The document outlines the efforts of a quality circle team, 'Rebooters', at Zahi Tyres Unit-1 to improve various aspects of tyre manufacturing, focusing on problem identification and categorization. Major issues include low lux levels, inspection delays, and poor cleanliness standards, with a structured approach to problem-solving and collaboration across departments. The team's goal is to enhance productivity and customer satisfaction by addressing these issues through targeted actions and improvements.

1. Making Mobility Safer & Smarter. Everyday.
QUALITY CIRCLE TEAM - REBOOTERS
ZAHI TYRES UNIT-1
AN OUT SOURCING UNIT OF
CEATTYRE LTD

2. ZAHI INTRODUCTION
2
Calicut Plant - Actual View
Total land area : 7.5 acres
Product Line
• Last mile Tyres
• Farm front/Implement tires
Tyres/Day
Installed capacity
LM
FARM
6000 / Day
• Estimated 150/day
24yrs
254 15

3. WHY QUALITY CIRCLE IS IMPORTANT
 Development of leadership quality
 Product/Process/Productivity improvement
 Improvement in decision making
 Increases self confidence
 Positive attitude
 Problem solving/Preventing attitude
3

4. QUALITY CIRCLE & TEAM DETAILS
4
NAME OF TEAM REBOOTERS
DEPARTMENT INSPECTION
STARTED MONTH AUGUST 24
LEADER BINEESH N
COORDINATOR MAHENDRA KUMAR
FACILITATOR JITHIN TOMY
NO. OF MEETINGS
ATTENDANCE %
MEETING FREQUENCY WEEKLY
NO. OF PROBLEMS IDENTIFIED 24
MEETING DAY WEDNESDAY
MEETING TIME 4.00-4.30 PM
MEETING PLACE CFT ROOM

5. QUALITY CIRCLE & TEAM DETAILS
5
S. NO. TEAM MEMBER NAME DETAILS
1 BINEESH TEAM LEADER
2 RAM PUKAR TEAM MEMBER
3 AJAY TEAM MEMBER
4 DEEPAK TEAM MEMBER
5 MUKESH TEAM MEMBER

6. 12 STEPS OF QUALITY CIRCLE
1. Identification of Problem
2. Selection of problem
3.Definition of problem
4. Analysis of problem
5. Identification of causes
6. Finding out the root cause
7. Data analysis
8. Developing solution
9. Foreseeing probable resistance
10. Trial implementation & check performance
11. Regular implementation
12. Follow up & review
6

7. STEP 1- IDENTIFICATION OF PROBLEM
7
IDENTIFICATION
OF
PROBLEM
Step-1

8. STEP 1- IDENTIFICATION OF PROBLEM
8
SI NO. PROBLEM
1 Low Lux Level.
2 Tyre scrap due to inspection delay
3 Dust from outside area.
4 Cured tyre inspection lag.
5 Cured tyre dirty due to engraved plates like (HD Plate, Tubeless plate ,Serial Number , etc ).
6 Unavailability of proper PPE.
7 Roof leak in first line inspection area
8 No defect gallery in second line inspection area
9 No proper marking in rework area.

9. STEP 1- IDENTIFICATION OF PROBLEM
9
SI NO. PROBLEM
10 Defect wise segregation not available.
11 Mix up of repair tyres in inspection area.
12 No defect name marking on cured tyres.
13 Helpers are unaware of size names.
14 Trimming tyres are pending in inspection area.
15 Unavailability of inspection supporting equipment for large sized and high weight tyres.
16 Inspectors are not aware of technical name of defects.
17 Availability of tyre shifting trolley and trolley servicing.
18 Floors are damage for tyre shifting.

10. STEP 1- IDENTIFICATION OF PROBLEM
10
SI NO. PROBLEM
19 Communication gap between first line and second line inspectors.
20 Communication gap between inspector and repair persons.
21 FIFO not followed in first line inspection area.
22 Low storage space in first line inspection area.
23 Defect manual not available.
24 Experienced backup inspectors are not available.

11. STEP 2- SELECTION OF PROBLEM
11
SELECTION
OF
PROBLEM
Tools/Techniques used:
1.BRAINSTORMING
2.BAR CHART
Step-2

12. CLASSIFICATION OF PROBLEMS
12
Category DESCRIPTION
Category-A PROBLEMS WHICH REQUIRE MINIMUM INVOLVEMENT OF OTHER
DEPARTMENT IN SOLVING THEM.
Category-B
PROBLEMS WHICH REQUIRE INVOLVEMENT OF OTHER DEPARTMENTS IS A
NECESSITY IN SOLVING THEM.
Category-C
PROBLEMS WHICH REQUIRE MANAGEMENT SANCTION IN IMPLEMENTING
THE SOLUTION.

13. CLASSIFICATION OF PROBLEMS
13
SI NO. PROBLEM CATEGORY STATUS
1 Low Lux Level. B Done
2 Tyre scrap due to inspection delay A Done
3 Dust from outside area. A
4 Cured tyre inspection lag. B Done
5
Cured tyre dirty due to engraved plates changes like (HD Plate, Tubeless plate ,Serial
Number ,etc ). A
6 Unavailability of proper PPE. B
Done
7 Roof leak in first line inspection area. C Done
8
No defect gallery in second line inspection area
B Done
9 No proper marking in rework area. A

14. CLASSIFICATION OF PROBLEMS
14
SI NO. PROBLEM CATEGORY STATUS
10 Defect wise segregation not available. A Done
11 Mix up of repair tyres in inspection area. A Done
12 No defect name marking on cured tyres. A
13 Helpers are unaware of size names. A
14 Trimming tyres are pending in inspection area. B Done
15 Unavailability of inspection supporting equipment for large sized and high weight tyres. C Done
16 Inspectors are not aware of technical name of defects. A
17 Availability of tyre shifting trolley and trolley servicing B
18 Floors are damage for tyre shifting B Done

