Dishari(s) Taj Present

WELCOME QUALITY CIRCLE
GARDEN REACH SHIPBUILDERS & ENGINEERS LIMITED (MINISTRY OF DEFENCE) 43/46, GARDEN REACH ROAD, KOLKATA 700 024
INDIA
GRSE
DISHARI-S
OUR COMPANY
GARDEN REACH SHIPBUILDERS & ENGINEERS LTD
CENTURY OLD GLORIOUS SHIPBUILDING ORGANISATION IN EASTERN REGION OF INDIA

MINI RATNA PUBLIC SECTOR UNDERTAKING UNDER MINISTRY OF DEFENCE, GOVT OF INDIA HAVING 4050 EMPLOYEES PRODUCING PRODUCTS FOR THE NATION
SLIDE 2
GRSE
DISHARI-S
FRIGATE
CORVETTE
FAST PATROL VESSEL
HOVERCRAFT
SLIDE 3
GRSE
DISHARI-S
DECK MACHINERY EQUIPMENT
DIESEL MARINE ENGINE
NAVAL PUMP
PORTABLE BAILEY BRIDGE
SLIDE 4
GRSE
DISHARI-S BRIEF HISTORY OF THE QUALITY CIRCLE

: 209 : DISHARI-S/SQC4
NO OF QC TEAM IN GRSE NAME / QUALITY CIRCLE NO.
NAME OF CONTACT PERSON

QCFI INSTITUTE MEMBERSHIP NO NUMBER OF MEMBER IN THE CIRCLE NUMBER OF MEETINGS HELD SINCE FORMATION OF THE CIRCLE DAY/DURATION OF WEEKLY MEETING
: SHRI K S VERMA, GM(IE&P)

: 08 36 04 033 : 06 : 430 (FROM 14. 09. 2001 TO 07.07.11) : THURSDAY / ONE HOUR (3:30 PM TO 4:30 PM) : 88% : 14
AVERAGE ATTENDANCE IN THE MEETING IN THIS PERIOD

NUMBER OF PROBLEMS SOLVED & IMPLEMENTED THE SOLUTIONS IN IN THIS PERIOD
SLIDE 5
GRSE
DISHARI-S
ONLY
STRUCTURAL
FABRICATION
SHOP
AT
FOJ
ENGAGED IN FABRICATION OF : ALMOST ALL STRUCTURAL OUTFITTING WORK MS & ALUMINUM PANELS (DECK & BHD) , SEAT FABRICATION OF YARD MTC. WORK. MAST,
FOR VARIOUS EQUIPMENTS ETC. INCLUDING
SLIDE 6
GRSE
DISHARI-S
MEMBERS & OFFICE BEARER OF QC TEAM DISHARI S
Facilitator : Mr. A GAURAV Coordinator : Mr. S RUDRA Leader: Shri Shyamakanta Polley Deputy Leader: - Shri Aloke Kumar Ghosh Members: 1. Shri Hiralal Roy 2. Shri S Bachar 3. Shri S Chakraborty
DISHARI - S
SLIDE 7
GRSE
SL NO
1
ACHIEVEMENTS
AREA OF COMPETITION
INTERNAL, GRSE EXTERNAL (THE ANANDA BAZAR PATRIKA,TRADE FAIR ORGANISED BY SSI ASSOCIATION, GOVERNORS HOUSE CHAPTER CONVENTION ON QUALITY CIRCLES CCQC-KOLKATA. NATIONAL CONVENTION ON Q.C.(N.C.Q.C.) MADURAI, MUMBAI, KERALA, KANPUR , KOLKATA BENGALURU,& HYD. C I I COMPETITION INTERNATIONAL CONVENTION ON QC (ICQCC), BANGKOK ,HYDERABAD &Vizag
DISHARI-S
REMARKS
NUMBER OF PRESENTATION
08 (2001-2008)
RANKED FIRST POSITION IN THE YEAR 2005 APPRECIATED BY QCFI, THE ANANDA BAZAR PATRIKA & GOVERNOR OF W.B.
01 (2003)
06 (2003, 04, 05,06, 07 , 08,09 & 10) 08 (2003, 04, 05,06, 07, 08 , 09 ,10,&11) 2003&07 03 (2004 , 2010 & 2011)
RANKED- OUTSTANDING / EXCELLENT
RANKED- PAR EXCELLENCE /EXCELLENT
5 6
APPRECIATED RANKED- GOLD

SLIDE 8
GRSE
DISHARI-S PDCA CYCLE WITH TWELVE STEPS FOR PROBLEM SOLVING

We have followed Dr. JURANs 12 steps from problem identification to follow up action which is exhibited here by a PDCA cycle
12
11 10
Act Check
1 2
Plan Do
3 4 5 6
SLIDE 9
GRSE
STEP 1( A)
DISHARI-S
IDENTIFICATION OF PROBLEM
IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA
SLNO. 1 2 3 4 5 PROBLEM AREA REWORK PRODUCTION LOSS HOUSE KEEPING/SPACE DIS-SATISFACTION FACILITY NO. OF PROBLEMS 11 11 10 6 4
6
7 8 9 10
DELAY
ACCIDENTAL HAZARD / SAFETY HAZARD POLLUTION / HEALTH HAZARD UTILIZATION WASTAGE/DAMAGE TOTAL
3
14 5 5 6 75
SLIDE 10
GRSE
STEP 1( A)
DISHARI-S
IDENTIFICATION OF 10 MAJOR WORK RELATED PROBLEM AREA AND THE CORRESPONDING PROBLEMS ON THAT AREA (THROUGH BRAINSTORMING)
SL. NO. MAJOR PROBLEM AREA SL. NO.
1 2
WORK RELATED PROBLEMS IN THE AREA OF REWORK REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC.
PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.
EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. PRESS BENDING MACHINE. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL.
SLIDE 11
REWORK
4 5 6
GRSE
STEP 1(A)
DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO. 9 WORK RELATED PROBLEMS IN THE AREA OF REWORK
REWORK
EXCESSIVE DISTORTION DURING FABRICATION OF AL. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIPS SUPERSTRUCTURE
WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS
10
SL NO
MAJOR PROBLEM AREA
SL. NO.
1
2 3
PRODUCTION LOSS
PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS.
SLIDE 12
GRSE
DISHARI-S
74 PROBLEMS IN 10- MAJOR WORK RELATED PROBLEM AREA OF A,B, C & A/K CATEGORIES (THROUGH BRAINSTORMING)
SL 1 2 PROBLEMS CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING. INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR, ESPECIALLY WHERE PRECISION WORK TAKE PLACE. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. A.M.C. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH, OXYGEN AND D.A. REGULATORS. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES, DRILLS, TAPS ETC. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. PROBLEM AREA ACCIDENTAL HAZARD / SAFETY DISSATISFACTION RATINGS A B
3 4
PRODUCTION LOSS RE WORK
A C
DELAY
6 7 8
PRODUCTION LOSS UTILIZATION DELAY
A C A
SLIDE 13
GRSE
DISHARI-S
SL
67
PROBLEMS
EXCESSIVE DISTORTION DURING FABRICATION OF AL. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION. GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER. INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION. IN SITU PREPARATION OF C-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIPS SUPERSTRUCTURE. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
PROBLEM AREA
REWORK
RATINGS
A
68 69
DISSATISFACTION ACCIDENTAL HAZARD
B B
70
ACCIDENTAL HAZARD
71 72 73
FACILITY DELAY REWORK
B A A
74
PRODUCTION LOSS
SLIDE 14
GRSE
DISHARI-S
IDENTIFICATION OF PROBLEM OUT OF 75 PROBLEMS WE HAVE ALREADY SOLVED 13 A CATEGORY PROBLEMS
(EXCLUDING CURRENT PROBLEM) & 08 NOS

