The point of interest of the approach is on the development of sigma level with the aid of using QC story which incorporates the best manipulate and quality improvement. All sorts of first-rate control efforts directly enhance sigma level of components. Additionally, through decreasing the level of Defectives consistent with defectives per million (DPM) which immediately affect to the sigma stage. Here, within the paper certain technique will be discussed to address the problems and dreams which can be an improvement in sigma stage for the shop and decreased DPM level will be done. In the course of machining operation, nos. of types of defects would be happened. Categories those defects and after analyze a few standards could be made so that possibility for going on the defects may be decreased and Sigma level might be improved. The getting to know of the quality controls procedure has to be surpassed directly to everyone within the company. Total Quality Control can be achieved by proper methodology and the initially start up for fully implementing TQM may take few months for any company to claim to be a TQM company. Thereafter, the standardized procedures may have to be followed by all concerned to retain the progress achieved.

1. VSRD International Journal of Mechanical, Civil, Automobile and Production Engineering, Vol. VIII Issue IV April 2018 / 95
e-ISSN: 2249-8303, p-ISSN: 2319-2208 © VSRD International Journals: www.vsrdjournals.com
RESEARCH PAPER
IMPROVEMENT OF QUALITY SIGMA LEVEL OF COPPER TERMINAL
AT VERTICAL MACHINING COMPONENTS BY USING QC STORY
1Vallabh Shah* and 2Shubham Awasthi
1Research Scholar, 2Assistant Professor, 1,2Department of Mechanical Engineering,
Parul Institute of Technology, Vadodara, Gujarat, India
*Corresponding Author EmailID:vallabhshah2013@gmail.com
ABSTRACT
the point of interest of the approach is on development of sigma level with the aid of using QC story which incorporates the best
manipulate and quality improvement. All sorts of first-rate control efforts directly enhance sigma level of components. Additionally,
through decreasing the level of Defectives consistent with defectives per million (DPM) which immediately affect to the sigma stage.
Here, within the paper certain technique will be discussed to address the problems and dreams which can be an improvement in sigma
stage for the shop and decreased DPM level will be done. In the course of machining operation, nos. of types of defects would be
happened. Categories those defects and after analyze a few standards could be made so that possibility for going on the defects may be
decreased and Sigma level might be improved. The getting to know of the quality controls procedure has to be surpassed directly to
everyone within the company. Total Quality Control can be achieved by proper methodology and the initially start up for fully
implementing TQM may take few months for any company to claim to be a TQM company. Thereafter, the standardized procedures
may have to be followed by all concerned to retain the progress achieved.
Keywords: DPM (Defectives per Million), Pareto Chart, Cause & Effect diagram, Hypothesis Analysis, Check Sheet, PFMEA
(Preventive Failure Modes Effectiveness and Analysis).
1. INTRODUCTION
QC story is sincerely trouble solving system through the
collection and evaluation of information to offer suitable
judgment in keeping with scientific evidences. QC story
isn't always most effective relevant to best issues,
however also productiveness, value, logistic, electricity,
safety and many others. A QC story is a file this is used
to explain work at some stage in an improvement
attempt. This method of commentary and records
collection and with analysis gives a systematic approach
to resolve a trouble quite, fast and appropriately. QC
story is used to improve the sigma level of copper
terminal which additionally include the reduction of
DPM (defectives per million) stage. If only dimensional
type defects will be decreased then immediately sigma
level can be stepped forward. After applying this
concept, dimensional variation and high rework and
rejection can also be reduced.QC Story allows the
problem solvers to find mistakes by themselves, Problem
solving can never be complete, to achieve break through
improvements, without going through proper process of
Quality control. Every individual in the company where
TQM implementation is going on must understand and
respect this process and no deviations are allowed in the
documentation. Once the quality control process
formulated by the organization appointed experts is
followed then, the savings achieved in improvements
must be documented as per the standardized procedures.
The QC Story procedures work as follows:
Step 1: Select the theme
Step 2: Justify the choice
Step 3: Understanding the current situation
Step 4: Select the target
Step 5: Analysis – Cause & Effect diagram, Why-Why
analysis
Step 6: Implement the corrective measures
Step 7: Confirm the results and effects
Step 8: Standardize
Step 9: Summarize and future action plan
Sigma is a statistical term that measures how much a
process varies from perfection, based on the number of
defects per million units. Six Sigma = 3.4 per million
units. When learning about Sigma Level, it may help to
consider these charts, which detail how sigma level
relates to defects per million(DPM). DPM is converted
to sigma level. We used a normal probability table to
look up the DPM value to determine the equivalent
standard deviations away from a normal distribution

2. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 96
which would produce that level of defectives (at attribute
conversion to an equivalent normal distribution). If the
defect data collected over a short period of time, we
would consider the z-value as the sigma level.
If we made the assessment over a long period then we
would add 1.5 sigma to the z-value before reporting the
sigma level.
2. THEORY AND MEASURES OF
QUALITY SIGMA LEVEL
This section comprises some of the literatures used for
quality sigma level measurement techniques developed
by various researchers using PDCA-Deming cycle, Total
Quality Management and quality control tools non-
invasive methods with their importance.
QC Story based on PDCA cycle:
As shown in Fig 1, 9-Steps for problem solving method
focuses on root-cause problem analysis and long term,
permanent solution with the goal of total elimination of
the problem for complex issues.
Fig. 1: PDCA Cycle
Importance of sigma level related to DPMO:
As shown in the table, there is a sigma level form 1 to 6. Different sigma level contains the different value of defectives
per million opportunities (DPMO). Whenever the sigma level is increases, the DPMO value has been decreases.
Table 1: Sigma Level vs. DPMO
Sigma Performance Levels – One to Six Sigma
Sigma Level Defects Per Million Opportunities (DPMO)
1 690,000
2 308,537
3 66,807
4 6,210
5 233
6 3.4
3. PROBLEM DEFINITION
In CNC Shop, on VMC machines there are 15 different types of copper terminals are manufactured. For the CNC Shop
average DPM level is 36,781. Here, at this stage all components are not responsible for the high DPM value, rework &
rejection. So, by using parato analysis identification of component would be found.
Fig. 2: Parato chart for component selected

3. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 97
Here, 5 defectives are found for component 1. Hence, for this component QC Story methodology is applied.
4. OBSERVATION
Fig. 3: Component selected for Study
Here, there are 3 different types of defects being found. Dimensional, Aesthetic and System types defects are found.
Also, dimensional type defect is divided into following groups.
Fig. 4: Parato for Dimensional Defects
5. RESULTS & DISCUSSION
Observation of process during walkthrough:
 Locating pin found warn out
 Resting clamp not available for 1 cavity.
 Out of 05 clamps 1 clamp not available which is leading to play in component against resting block.
 Pusher pin not available for 2 components out of 5.
 Gauge not available for operator to check dimension at machine
.
Fig. 5: Action taken during Walkthrough

4. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 98
After solving small problems at lower level the brainstorming process has been carried out through cross functional team.
Fig. 6: Control charts before action
As shown in the figure observation not falls within the control limits. Hence, it needs action on it.
6. BRAINSTORMING
During this process total 26 causes are found.
After that all these causes are categories into Man, Machine, Material, Method and Measurement. It’s called a Cause &
Effect diagram. This diagram is shown in the figure.
Fig. 7: Cause & Effect diagram
Validation of Possible Causes
During brainstorming process, there are 26 causes are to be found. Among these causes on the basis of observation, all
possible causes are again validated and analyze it. Here, possible causes are converted into probable causes. In this case,
among 26 causes only 3 probable causes are to be found. These causes are most relevant for problem happening. After

5. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 99
that why-why analysis has been carried out for these causes.
WHY-WHY ANALYSIS
Table 2: Why-Why analysis
Here, there are 3 root causes has been found and it required some necessary action on it.
ACTION TAKEN
Fig. 8: Modification of New Fixture
Here, ball pusher ensures component resting perpendicular to component edges to eliminate chances of misalignment.
Ball pusher eliminates cause of operator miss to clamp the component.
Here, whole fixture is modified. In an old fixture only 1 component is manufactured while in new fixture 2 components
are manufactured per cycle.
Fig. 9: Components Manufactured Per Cycle

6. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 100
Fig. 10: Control charts after Action Taken
As shown in above fig all observations are falls in between the control limits. Also, the value of Cpk is improved from
0.33 to 1.26. Hence, we can say that the process is stable and capable for doing the operation.
7. EXPERIMENTAL RESULTS
Table 3 : Month wise DPM level
As shown in the table, the DPM value for this component is continuously decreases. In the month of January, DPM value
is 628 and rejection level is 0.06%
Fig. 11: % of Rejection
Table 4: Sigma level vs. DPMO

7. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 101
As shown in above table the sigma level is increases. For this component the sigma level is 4.73. Although the sigma
level for CNC shop is increases from 3.01 to 4.08.
Fig. 12: DPM trends after action taken
As shown in the above chart, the DPM level is gradually
decreases. Hence, after implementation of new fixture
productivity and quality of the component have been
increases.
8. CONCLUSION
This study is directly focused on improvement of quality
control and sigma level. It is purely based on PDCA
cycle. This cycle helps us to establish the objectives,
take actions, check its physibility and follow up the
actions for next procedure. For high rate of DPM level,
nos. of defects is occurred. Here, the DPM level is
reduced from 36,781 to 628 and also the sigma level is
increases form 3.01 to 4.73 for the CNC Shop.
9. ACKNOWLEDGMENT
I am extremely thankful to my respected guide Mr
Shubham Awasthi Assistant Professor, Mechanical
Engineering Department, Parul Institute of Technology
for his kind and inspiring advice which helped me to
understand the subject and its semantic significance. He
enriched me with valuable suggestions regarding my
topic and presentation issues.
10. REFERENCES
[1] Dr. D.Y.Sha and Hong Yi Chen- Creative Problem
Solving QC Story Based on Systematic Innovation TRIZ
– a case study in continuous development product, The
TRIZ Journal – vol. 23, No.1, January 2016.
[2] Dr. Sabah Khan- Total Quality Management in Research
and Development Sections of Different Sectors: A Social
Responsibility - International Journal on Recent and
Innovation Trends in Computing and Communication –
vol. 3Issue 2, 2015.
[3] Gregory H Watson – Engineering the Process of
Continual Improvement, Advancing Quality as Science,
Improving Analytical Structure and Methods – A Case
Study in Improvement of Process On The Basis of Quality
– Octomber2014.
[4] Sandeepsoni and Dr. Ravindra Kumar – Quality Circle: A
Methodology to Identify Scope of Quality Improvement –
International Journal of Modern Engineering Research –
vol. 3, Issue 7, July2015.
[5] Jagdeesh Rajashekharaiah – Quality Leaders Learning
from the Deming Prize winners in India – International
Journal for Quality Research – 2013.
[6] Glorija Paliska – Selected Components Affecting Quality
of Performance Management System – 4th
International
Conferences on Leadership, Technology, Innovation and
Business Management – 2013.
[7] Ola Ibrahim – Total Quality Managment(TQM) and
Continous Improvment as Addresed by Researchers –
International Journal of Scientific and Research
Publications – vol. 3, Issue 10, November2012.
[8] M. Shanmugaraja, M. Nataraj and N. Gunasekaran –
Defect Control Analysis for Improving Productivity and
Quality: An Inovative Six Sigma Case Study –
International Journal for Quality and Inovation – vol. 1,
No 3, April2011.
[9] Marta Kucerova and Helena Fidlerova – Important
Aspects of Continuous Quality Improvement in Slovak
Enterprices – Research Paper from Faculty of Material
Science and Techonology in Trnava – 2009.
[10] Laxmikumari – Total Quality Management(TQM) A
Quality and Performance Enhancer - International
Journal of Engineering and Science – vol. 4, Issue 8,
August2014.
[11] Sheng-Yuan-Hsu – Application of 7 Quality Control
(7QC) Tools for Continuous Improvement of
Manufacturing Process - International Journal of
Engineering Research and General studies – vol. 3, No 1,
January2011.
[12] Stephen Roper - Innovation, Quality Management and
Leraning: Short Term and Longer Effects – Research
Paper from Department of Economics, Cork University
Business School, University College Cork, Ireland–vol. 4,
Issue 4, July2009.
[13] Dr. Sergio Sousa and Nuno Rodrigues – Application of
SPC and Quality Tools for Process Improvement – 27th
International Conference on Flexible Automation and
Intelligent Manufacturing – vol. 2, Issue 5, June, 2008.

8. Vallabh Shah and Shubham Awasthi VSRDIJMCAPE, Vol. VIII (IV) April 2018 / 102
[14] TaquiT Quazi – A Review of DMADV: Methodology,
Customer Satisfaction and Research Area - International
Journal of Scientific and Engineering Research – vol. 6,
Issue 1, January2007.
[15] Devendra G. Pendokhare Practical Application of Tools –
2nd
International Quality Conferences, Quality Festival –
vol. 6, Issue 4, March2008.
[16] Hilal Olcay – The Effects of Total Quality Management
Practices On Performance and the Reasons of The
Barriers to TQM – Hindwai publishing Corporation,
Advances in Decision Sciences – vol.14, Issue 1,
June2010.
[17] Dr Y Vijay kumar and Dr. V.Venkata Ramana –
Application of SPC and Quality Tools for Process
Improvement – 27th
International Conference on Flexible
Automation and Intelligent Manufacturing – vol.8, Issue
10, June, 2006.
[18] Maria E. Prosvirina and Konstantin S. Yelenev – Quality
of Enterprise Management during Ramp-Up Preparation
and Launch: Concept and Evaluation Method – 3rd
International Conference on Ramp-Up Management –
Vol.5, Issue 8, June2006.
[19] Anzhen Chen and Lei Sun – A holistic Strategy for
Quality and Safety Control of Traditional Chinese
Medicines by The ivards Standards System – Journal of
Pharmaceutical Analysis – vol. 8, Issue 6, June2012.
[20] Joscha Schnell and Gunther Reinhart – Quality
Management for Battery Production: A Quality Gate
concept – 49th
CRIP Conference on Manufacturing
System – Vol.5, Issue 7, March2002.
List of books:
[21] Fundamentals of Quality Control & Improvement –
AmitavaMitra, 3rd
Edition
[22] Introduction of Quality Control – Douglas C Montgomery
[23] Statistical Quality Control Handbook – Western Electric
Company
[24] Lean Implementation Tools – Lonnie Wilson, Tata Mc
grow hill publication Company Ltd. Delhi
List of links:

[1] https://en.wikipedia.org/wiki/QCTools
[2] https://en.wikipedia.org/wiki/SigmaLevel
[3] https://en.wikipedia.org/wiki/PDCACycle