrance Of Sechet Section & Filling Room
17 Adjoining Wire Of The Packing Table & Conveyer Should Be Covered
18 .Stopped Working Of The Emergency Stop OF The Wraptech Machine. Even In The Low Air Pressure
Machine Don’t Stop Working.
19 Wraptech Machine’S FarMer 'hole have to Be cloSeD
20 Untidy Cleaning Bay
21 even in the loW air preSSure Machine Don’t Stop Working.
22 Due to the Wrinkle at the corner oF the laMinate roll the Machine’S photo SenSor can’t Work that’S
Why Increased Laminate Wastage.
23 Broken Water Tap Pipe In Lab.
53. THE TOOLS AND TECNIQUES FOR
PROBLEM SOLVING
Stratification
Cause And Effect Diagram
Pareto Chart
Pie Chart
Ranking Method
4 W & 1 H
Brainstorming
54. CONCLUSION
Lessons Learnt:-
• Innovations and working as a team towards achieving target.
•Systematic Problem Solving approach.
•Keep regular watch on key area after project implementation
