This document summarizes quality analysis data from the machine shop (HMC) of a leading manufacturing company. It includes process flow charts and data on turning, facing, milling and drilling operations with measurement charts and capability analysis. Key findings are that the current process efficiency is 55.24% and sigma level is 3.2, below the company's ISO standards. The document recommends upgrading machinery, implementing computer numerical control, hiring skilled workers, and following six sigma to improve quality and efficiency.

1. Quality analysis of Machine Shop
(HMC)
Presenting:
GROUP # 01
Abu Bakar Siddique ME123009
Shahid Hussain ME123019
Muhammad Ifraheem ME123022
Fahad Akhter ME123082

2. Introduction of HMC
• Leading enterprise in a country.
• Two main Production unit
• Mechanical works
• Foundry & Forge works
• Mechanical works starts 1971

3. Machine Shop
• Most Important Shop
• Contributes major part in income of industry
• Divided in three categories
• Small Bay
• Medium Bay
• Heavy Bay
• Batch Production

4. Turning
Drawing
Reading
Dimension
Correct
Facing
Dimension
CorrectMilling
Dimension
Correct
Drilling
Store
Dimension
Correct
If YES
If YES
• If NO
If YES
IfNO
If NO
If NO
If NO If NO
IfYES
Flow Chart

5. Turning Data
Turning 1 2 3 4 Avg Dia Range
1 420.2 419.6 419.8 420.1 419.925 0.6
2 419.9 420.3 420.1 419.9 420.05 0.4
3 420.8 420.2 420.5 420.3 420.45 0.6
4 420 419.9 419.8 420 419.925 0.2
5 420.4 420 420.3 420.1 420.2 0.4
6 419.5 420.2 419.9 420.1 419.925 0.7
7 420.4 419.8 420.2 419.9 420.075 0.6
8 420.2 419.9 420 420.1 420.05 0.3
9 420.3 419.9 420.2 419.9 420.075 0.4
10 420.2 419.6 420.1 419.7 419.9 0.6

6. Charts and Capability
Cp= 0.574 Cpk= 0.508,0.640
419
419.2
419.4
419.6
419.8
420
420.2
420.4
420.6
1 2 3 4 5 6 7 8 9 10
DIAMETER(MM)
X- Bar Chart
Avg. Diameter Mean UCL LCL
0
0.2
0.4
0.6
0.8
1
1.2
1 2 3 4 5 6 7 8 9 10
RANGE
R-Chart
Range R UCL(R) LCL(R)

7. Facing Data
Facing 1 2 3 4 Avg. Width Range
1 36.4 35.8 36.2 35.9 36.075 0.6
2 35.8 36.2 36 36.1 36.025 0.4
3 36.5 35.5 36.2 35.3 35.875 1.2
4 36.3 35.9 36.1 35.8 36.025 0.5
5 35.7 36.2 35.9 36 35.95 0.5
6 35 36.5 36.4 36.1 36 1.5
7 35.8 36.4 36.2 35.9 36.075 0.6
8 36.2 35.7 35.9 36.2 36 0.5
9 36.8 36.4 35.9 36 36.275 0.9
10 35.6 36.3 36.3 35.8 36 0.7

8. Charts and Capability
Cp= 1.66 Cpk= 1.566,1.76
34.8
35
35.2
35.4
35.6
35.8
36
36.2
36.4
36.6
36.8
1 2 3 4 5 6 7 8 9 10
WIDTH(MM)
X- Bar Chart
Avg, Width Mean UCL LCL
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
1 2 3 4 5 6 7 8 9 10
RANGE
R-Chart
Range R UCL(R) LCL(R)

9. Milling Data
Milling 1 2 3 4 Avg Depth Range
1 24.4 23.8 24.2 23.7 24.025 0.7
2 24.6 24.2 24.3 24.6 24.425 0.4
3 23.7 24.2 24.1 23.9 23.975 0.5
4 24.4 23.6 23.9 24.2 24.025 0.8
5 24.2 23.9 23.9 24.1 24.025 0.3
6 23.9 24.7 24.5 23.9 24.25 0.8
7 24.2 23.7 23.9 24 23.95 0.5
8 24.3 23.7 23.9 24.1 24 0.6
9 23.8 24.1 24 23.9 23.95 0.3
10 24.5 23.6 23.7 24.4 24.05 0.9

10. Charts and Capability
Cp= 1.15 Cpk= 1.00,1.313
23.2
23.4
23.6
23.8
24
24.2
24.4
24.6
1 2 3 4 5 6 7 8 9 10
DEPHT(MM)
X- Bar Chart
Avg. Depth Mean UCL LCL
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1 2 3 4 5 6 7 8 9 10
RANGE
R-Chart
Range R UCL(R) LCL(R)