PROBLEM RELATED TO KAIZEN AND WE ARE ENJOYING THE BENEFITS AFTER IMPLEMENTATION OF THE SOLVED PROBLEMS
SLIDE 15
GRSE
DISHARI-S
SOLVED PROBLEM
(13- A CATEGORY PROBLEMS)
PROBLEM SL. NO. PROBLEMS RATINGS
5. 9. 21. 26. 33. 39. 50. 53.
A.M.C. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH, OXYGEN AND D.A. REGULATORS IMPROPER UTILIZATION OF CUT PIECE MATERIAL ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED. KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME. PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG. WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. GASKET CUTTING FOR PLUMBING WORK. PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH DURING TIG WELDING. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS.
A A A A A A A A
SLIDE 16
GRSE
DISHARI-S
SOLVED PROBLEM
(13- A CATEGORY PROBLEMS)
PROBLEM SL. NO. PROBLEMS RATINGS
58.
REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. PRESS BENDING MACHINE. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING REWORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL. EXCESSIVE DISTORTION DURING FABRICATION OF AL. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. IN-SITU PREPARATION OF C-CLAMPS CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIPS SUPERSTRUCTURE.
61.
67.
72 73
A A
SLIDE 17
GRSE
DISHARI-S
SOLVED PROBLEM
(08- A/K KAIZEN RELATED PROBLEMS)
PROBLEM SL. NO. PROBLEMS RATINGS A/K
10.
MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC.
14.
20. 24. 34. 42. 47.
BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPEING OF DAMAGE CABLE.

DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE. PERSONAL/ OUTSIDERS. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION IMPROPER. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM. HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING ITS OPERATION CAUSES SAFETY HAZARDS.
A/K
A/K A/K A/K A/K A/K
52.
A/K
SLIDE 18
GRSE
DISHARI-S
SOME OF THE IMPORTANT SOLVED PROBLEM

1. PROBLEM 2. PROBLEM 3. PROBLEM
EXCESSIVE MANPOWER CONSUMPTION AND WASTAGE OF MATERIAL FOR GASKET CUTTING
FREQUENT DAMAGE OF TIG TORCH DURING WELDING
PRODUCTION LOSS AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GAUGING WORK
SOLUTION
CUTTING GASKET WITH THE HELP OF DIE & PUNCH USING BALL PRESS MACHINE
SOLUTION
INDEPENDENT SUPPLY OF WATER FROM A SEPARATE OVER HEAD TANK THROUGH MANIFOLD FOR SIMULTANEOUS SUPPLY OF WATER TO SIX TIG TORCHES.
SOLUTION
INTRODUCTION OF SEMIAUTOMATIC GRINDING FIXTURE FOR EDGE PREPARATION
SLIDE 19
GRSE
STEP 2(A)
DISHARI-S
SELECTION OF PROBLEM
STRATIFICATION OF 52 PROBLEM IN A,B,C, CATEGORY 20 17 16
20
15 10
TOTAL NO. OF PROBLEM = 53
5
0 A B C
20 17
A : Problem can be solved by Q.C. Members with minimum involvement of other department. B : Problem can be solved with the help of other Dept.
C : Problem can be solved with the help of management. 16 A/K : Problem can be solved through Kaizen (08 - ALREADY SOLVED) SLIDE 20
GRSE
DISHARI-S
FROM THE BAR DIAGRAM IT IS SEEN THAT CATEGORY A CONTAINS 20 PROBLEMS WHICH IS MAXIMUM AND THE SAME CAN BE SOLVED BY OUR SELVES. FOR SHORT LISTING OF 20 A CATEGORY PROBLEMS WE HAVE DECIDED TO TAKE THE HELP OF E.C.T. OPTION CHART.
SLIDE 21
GRSE
STEP 2(B)
DISHARI-S
SELECTION OF THE PROBLEM

E.C.T. OPTION CHART
SL
1 3 6 8 11 23 27
LIST OF A CATEGORY PROBLEM

CHANCES OF ACCIDENTAL HAZARD FROM DAMAGE WELDING CABLE DURING WELDING. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL REWORK &FAILURE OF WELDING JOINTS FROM IMPROPER PLATE PREPARATION BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON.
E
4 5 5 4 3 2 4
C
4 5 4 4 2 2 5
T TOTAL
4 5 5 4 3 2 5 12 15 14 12 8 6 14
RANK
4 1 2 4 8 10 2
29 30
35 36 38 40
FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR .
EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES MAN POWER LOSS. DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING.
4 5
4 4 5 2
3 5
3 3 4 3
3 4
4 2 4 2
10 14
11 9 13 7
6 2
5 7 3 9
SLIDE 22
GRSE
SELECTION OF THE PROBLEMS

