The document outlines several issues contributing to flatness problems in cut-to-length sheets. It notes a lack of proper measurement systems, calibration of levelling equipment, training of employees, and communication between departments. Adopting new quality management systems and keeping maintenance, operating procedures, and customer requirements up to date could help address flatness issues. A new data collection system and training on material properties and levelling principles are also recommended.

1. Documentation Machine Material Personnel Customer : Product
Management : Policies
and Procedures
No measuring data available
of fine leveller measuring
scale.
Maintenance Leveller Unit Calibration
RM profile not uniform throughtout
width and Length
Culture " Dinosaur"
thinking
Knowledge Trainning
Customer requirment not as
per standard.
Poor Commuination between
department in the company.
Need new Data collection
system
Perventive Maintenaces Check
sheet not revised.
Coarses and Fine Leveller roll
wearout.
Fine Leveller not Calibrated
RM internal / residual stress not
removed during levellering
Fear in change in Process /
System
Lack of knowlegde about material
behaviour / structural
No training conducted for new
joinning employee.
No TDC/TPR available of
concerned Customer and
their End Application
Need Better SOP and
Measurement System.
No any Format avilable to
capture the Leveller Setting
Paraments
Monthly Planning Check Sheet
not Followered
Unviersal joint not assembled/
available to all leveller roll
Leveller up/down Measuring
Scale not Caliberated.
90% plastice require to obtain flatness
Lack of adopting the new
QMS System
Lack of knowledge about leveller
principal & Operating theory.
Senior resistant to required time to
train
Not submitted NPD/ PAG
report to Production and
Quality Dept.
Procedure is unclear.
Revision TPR / TDC
History of each part not
mentained
Poor Quality of Bearing
{Purchase Policy}
Culture does not encourage
Lean Thinking
Lack of knowledge about different
grade of material and their Proporties.
Distrust of New initiative No idea about End Appliation.
Policies and Procedures not
share with worker.
Changing any Parts of
Machine, Policy need to
Revised.
Unpredictable behaviour of fine
leveller unit
Lack of knowledge about Techanical
terms such as Residual Stress / Internal
Stress, Plasticity & Elasticity Phases,
Springback Effect.
Frequency of Trainning
Process Route of Customer
not known
Poor Co-operation among
department
Choose the Right Maintenance
Strategy
Assembly of Leveller Unit
Missalignment
Lack of knowledge about how to
remove the residual like 90% plastic of
material to break by leveller.
Misleading the Customer
when Purchase,
Performance measures
discourage co-operation
No Process Flowchart
designed.
AFFINITY DIAGRAM
Problem: Flatness Issues on Cut-To-Length
By Prasahnt Uttarkar