11. Drilling Data
Drilling 1 2 3 4 Avg. Depth Range
1 15.8 16 15.9 15.8 15.875 0.2
2 16.4 16.5 16.1 16.2 16.3 0.4
3 15.9 16 16 16 15.975 0.1
4 16.5 16.2 16.3 16.4 16.35 0.3
5 15.8 15.9 16 15.9 15.9 0.2
6 15.8 15.9 15.9 15.9 15.875 0.1
7 16.1 15.8 15.9 16.1 15.975 0.3
8 16.3 16.1 16.2 16.1 16.175 0.2
9 16 16 15.9 15.9 15.95 0.1
10 16.4 16.1 16.3 16.4 16.3 0.3

12. Charts and Capability
Cp= 0.877 Cpk= 0.76,0.994
15
15.2
15.4
15.6
15.8
16
16.2
16.4
16.6
1 2 3 4 5 6 7 8 9 10
DIAMETER
X-Chart
Avg. Dia UCL LCL Mean
0
0.1
0.2
0.3
0.4
0.5
0.6
1 2 3 4 5 6 7 8 9 10
RANGE
R-Chart
Range UCL(R) LCL(R) R

13. Cause and effect diagram

14. Flow Process Chart
Processes Time ⃝ → □ D ∇
Drawing Reading 05 min √
Transfer to Turning machine 02 min √
Machine checking 02 min √
Turning 12 min √
Transfer to Grinding machine 02 min √
Tool Grinding 01 min √
Check dimensions 02 min √
Transfer to another machine for facing 03 min √
Facing 10 min √
Check dimensions 02 min √
Transfer to Grinding machine 01 min √
Tool Grinding 01 min √
Supervisor inspection 05 min √
Transfer to Milling 02 min √
Wait for completing job 14 min √
Milling 40 min √
Check dimensions 05 min √
Supervisor inspection 05 min √
Transfer to Drilling 02 min √
Drilling 10 min √
Check dimensions 02 min √
Transfer to QC Department 05 min √
Quality Inspection 07min √
Transfer to store 05 min √
Store ---- √

15. Calculations
Total Time= 143 min
Operation Time= 79 min, Transport Time=22 min, Inspection Time= 30 min,
Delay Time =14 min
Efficiency % =
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑡𝑖𝑚𝑒
𝑡𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒
=
79
143
× 100 = 55.24 %

16. Questionnaire
Questions SA A N D SD
Material quality of HMC products is good enough. 1 5 2 2 1
Dimensional accuracy is within specified limits. 2 4 3 1 1
HMC is able to ship out products in a given time period. 2 4 1 3 1
Are all design reviewed tested and verified? 1 3 5 2 0
HMC products are reliable. 3 5 3 0 0
HMC manufacture products are low cost as compared to other firms. 4 2 2 2 1
latest technology is being used in HMC. 0 3 4 4 0
HMC has a good benchmark for other relevant firms. 1 4 5 0 1
HMC is meeting all customer requirements. 3 5 3 0 0
Is HMC fulfilling ISO standards? 2 2 1 4 2
19 37 29 18 7

17. Importance Performance Matrix
IMPORTANCE
HIGH
HMC
LOW
LOW HIGH
PERFORMANCE
Total Value=
11x (1+2+3+4+5+6+7+8+9+10)x5=3025
Total obtained=2071
Our Target Value =3
On scale 5=
2071
3025
× 5 = 3.42

18. Cost per Month
Labor cost 104,000 Rs 36.62%
Electricity 150,000 Rs 89.70%
Maintenance 20,000 Rs 96.57%
Others 10,000 Rs 100.00%
Total 284,000 Rs
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
0
20000
40000
60000
80000
100000
120000
140000
160000
electricity labor cost maintenance others
Cost per Month

19. Cost of Quality
Years External
Cost
Internal
Cost
Preventio
n Cost
Appraisal
Cost
Total
Quality
Cost
1 4.5 2 1 0.55 8.05
2 4.5 2.5 1.2 0.55 8.75
3 4.25 3 1.2 0.54 8.99
4 3.75 3.5 1.3 0.53 9.08
5 2.75 3 1.6 0.52 7.87
6 2.5 2.7 1.5 0.51 7.21
7 2 2.5 1.25 0.5 6.25
Note: Each cost * 100,000 Rs
0
1
2
3
4
5
6
7
8
9
10
0 2 4 6 8
Cost
Years
Cost Of Quality
External Cost Internal Cost Prevention Cost
Apperasial Cost Total Quality Cost

20. Current Sigma Level
Number of units Nu 5,000
Number of opportunities No 04
Number of defects Nd 85
Number of defective units Ndu 53
𝐷𝑃𝑀𝑂 = 1,000,000 ×
85
5,000 × 4
= 4250
• 4250 defects per million opportunities.
• This corresponds to the 3.2 sigma level.

21. ISO Standard
• ISO 9001 certified
• Authorized to use 4 ASME stamps U, U2, S & PP for equipment
manufacturing

22. Conclusion
HMC management has to take some decisions.
• Buy new machinery
• Shift machines from manual to Computer Numerical Control
• Hire highly skilled people
• Follow Six sigma principles

23. Questions???