15. CLASSIFICATION OF PROBLEMS
15
SI NO. PROBLEM CATEGORY STATUS
19 Communication gap between first line and second line inspectors A Done
20 Communication gap between inspector and repair persons A Done
21 FIFO not followed in firstline inspection area A Done
22 Low storage space in first line inspection area C
23 Defect manual not available A Done
24 Experienced backup inspectors not available C Done

16. CLASSIFICATION OF PROBLEMS
16
CATEGORY TOTAL SOLVED PENDING
Category A 13 7 6
Category B 7 6 1
Category C 4 3 1
TOTAL SOLVED PENDING
0
2
4
6
8
10
12
14
13
7
6
7
6
1
4
3
1
CATEGORY WISE DATA
Category A Category B Category C
Category
Number
of
problemss

17. CLASSIFICATION OF PROBLEMS
17
PIE CHART : DISTRIBUTIONTHROUGH PIE CHART
We have
selected ( A )
categories
problem to
solve as it
has the high
percentage.
54.35
29.42
16.23
A B C

18. CLASSIFICATION OF PROBLEMS
18
WE SELECT “A’’- TYPE UNSOLVED PROBLEM.
AS “A”- TYPE HAVE MAJORITY OF UNSOLVED
6 PROBLEMS.

19. SELECTION OF PROBLEM
19
PROPRIETARY
PRIORITY
PREFERENCE
Based on our experience regarding company's policy & needs we have decided 03 proprietary's
as our work requirement & all “ A / B / C ” type problems located against' each proprietary
were the problem had adverse effect.
:- 1st
Stage nominal grouping in relevance to
companies Policy and needs
:- 2nd
Stage selection of one of above based
on ETC & Departmental needs/ perception
:- 3rd
Stage (Final selection of one problem
based on data collection & analysis )

20. Pending problems categorization on the basis of S,Q,C,P,D,M
20
SI NO.8 PROBLEM CATEGORY
5
Cured tyre dirty due to engraved plates changes like (HD Plate, Tubeless plate,
Serial Number).
Q,P,M,C
3 Dust from outside area. S,Q,M
9 No proper marking in rework area. Q,P
12 No defect name marking on cured tyres. P,Q
13 Helpers are unaware of size names. Q
16 Inspectors are not aware of technical name of defects. Q
8 No defect gallery in second line inspection area M

21. “A – CATEGORY” UNSOLVED PROBLEM CATEGORIZATION
21
S Q C P D M
0
1
2
3
4
5
6
1
6
1
3
0
3
Highest problems are found in Quality
No
of
Problems

22. SELECTION OF PROBLEM
22
Scale for Rating:- 1 - Not relevant, 2 - Minor, 3 - Significant, 4 - Major, 5 - Critical
Inference : Problem no 5 is our top priority problem selected as per our QC team Marking.
Si. No. Problem Category Bineesh
Ram
pukar
Ajay Deepak Mukesh Total
5
Cured tyre dirty due to engraved plates
changes like (HD Plate, Tubeless plate,
Serial Number , etc).
Q,P,M,C 4 3 4 2 3 16
3 Dust from outside area. S,Q,M 2 2 3 3 2 12
9 No proper marking in rework area. Q,P 3 2 3 2 2 12
16
Inspectors are not aware of technical
name of defects.
Q 3 3 3 2 2 13

23. SELECTION OF PROBLEM
23
Cured tyre dirty due to engraved
plates like (HD plate, Tubeless plate,
Serial Number ,etc).
PROBLEM NO. - 5

24. MILESTONE CHART
24
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN ACTUAL DELAY
COORDINATOR RETHEESH K K FACILITATOR JITHIN TOMY
MILESTONE CHART
NAME OF TEAM REBOOTERS DEPARTMENT INSPECTION
TEAM LEADER BINEESH N
TEAM MEMBERS BINEESH N, PAPPU, KAARU, MUKESH
Nov-23 Dec-23
1 IDENTIFICATION OF PROBLEM
2 SELECTION OF PROBLEM
SR. NO. ACTIVITY
Sep-23 Oct-23
3 DEFINITION OF PROBLEM
4 ANALYSIS OF PROBLEM
5 IDENTIFICATION OF CAUSES
6 FINDING OUT THE ROOT CAUSE
7 DATA ANALYSIS
8 DEVELOPING SOLUTION
9 FORESEEING PROBABLE RESISTANCE
10
TRIAL IMPLEMENTATION & CHECK
PERFORMANCE
11 REGULAR IMPLEMENTATION
12 FOLLOW UP & REVIEW

25. STEP 3- DEFINITION OF PROBLEM
25
DEFINITION
OF
PROBLEM
Step-3

26. STEP 3- DEFINITION OF PROBLEM
26
Definition - Cured tyre dirty due to engraved plates like
(HD Plate, Tubeless plate, Serial Number).
Pain Area :-
1. Cured tyre appearance not good.
2. Production loss due to re-sandblasting.
3. Double work for sand blasting and Engg team.
4. Effected to mould efficiency due to uneven sandblast.
5. Effected to Customer satisfaction on market.

27. STEP 3- DEFINITION OF PROBLEM
27
OBJECTIVES
Goal Setting
Team has decided to reduce the
dirty mould due to engraving
plates changes 8 to 0.
 GOOD AND CLEAN TYRE APPERANCE
 COST REDUCTION
 INCREASE THE PRODUCTIVITY
 CUSTOMER SATISFACTION
 IMPROVE THE MORALE OF EMPLOYEES
 EASY WORK FOR ENGG TEAM