E.C.T. OPTION CHART
LIST OF A CATEGORY PROBLEM E PROBLEM FOR 3 2 4 C 3 2 3
DISHARI-S
SL 43 57 60
T 2 2 3
TOTAL 8 6 10
RANK 8 10 6
IMPROPER STORING ARRANGEMENT IDENTIFICATION OF REUSABLE MATERIAL.
CAUSES
UN UTILIZATION OF BROKEN \OVER USED DRILL BITS & TAPS. PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF T . I. G. /M . I. .G . & PLASMA WELDING MACHINE OF DIFFERENT MAKE. NON AVAILABILITY OF ALARM BELL IN E. O. T. CRANE MAY CAUSES ACCIDENTAL HAZARD. PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS. UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
62 63 64 74
2 3 3 5
3 3 2 5
3 3 2 5
8 9 7 15
8 7 9 1
E : Effectiveness in improving Man-hours or Quality of work C : Cost Effectiveness T : Cut Down Time
RATING SCALE FOR E.C.T. ANALYSIS

1
Does not meet criteria
2
Meet criteria fairly well
3
Meet criteria well
4
Meet criteria very well
5
Meet criteria extremely well SLIDE 23
GRSE
DISHARI-S
QC MEMBERS SHORT LISTED SIX PROBLEMS FROM 20 A CATEGORY PROBLEMS ON THE BASIS OF TOP RANKING OF PROBLEM BY E.C.T. ANALYSIS RANK 1 2 3 4 A-CATEGORY PROBLEM ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM (SL NO 74) PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. (SL NO 3) PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE.(SL NO 6) ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR . (SL NO 30) EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON.(SL NO 27).
HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE.(SL NO 38)
SLIDE 24
GRSE
STEP 2(C) SELECTION OF PROBLEM CHECK SHEET
DISHARI-S
DATA WERE COLLECTED FROM SHOP / SITE FOR 4 WEEKS TO OBSERVE THE NUMBER OF OCCURRENCE OF 6 PROBLEMS.
SHOP STRUCTURAL SHOP (FOJ ) Data collected By :- Sri S.K.POLLEY, Sri A.GHOSH, Sri H.ROY
SL NO PROBLEM
Shop In-charge
REMARKS
DATA COLLECTION FOR THE PERIOD OF 26.11.10 TO 30.12.10

1ST WK 2ND WK 4 3RD WK 4 4TH WK 4 TOTAL FOR THE MONTH 15
1
2
PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE.

EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR. HOUSE KEEPING PROBLEM OF HANDLING TIG/MIG WELDING ACCESSORIES IN DISTANT PLACE. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE.
FROM SHOP & SITE

FROM SHOP
6 FROM SHOP FROM SHOP & SITE FROM SHOP FROM SHOP
3 4
22
5 6
1 3
2 4
1 5
1 4
5 16
SLIDE 25
GRSE
STEP 2(D)
DISHARI-S
( BY PARETO ANALYSIS )
PARETO ANALYSIS WERE DONE BASED ON AVAILABLE DATA ON THE CHECK SHEET
SL NO
A
PROBLEM
FREQUENCY
INDVL CUMM 22
PERCENTAGE
INDVL 31 CUMM. 31
ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE.
22
B C D
16 15 8
38 53 61
22 21 11
53 74 85
67
93
72
100 SLIDE 26
GRSE
SELECTION OF PROBLEM PARETO DIAGRAM

( DRAWN ON THE BASIS OF PARETO ANALYSIS)
CUMULATIVE % LINE
DISHARI-S
VITAL FEW
60
93
100
100
80
85 74
USEFUL MANY
60
40 31
53
BREAK POINT
40
20 20 0 0
C D PROBLEM
IT IS OBSERVED FROM THE PARETO DIAGRAM THAT PROBLEM A,B & C ARE THE VITAL FEW PROBLEMS, OUT OF WHICH PROBLEM A IS MOST IMPORTANT THAN OTHERS
SLIDE 27
PERCENTAGE
FREQUENCY
GRSE
DISHARI-S
ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
SLIDE 28
GRSE

MILESTONE CHART
DISHARI-S
MILESTONE CHART IS PREPARED OF 20 WEEKS TO COMPLETE THE PROJECT MILESTONE CHART IS HANDED OVER TO OUR CO-ORDINATOR FOR REGISTRATION OF THE PROJECT
QC MEMBERS: S. K. POLLEY, H. ROY, A. K. GHOSH, S. CHAKRABORTY, S BACHAR
QC TEAM : DISHARI ( S ) / STRUC. SHOP (FOJ ) STARTING DATE --- 06.01.11 PROJECT : ALUMINIUM ANGLES AS STRONG BACK COMPLETION DATE 25.05.11 OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM QC STEP ACTIVITIES 1 PLAN 3 4 5 DO 6 7 8 DEFINING THE PROBLEM ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES DATA ANALYSIS DEVELOPMENT OF SOLUTION 2 3 4 5 6 7
TIME SCHEDULE IN WEEKS 8 9 10 11 12 13 14 15 16 17 18 19 20
9
CHECK 10
FORESEEING PROBABLE RESISTANCE

TRIAL IMPLEMENTATION
11 REGULAR IMPLEMENTATION ACT 12 FOLLOW-UP ACTION & REVIEW
SLIDE 29
GRSE
STEP 3(A)
DISHARI-S
DEFINING THE PROBLEM

FABRICATION & ERECTION OF AL WHEEL HOUSE IS DONE BY AL PANEL AT SITE & BRIDGE DECK OF SHIPS. SINCE ALUMINIUM ARE LIGHT IN WEIGHT AND PLATE THICKNESS IS 4MM, THERE IS A TENDENCY OF DISTORTION DURING LIFTING, TRANSPORTATION & ERECTION. TO AVOID THIS DISTORTION 4-SIDES OF ALUMINIUM PANELS ARE TEMPORARILY STRONG BACKED BY AL. ANGLES. IT IS OBSERVED THAT THE AL. STRONG BACKS GETS EITHER DISTORTED OR DEFORMED AFTER REMOVAL CAUSING WASTAGE OF MATERIAL AS WELL AS TIME.
THE SEQUENCE OF OPERATION ERECTION OF AL. WHEEL HOUSE AT SITE AND BRIDGE DECK OF SHIP BY CONVENTIONAL METHOD ARE EXHIBITED HERE WITH THE HELP OF A FLOW DIAGRAM.
SLIDE 30
GRSE
DISHARI-S
FINALLY WHEEL HOUSE ERECTED ON BRIDGE DECK OF SHIP

