project yellow belt

1. Reduce Internal Rejection
PROJECT NO- 1
THEME
Project – Yellow belt
Responsibility – Anuj kumar
To Reduce Internal Moulding Rejection - YHB DR

2. PROJECT NO- 1
 Internal cost is very high.
 Productivity affected.
 Defective material may pass on to customer.
 More inspection required.
 More inventory required.

3. Project Team
SL.
NO.
NAME DEPARTMENT RESPONSIBILITY
1 Mr. Amrender sir Production Facilitator
2 Mr. Anuj kumar Production Leader
3 Mr. Abhishek Production Member
4 Mr. Lalit kumar Quality Member
5 Mr. Khagol Tool Room Member
6 Mr. Parveen Maintenance Member

4. Operation Wise Scoping Tree
Avg. 1.8%
HIGH INTERNAL REJECTION AREA
Extrusion
Lalru
Moulding
GGN
1.97
1.79 1.78
1.79
1.71
1.77
1.74
1.76
1.8
1.84 1.83
1.82
1.55
1.6
1.65
1.7
1.75
1.8
1.85
1.9
1.95
2
Rejection
%
Monthly Internal Rejection Trend Jul’17 - Jun’18

5. Part Wise Scoping Tree
3.58
2.94 2.88
2.57
0.00
1.00
2.00
3.00
4.00
YRA DR YAD DR YSD NB YP8 D/R
Rejection
%
YRA DR YP8 DR
YAD DR YSDNB DR
HIGH INTERNAL REJECTION AREA
Extrusion
Lalru
Moulding
GGN

6. Monthly Internal Rejection Trend : Jul17 – Jun18
3.85 4.2
3.6 3.01 3.09
3.82
3.72 3.97
3.3 3.63
3.65
3.11
0
1
2
3
4
5
Rejection
%
Baseline 3.58%
Entitlement 3.01%
YRA DR YP8 DR
YAD DR YSDNB DR
HIGH INTERNAL REJECTION AREA
Extrusion
Lalru
Moulding
GGN

7. YRA DR Defect wise Distribution
24
45
59
70
80
89
93 96 98 99 100 100
0
20
40
60
80
100
0
6664.8
13329.6
19994.4
26659.2
33324
Rejection
Qty.

8. Particulars Rejection (%)
Baseline 3.58
Entitlement 3.01
Difference 0.57
70% of Diff. 0.4
Target(Baseline -70% of Diff.) 3.18
Target (Entitlement) 3.01
Target more effective 1.8
8
Target Setting Calculation for YRA DR

9. Target Setting – YRA DR Internal Rejection
3.58
1.8
0
0.5
1
1.5
2
2.5
3
3.5
4
Rejection
%

10. Activity Plan
Sl.
Activity
June'18 July'18 Aug'18 Sep'18 Oct'18 Nov'18 Dec'18 Jan'19
No Week Week Week week week Week Week Week
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1
Data Collection
& Project
identification
P
A
2
Quality
Stratification
P
A
3
Brainstorming
and Root cause
analysis / Time
study & Activity
analysis
P
A
4
Kaizen for
process
improvement
P
A
5
System
Adherence
P
A
6
Result
monitoring /
Effectiveness
monitoring
P
A

11. Effectiveness monitoring
Kaizen Implementation
Defect Analysis & Root Cause Analysis
Identification Area
METHODOLOGY

12. Thank You