qcc-191018130705.pdf
- 1. ( Level –1 ) Trainer : Mr. A.S. Rajarajan Human Resource Division
- 2. QCC = Quality Control Circle Purpose of QCC activity : * To have an enjoyable work place. What is “ QCC ” ? * To ensure positive communication ( ie, Superior Me Sub-ordinate ) & thereby build “ Team work “
- 3. Definitions of frequently used terms : QC Circle Activity : * Activity conducted by a group of people in the same workplace. * Solving of problems by all circle members according to the QC basic principles & using QC tools Quality : * The condition after completion of work. Problem : * Gap between the “ Present situation “ and the “ Standard / Target / Ideal condition “. Kaizen : * Changing the present situation to a further better situation.
- 4. 3 QC Basic Principles 1. Rotate the PDCA CYCLE : * Appropriate rotation of the PDCA cycle will result in a good job. P - Plan D - Do C -Check A-Action PDCA cycle Judge and act Standardization ( Note : If 1 rotation of PDCA cycle is not enough, further rotation to be done ).
- 5. 3 QC Basic Principles ( Contd… ) : 2. JUDGE AND ACT based on the facts and data : * Check the facts with your 5 senses ( See - Eyes, Feel - Hands, Hear - Ears, Smell - Nose, Taste - Mouth ) = Genchi genbutsu . * Express the fact in words and numerals. 3. Perform STANDARDIZATION and ensure that everyone keeps up to the standard. * Standard : Method and rule for simplification, so that everyone can understands. * Standardizing action : Setting up and revising standard operation sheets etc.
- 6. Problem Solving Procedure Steps of QC circle Identify the problems. Grasp the current situation. Analyze the cause Carry out the Countermeasures Standardize If ‘OK’ If “ Not OK “ Set the target ( Make an activity plan ). Check the results.
- 7. Outline of QC Tools : Different QC Circle Tools : * Check sheet. * Graph. * Pareto diagram. * Cause and effect diagram ( Fish bone diagram ). * Histogram. * Control chart. * Scatter diagram. * Matrix diagram.
- 8. Problem : The following table gives us the list of ‘ Quality defects ‘ occurred in Press shop during Dec’ 03. Sketch a “ Pareto diagram “ for the same. Press shop : No. of Quality defects : Part name No. of quality defects Hood 07 Door 12 Roof 10 Bumper 05 Fender 03 Ex 1. : “ PARETO DIAGRAM “
- 9. Part name No. of Defect Door 12 Roof 10 Hood 07 Bumper 05 Fender 03 Ans : Step - 2 : Cumulative of no. of defect. Step - 1 : Arrange the list in descending order ( with reference to No. of defects ) Step - 3 : Cumulative in percentage of no. of defect. No. of Defect ( cumulative ) 12 22 29 34 37 Cumulative in %tage 32 59 78 92 100 " PARETO DIAGRAM " 0 2 4 6 8 10 12 14 Door Roof Hood Bumper Fender No. of defects 0 10 20 30 40 50 60 70 80 90 100 %tage If we eliminate these 3 problems, we can reduce about 78 % of defects STEP - 1 STEP - 2 STEP - 3
- 10. ( Fish bone diagram ) Ex 2. : “ CAUSE AND EFFECT DIAGRAM “ Problem : Dents occurring on Rr.Door panel. Sketch a “Fish bone diagram “ for the same. DENT on Rr. Door panel Material Man Method Machine Dust on jig surface Improper use of Hemming gun TM not following SOP Fatigue Not cleaning the jigs Not following standard methods Dust on Die surface Applying more force while working. Not related These are the main facts to cause this defects