SLIDE 31
GRSE
DISHARI-S

ERECTION OF ALUMINIUM WHEEL HOUSE BLOCK
ERECTION OF ALUMINIUM PANELS / PARTITION WALL OF WHEEL HOUSE BLOCK AT SHIPSITE
SLIDE 32
GRSE
DEFINING THE PROBLEM BY FLOW DIAGRAM
START
MARKING, CUTTING, DEBARRING, BUFFING OF. AL. ANGLES
DISHARI-S
TACKING/FITTING OF AL. ANGLES ON 4-SIDES OF FABRICATED PANELS FOR STRONG BACKING
LIFT AND TRANSPORT PANELS BY MOBILE CRANE AND PLACED VERTICALLY ON DECK HEAD AT SITE . ALIGN. THE PANELS ON DECK HEAD, THEN FITTING/RUNNING WELDING TO COMPLETE ERECTION REMOVE STRONG BACK S AFTER COMPLETION OF ERECTION OF WHEEL HOUSE ON BRIDGE DECK.
NOT OK
DEFORMED ANGLES
CHECK THE DEFORMATION / DISTORTION OF ANGLE
OK
MARKED THE DISTORTED ZONE
GRINDING & STRAIGHTENING THE AL. ANGLES BY FAIRING.
NOT OK
REJECTED FOR SCRAP
CHECK THE STRAIGHTNESS
OK
REUSE AS STRONG BACK
FINISH
SLIDE 33
GRSE
DISHARI-S
MARKING, CUTTING, DEBARRING,) BUFFING OF. 75 X 50 X 6 MM AL. ANGLES AS PER REQUIRED LENGTH.
TACKING/FITTING OF AL. ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS .
SLIDE 34
GRSE
DISHARI-S

ALIGN THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD, THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK.
LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE.
SLIDE 35
GRSE
DISHARI-S
REMOVE ALL THE STRONG BACK (AL ANGLE) BY DISMANTLING FROM ERECTED PANELS , OTHER THAN OPEN SIDE OF PANELS OF WHEEL HOUSE BLOCK.
LIFT AND TRANSPORT THE WHEEL HOUSE BLOCK BY CRANE & POSITIONED & COMPLETE ERECTION OF WHEEL HOUSE BY ALIGN/TACKING/FITTING & RUNNING WELDING OF PANELS ON CORRECT POSITION OF SHIPS BRIDGE DECK.
SLIDE 36
GRSE

SEGREGATE THE DEFORMED ANGLE
DISHARI-S
STRAIGHTENING THE AL. ANGLES BY FAIRING.
SLIDE 37
GRSE GRSE
DISHARI-S DEFINING THE PROBLEM BY FLOW DIAGRAM DISHARI-S

START
MARKING, CUTTING, DEBARRING, BUFFING OF. 75 X 50 X 6 MM AL. ANGLES AS PER REQUIRED LENGTH. TACKING/FITTING OF AL. ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS . LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE . ALIGN. THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD, THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK. REMOVE ALL THE STRONG BACK (AL ANGLE) AFTER COMPLETION OF FABRICATION OF WHEEL HOUSE BLOCK AND ERECTION OF WHEEL HOUSE ON BRIDGE DECK.
NOT OK
DEFORMED ANGLES
CHECK THE DEFORMATION / DISTORTION OF ANGLE
OK
MARKED THE DISTORTED ZONE
GRINDING/FILING/DRESSING & STRAIGHTENING THE AL. ANGLES BY FAIRING.
NOT OK
REJECTED FOR SCRAP
CHECK THE STRAIGHTNESS
OK
REUSE AS STRONG BACK
FINISH
SLIDE 38
GRSE
STEP 3(B)
DISHARI-S
CURRENT SITUATION AND IMPACT OF THE PROBLEM

CURRENT SITUATION THE PREVAILING PRACTICE OF STRONG BACKING AL PANELS DURING ERECTION & FABRICATION OF WHEEL HOUSE INVOLVES LOSE OF PRODUCTION AS WELL AS WASTAGE OF COSTLY MATERIAL THE IMPACT OF THE PROBLEM ARE : ADDITIONAL TIME (INEFFECTIVE TIME) IS ADDED TO PRODUCTION TIME TO REMOVE THE WELDING BURRS OF AL. ANGLES BY GRINDING /DRESSING/ AND STRAIGHTENING THE AL ANGLES BY FAIRING TO REMOVE THE DISTORTION. WASTAGE OF ABOUT 50% COSTLY ALUMINIUM ANGLE DUE TO DEFORMATION AND / OR DISTORTION AFTER ITS REMOVAL.
DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB DUE TO INVOLVEMENT OF ADDITIONAL WORK.
SLIDE 39
GRSE
STEP 3(C)
DISHARI-S
1) TO INCREASE PRODUCTION / PRODUCTIVITY 2) TO REDUCE WASTAGE OF MATERIAL 3) TO IMPROVE QUALITY & WORK 4) TO MAINTAIN THE DELIVERY SCHEDULE 5) OPTIMUM UTILIZATION OF AVAILABLE RESOURCES (MAN, MATERIAL, METHOD, MONEY) 6) TO REDUCE INEFFECTIVE TIME
SLIDE 40
GRSE
STEP 3(D)
DISHARI-S
TARGET SETTING
SAMPLE DATA FOR STRONG BACKING OF 5.25M X 2.4 M PANEL BY AL ANGLE OF YARD NO 2064
DATA TABLE FOR TARGET SETTING

DESCRIPTION OF WORK MAN HOUR CONSUMED /PANEL
EFFECTIVE TIME STRONG BACKING OF AL PANEL (5.25M X 2.4 M) BY AL ANGLE 9.0 IN EFFECTIVE TIME 9.0 50%
AV. % REJECTION OF AL. ANGLES
SLIDE 41
GRSE
STEP 3(D)
DISHARI-S
TARGET SETTING
IN ORDER TO REDUCE THE INEFFECTIVE TIME FOR REMOVING WELDING BURRS BY GRINDING & FOR REMOVING THE DISTORTION OF AL. ANGLES BY FAIRING WORK AS WELL AS TO REDUCE WASTAGE OF COSTLY ALUMINIUM ANGLES. WE SET THE FOLLOWING TARGETS:-
1.
TO REDUCE THE INEFFECTIVE TIME FROM 50% TO 5% BY WORK SIMPLIFICATION WITHIN 17WEEKS.
50%
5%
2.
TO REDUCE THE WASTAGE OF COSTLY MATERIAL FROM 50% TO 10% LEVEL WITHIN 17 WEEKS.
50%
10%
SLIDE 42
GRSE
STEP 4(A)
DISHARI-S
ANALYSIS OF THE PROBLEM

WE HAVE TAKEN THE HELP OF 4-W & 1-H TECHNIQUE FOR ANALYSING OUR PROBLEM. 4-W & 1-H TECHNIQUE WHAT?
DURING AND AFTER ERECTION OF PANELS OF WHEEL HOUSE AT SITE AND BRIDGE DECK OF SHIP. AFTER REMOVING THE STRONG BACK FROM AL. PANELS AND MAKE READY FOR RE-USE. PREVAILING PRACTICE OF STRONG BACKING THE AL. PANELS DURING ITS FABRICATION & ERECTION WITH WHEEL HOUSE. A. INVOLVEMENT OF ADDITIONAL TIME( INEFFECTIVE TIME) DURING REMOVAL OF DISTORTION OF AL. ANGLES BY FAIRING. B. WASTAGE OF COSTLY ALUMINIUM ANGLES WHICH ARE TEMPORARILY USED FOR STRONG BACKING THE PANELS.
WHERE?
WHEN? WHO? HOW?
SLIDE 43
GRSE
STEP 4(B)
DISHARI-S

DATA WERE COLLECTED FROM DETAILED DRAWING OF WHEEL HOUSE FOR IPV CLASS OF SHIPS. THE AVAILABLE DATA REVEALS THAT EACH WHEEL HOUSE COMPRISES OF 12 NO. OF VARIOUS SIZES AL. PANELS TO BUILT BULK HEADS AND PARTITION WALLS AS SHOWN BELOW:SL. NO. 1 2 3 4 5 6 7 8 9 10 DESCRIPTION OF ITEMS SIDE BHD.(S&P) SIDE BHD.(S) SIDE BHD.(P) FORD. BHD. AFT. BHS. PARTITION BHD. PARTITION BHD. PARTITION BHD. PARTITION BHD. PARTITION BHD. SIZE IN mm 8300 X 2400 5250 X 2400 3800 X2400 5006 X 2600 2500 X 2400 1400 X 2400 2500 X 2400 1450 X 2400 940 X 2400 1560 X 2400 QUANTITY 2 1 1 1 1 2 1 1 1 1
SLIDE 44
GRSE
STEP 4(C)
DISHARI-S

SHIP WISE PAST PRODUCTION DATA WERE COLLECTED FOR TOTAL LENGTH OF AL. ANGLES OF VARIOUS SIZES ARE REQUIRED VIS--VIS REJECTED AS WELL AS TIME CONSUMED FOR REMOVING THE WELD METALS & FAIRING THE ANGLES FOR STRAIGHTENING ARE SHOWN IN THE DATA TABLE. WITH THE HELP OF AVAILABLE DATA A RUN CHART & A LINE & BAR DIAGRAM WERE PREPARED.
DATA TABLE
TOTAL LENGTH IN METER OF AL. ANGLES (75 X 50 X 6mm) SHIP/ CONST.NO. DESCRIPTION OF WORK REQUIRED FOR STRONG BACKING 138 137 126 125 REJECTED AFTER REMOVING 70 66 63 65 MAN-DAYS SPENT(IN EFFECTIVE TIME) FOR REMOVING WELDING BURRS & STRAIGHTENING THE ANGLE 16 15 15 14
SLIDE 45
WJ FAC/2063 WJ FAC/2064 IPV/2075 APV/2076
STRONG BACKING OF AL. PANELS FOR TRANSPORTATIO N & ERECTION OF WHEEL HOUSE.
GRSE
DISHARI-S

200 180
RUN CHART
138 137 126 126
160 140 120 100 80 60 40 20 0
INEFFECTIVE TIME(MANDAYS)
LENGTH IN Mtr.
20 18 16 14 12 10 2064 2065 2073 2074 16 15 15 14
70
66
63
65
2064
2065
2073
2074
REQUIRED FOR STRONG BACKING REJECTED AFTER REMOVING
SHIP NO.
AVERAGE INEFFECTIVE TIME = 15 MANDAYS
ON AND AVERAGE WASTAGE OF ALUMINIUM ANGLE/SHIP = 66 Mtr.
OBSERVATION :
WASTAGE OF AL. ANGLES PER SHIP = 50% AVERAGE INEFFECTIVE TIME = 15 MAN DAYS
SO WE HAVE TO FIND OUT THE REASONS BEHIND THE PROBLEM

SLIDE 46
GRSE
DISHARI-S
STEP 5
PROBABLE CAUSES OF PROBLEM

TO DRAW CAUSE & EFFECT DIAGRAM & TO FIND
OUT ALL THE POSSIBLE CAUSES INFLUENCING
THE EFFECT, QC MEMBERS CARRIED OUT

BRAINSTORMING WITHOUT ANY RESTRICTION. FREE FLOWING OF VARIOUS VIEWS FROM QC MEMBERS ENABLED US TO GET A LARGE NUMBER OF IDEAS.
SLIDE 47
GRSE
STEP 5(A) PROBABLE CAUSES OF THE PROBLEM
DISHARI-S
AFTER ELIMINATING SUPERFLUOUS AND IRRELEVANT CAUSES BASED ON DISCUSSION, WE ORGANIZED THE REMAINING VARIOUS PROBABLE CAUSES INTO MAIN CAUSE, SUB CAUSE & SUB-SUB CAUSES ETC. BY STRATIFICATION. FINALLY ISHIKAWA DIAGRAM WAS DRAWN (CAUSE ENUMERATION TYPE).
ELIMINATED SUPERFLUOUS AND IRRELEVANT CAUSES
1) Tedious & primitive method of fabrication of Al. panel 2) Non-availability of scrap material in the yard. 3) Non availability of dead weight during fabrication of panel 4) Work is performed by Trainees.
HEADER / MAIN CAUSE

OPERATOR
SUB- CAUSE / SUB-SUB-CAUSE

1. Improper attention. 2. Non-adherence to the recommended practice . 3. Lack of knowledge about the fairing work. 4. Lack of Skill
ERECTION PROCEDURE.
1. distortion during positioning/alignment by pulling the panels by bottle screw 2.

Generation of heat during tacking & running welding of Panels during Erection leads to distortion
TRANSPORTATION OF AL. PANELS TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK MATERIAL (USED FOR STRONG BACK)
1. Distortion due to self weight during lifting by crane. 2. Improper lifting & handling of panels. 3. Non availability of crane for handling. 1. Improper Dismantling of Strong Back (Al. Angles) leads to high Distortion. 2. Improper protection against excessive distortion during tacking/fitting. 3.Ignorance of proper sequence of tacking/fitting. 4. Incorrect tacking/fitting 1. Use of softer & costly Material. 2. Additional time is spent to remove distortion & Weld metal from Strong Back after removal. 3. High Distortion/ Deformation of Al. Angles leads to Rejection 4. Excessive softness of material . 5. Inherent material defect. 6. Material not at per specification. 7. Non use of any alternative Harder & chipper Material SLIDE 48
GRSE
ISHIKAWA DIAGRAM
(CAUSE ENUMERATION TYPE)
STEP 5(B)
OPERATOR
DISHARI-S
Mapping out all the probable Sub &Sub-Sub causes under each Headers (Main Causes) and Relate the Logical Linkage.
ERECTION PROCEDURE distortion during positioning/alignment by pulling the panels by bottle screw . Lack of Skill Non-adherence to the recommended practice Lack of knowledge about the fairing work TRANSPORTATION OF AL. PANELS Distortion due to self weight during lifting by crane Non availability of crane for handling Generation of heat during tacking & running welding of Panels during Erection leads to distortion Improper lifting & handling of panels
Improper attention
EFFECT EFFECT EFFECT

Improper protection against excessive distortion during tacking/fitting Additional time is spent to remove distortion & Weld metal from Strong Back after removal High Distortion/Deformation of Al. Angles leads to Rejection
EFFECT EFFECT
Use of softer & costly Material
Improper Dismantling of Strong Back(Al. Angles) leads to high Distortion Ignorance of proper sequence of tacking/fitting
Inherent material defect
Material not at per specification Non use of any alternative Harder & chipper Material.
Incorrect tacking/fitting
TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK
MATERIAL (USED FOR STRONG BACK)
SLIDE 49
GRSE
STEP 5(C)
OPERATOR Improper attention Non-adherence to the recommended practice
ISHIKAWA DIAGRAM
(CAUSE ENUMERATION TYPE)
ERECTION PROCEDURE Generation of heat during tacking & running welding of Panels during Erection leads to distortion Lack of Skill
DISHARI-S
Finally we drew the ISHIKAWA DIAGRAM
TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK distortion during positioning/alignment by pulling the panels by bottle screw
Ignorance of proper sequence of tacking/fitting Incorrect tacking/fitting
Lack of knowledge about the fairing work
Improper Dismantling of Strong Back (Al. Angles) leads to high Distortion
Improper protection against excessive distortion during tacking/fitting
Improper lifting & handling of panels
Distortion due to self weight during lifting by crane
Non availability of crane for handling High Distortion/Deformation of Al. Angles leads to Rejection
Use of softer & costly Material not at per Material specification Additional time is spent to remove distortion & Weld Non use of any metal from Strong Back after alternative Harder removal & chipper Material. Inherent material defect
TRANSPORTATION OF AL. PANELS
MATERIAL USED FOR STRONG BACK
SLIDE 50
GRSE
STEP 6
DISHARI-S
FINDING OUT THE ROOT CAUSE OF THE PROBLEM

BY WHY WHY ANALYSIS
BY FURTHER BRAINSTORMING WE HAVE DECIDED TO MAKE AN EXTENSIVE INVESTIGATION FOR SEVEN DAYS TO FIND OUT THE ROOT CAUSE OF THE PROBLEM, WE ANALYZE THE AVAILABLE INFORMATION AND WITH THE HELP OF WHY- WHY ANALYSIS WE FIND OUT THE ROOT CAUSE OF THE PROBLEM BY VALIDATING THE PROBABLE CAUSES SEQUENTIALLY:
SLIDE 51
GRSE
STEP 6 ( A )
BY WHY -WHY ANALYSIS
DISHARI-S
FINDING OUT THE ROOT CAUSE OF THE PROBLEM.

PROBLEM
REASON /SUB CAUSE
IS IT DUE TO OPERATOR ?
WHY?
THE OPERATOR IS COMPETENT ENOUGH TO WORK WITH THE EXISTING METHOD. THERE IS NO SUCH PROBLEM DURING ERECTION OF PANELS.
IS IT DUE TO ERECTION PROCEDURE ?
WHY?
IS IT DURING TRANSPORTATION OF AL. PANELS ? IS IT DUE TO TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK ?
Y
Y
N
N
WHY?
THE PANELS ARE CAREFULLY HANDLED DURING ITS TRANSPORTATION & ERECTION TO AVOID ANY DISTORTION.
THERE IS NO SUCH PROBLEM DURING TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK. USE OF SOFT , HIGHLY MALLEABLE & LIGHTER IN WEIGHT AL. ANGLES AS STRONG BACK IS THE MAIN REASON BEHIND THE PROBLEM (DISTORTION/ DEFORMATION)
WHY?
IS IT DUE TO MATERIAL( USED FOR STRONG BACK) ?
WHY?
SLIDE 52
GRSE
STEP 6 ( B )
BY WHY -WHY ANALYSIS
DISHARI-S

VALIDATION THE PROBABLE CAUSES SEQUENTIALLY
IS IT DUE TO OPERATOR ? Y N WHY?
OPERATOR
EFFECT SUB-CAUSES
LACK OF SKILL.
VALIDATION
REASON
OPERATOR HAS GOT ADEQUATE SKILL TO PERFORM THE JOB. PROPER ATTENTION IS GIVEN DURING PERFORMING THE JOB. THE RECOMMENDED PRACTICE FOR REMOVING THE STRONG BACK IS FOLLOWED THERE IS NO LACK OF KNOWLEDGE ABOUT THE FAIRING WORK
ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM.
IMPROPER ATTENTION. NON-ADHERENCE TO THE RECOMMENDED PRACTICE LACK OF KNOWLEDGE ABOUT THE FAIRING WORK
REASON / SUB-CAUSE :- THE OPERATOR IS COMPETENT ENOUGH TO WORK WITH THE EXISTING METHOD.
SLIDE 53
GRSE
STEP 6 ( B )
BY WHY WHY ANALYSIS VALIDATION THE PROBABLE CAUSES SEQUENTIALLY
IS IT DUE TO ERECTION PROCEDURE ? Y N
DISHARI-S
WHY?
ERECTION PROCEDURE
EFFECT SUB-CAUSES
GENERATION OF HEAT DURING TACKING & RUNNING WELDING OF PANELS DURING ERECTION LEADS TO DISTORTION DISTORTION DURING POSITIONING/ALIGNMEN T BY PULLING THE PANELS BY BOTTLE SCREW .
VALIDATION
REASON
GENERATION OF HEAT DURING TACKING & RUNNING WELDING OF PANELS DURING ERECTION IS NOT RESPONSIBLE FOR DISTORTION OF STRONG BACKS PULLING THE PANELS BY BOTTLE SCREW DURING POSITIONING/ALIGNMENT IS NOT RESPONSIBLE FOR DISTORTION OF STRONG BACKS OF PANELS .
REASON / SUB-CAUSE :- THERE IS NO SUCH PROBLEM DURING ERECTION OF PANELS.

SLIDE 54
GRSE
STEP 6 ( B )
BY WHY WHY ANALYSIS VALIDATION THE PROBABLE CAUSES SEQUENTIALLY
IS IT DURING TRANSPORTATION OF AL. PANELS ?
DISHARI-S
Y N
WHY?
TRANSPORTATION OF AL. PANELS

EFFECT SUB-CAUSES
IMPROPER LIFTING & TRANSPORTATION OF PANELS
VALIDATION
REASON
PRECAUTION IS TAKEN DURING LIFTING & TRANSPORTATION OF PANELS.
NON AVAILABILITY OF CRANE FOR HANDLING

DISTORTION DUE TO SELF WEIGHT DURING LIFTING BY CRANE.
THERE IS NO SUCH PROBLEMS FROM NON AVAILABILITY OF MOBILE CRANE.

TO AVOID DISTORTION DUE TO SELF WEIGHT DURING LIFTING BY CRANE ALL THE 4-SIDES OF PANELS ARE STRONG BACKED BY AL. ANGLES
REASON/SUB-CAUSE:- THE PANELS ARE CAREFULLY HANDLED DURING ITS TRANSPORTATION & ERECTION TO AVOID ANY DISTORTION.
SLIDE 55
GRSE
STEP 6 ( B )
BY WHY WHY ANALYSIS
DISHARI-S

IS IT DUE TO TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK ?
WHY?
TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK.

EFFECT SUB-CAUSES
IGNORANCE OF PROPER SEQUENCE OF TACKING/FITTING INCORRECT TACKING/FITTING IMPROPER DISMANTLING OF STRONG BACK (AL. ANGLES) LEADS TO HIGH DISTORTION IMPROPER PROTECTION AGAINST EXCESSIVE DISTORTION DURING TACKING/FITTING.
VALIDATION
REASON
PROPER SEQUENCE OF TACKING/FITTING IS MAINTAINED TACKING/ FITTING IS DONE AS REQUIRED. STRONG BACK (AL. ANGLES) IS DISMANTLED BY USING FORK. PROPER PROTECTION AGAINST DISTORTION DURING TACKING/FITTING WERE TAKEN.
REASON / SUB-CAUSE :- THERE IS NO SUCH PROBLEM DURING TACKING/FITTING & DISMANTLING PROCEDURE OF STRONG BACK.
SLIDE 56
GRSE
STEP 6 ( B )
BY WHY WHY ANALYSIS
DISHARI-S

IS IT DUE TO MATERIAL( USED FOR STRONG BACK) ? MATERIAL( USED FOR STRONG BACK)
EFFECT SUB-CAUSES USE OF SOFTER & COSTLY MATERIAL INHERENT MATERIAL DEFECT. MATERIAL NOT AT PER SPECIFICATION ADDITIONAL TIME IS SPENT TO REMOVE DISTORTION FROM STRONG BACK AFTER REMOVAL HIGH DISTORTION/DEFORMATION OF AL. ANGLES LEADS TO REJECTION HIGH INEFFECTIVE TIME DUE TO FAIRING FOR REMOVAL OF DISTORTION NON USE OF ANY ALTERNATIVE HARDER & CHIPPER MATERIAL VALIDATION REASON DISTORTION AFTER REMOVAL OF STRONG BACK SINCE ALUMINIUM IS SOFT, HIGHLY MALLEABLE & LIGHTER IN WEIGHT . MATERIAL IS NOT DEFECTIVE. MATERIAL IS AS PER SPECIFICATION ADDITIONAL TIME IS SPENT TO REMOVE WELD MATERIAL & DISTORTION BY FAIRING WORK FROM STRONG BACK AFTER REMOVAL HIGHLY DISTORTED & DEFORMED AL. ANGLES IS UNSUITABLE FOR REUSE . ADDITION OF INEFFECTIVE TIME TO PRODUCTION TIME CAUSES DELAY IN DELIVERY OF FINISHED PRODUCT. USE OF ANY HARD, LESS MALLEABLE & HEAVER WEIGHT THAN ALUMINIUM ANGLES CAN ELIMINATE THE EXISTING PROBLEM.
WHY?
x x

REASON / SUB-CAUSE :- USE OF SOFT , HIGH MALLEABLE & LIGHTER IN WEIGHT AL. ANGLES AS STRONG BACK IS THE MAIN REASON BEHIND THE PROBLEM (DISTORTION/ DEFORMATION SLIDE 57
GRSE
STEP 7(A)
DISHARI-S
DATA ANALYSIS ON THE ROOT CAUSE

ACTIVITY-WISE DATA COLLECTION & STRATIFICATION FOR STRONG BACKING ALUMINUM PANEL
STRATIFICATION OF ACTIVITIES IN TO 5- MAIN ACTIVITIES
SL NO.
1.
SUB - ACTIVITIES
MAIN ACTIVITY
MAN HOUR CONSUMED PER PANEL

2.0
a.) MARKING b) CUTTING c) DEBARRING d) BUFFING OF 4 NOS. 75 X 50 X 6 MM AS PER REQUIRED LENGTH FOR ONE NO. OF PANEL. a) TACKING/FITTING OF ALUMINIUM ANGLES ON 4- SIDES OF AL. PANEL FOR STRONG BACKING THE PANELS. b) CHECK THE STRAIGHTNESS OF AL. PANELS C) LIGHT HAMMERING BY WOODEN MALLET FOR NECESSARY FAIRING AS REQUIRED. a) REMOVE ALL THE STRONG BACKS (AL. ANGLES) AFTER COMPLETION OF ERECTION OF WHEEL HOUSE BLOCK AT SITE USING METAL FORK. b) REMOVE ALL THE STRONG BACKS (AL. ANGLES) AFTER COMPLETION OF ERECTION OF WHEEL HOUSE AT BRIDGE DECK OF SHIP USING METAL FORK. a) CARRY THE AL. ANGLES TO SHOP FROM SITE & SHIP . b) REMOVE WELD METAL FROM AL. ANGLES BY GRINDING. a) CHECK THE STRAIGHTNESS OF ANGLES. b) SEGREGATE THE DEFORMED ANGLES. c) CUT & REJECT THE DEFORMED ANGELS d) REMOVE WELDING BURRS ON ANGLES BY GRINDING e)FAIRING BY HEATING AND COOLING FOR STRAIGHTENING THE ANGLES.
PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS . TACKING/ FITTING OF STRONG BACK ON ALUMINIUM PANEL. REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS. REMOVE WELDING BURRS FROM ANGLES. SEGREGATION THE REJECTED ANGLES ,FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING.
2.
3.0
3.
1.5
4. 5.
2.5 9.0
SLIDE 58
GRSE
STEP 7(B)
DISHARI-S

WITH THE HELP OF AVAILABLE DATA FROM DATA ANALYSIS PARETO ANALYSIS WERE DONE AND SUBSEQUENTLY PARETO DIAGRAM WERE DRAWN
PARETO ANALYSIS
SL NO MAIN ACTIVITIES MAN MIN. CONSUMED INDVL CUMM PERCENTAGE INDVL CUMM
SEGREGATION THE REJECTED ANGLES & FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING.
TACKING/FITTING OF STRONG BACK ON ALUMINIUM PANEL REMOVE WELD METAL FROM ANGLES
9.0
9.0
50
50
B C
3.0 2.5
12.0 14.5
17 14
67 81
D
E
PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS.

REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS
2.0
1.5
16.5
18.0
11
8
92
100
SLIDE 59
GRSE
DISHARI-S

PARETO DIAGRAM
100 15
FREQUENCY
100 92 81 67 80 60 40
PERCENTAGE
SLIDE 60
10
50
5 20 0
A B C D E
0 PROBLEM
IT IS OBSERVED FROM PARETO DIAGRAM THERE IS 50% INVOLVEMENT OF INEFFECTIVE TIME FOR FAIRING OF AL ANGLE
GRSE
DISHARI-S

DATA RELATED TO RE-USE, DEFORMED & HIGHLY DISTORTED AL. ANGLE AFTER ITS REMOVAL FROM AL. PANEL.
SHIP/ CONST. NO. DESCRIPTION OF WORK TOTAL LENGTH IN METER OF AL. ANGLES(75 X 50 X 6mm) REQUIRED REUSED AFTER REJECTED AL. ANGLE FOR STRAIGHTENING DUE TO NOT USEABLE STRONG BY FAIRING DUE TO DEFORMATIO BACKING N AFTER HIGH THE PANEL REMOVING DISTORTION AFTER STRAIGHTENIN G BY FAIRING
WJ FAC 2063 WJ FAC /2064 IPV/2075 APV/2076
STRONG BACKING OF AL. PANELS FOR TRANSPORTA TION & ERECTION OF WHEEL HOUSE. AVERAGE PER SHIP
138 137 126 125 132
70 66 60 65 65
21 25 18 20 21 (16%)
47 46 48 40 46 (35%)
SLIDE 61
GRSE
DISHARI-S

PIE CHART SHOWS % OF REUSE & REJECTED AL. ANGLES.
35% 16% 49%
RE-USE
DEFORMED
HIGHLY DISTORTED
IT IS OBSERVED FROM PIE CHART THERE IS 51% REJECTION OF AL ANGLE I.E. 16% DUE TO DEFORMATION AFTER REMOVING STRONG BACK & 35% IS NOT RE-USEABLE DUE TO HIGH DISTORTION AFTER FAIRING
SLIDE 62
GRSE DATA ANALYSIS ON THE ROOT CAUSE
DISHARI-S
CONCLUSION OF ROOT CAUSE ANALYSIS

PHYSICAL PROPERTIES OF METAL
METAL
DENSITY (gm./cm2 )
MELTING POINT (DEGREE CENTIGRADE)

659.7 1535
HARDNESS NO. (BHN)
MALLEABILITY
ALUMINIUM IRON
2.7 7.87
16 42
HIGH (2ND HIGHEST) LOWER THAN ALUMINIUM
IT IS OBSERVED FROM THE TABLE THAT IRON IS MUCH MORE HEAVIER, HARDER & LESS MALLEABLE THAT ALUMINIUM
FINALLY CONCLUDED FROM THE PHYSICAL PROPERTIES OF METAL THAT THE ROOT CAUSE BEHIND THE PROBLEM ARE THE PREVAILING PRACTICE OF USING SOFT, HIGHLY MALLEABLE & LIGHT IN WEIGHT AL. ANGLES FOR STRONG BACKING THE AL PANELS
SLIDE 63
GRSE
STEP 8(A)
DISHARI-S
DEVELOPMENT OF SOLUTION
AFTER FINDING OUT THE ROOT CAUSE OF PROBLEM BASED ON DATA ANALYSIS, QC MEMBERS DECIDED TO DEVELOP THE SOLUTION OF THE PROBLEMS. DURING BRAINSTORMING SESSION, MEMBERS SUGGESTED
TWO ALTERNATIVE METHODS FOR THE SOLUTION OF THE

PROBLEM. BASED ON ADVANTAGES & DISADVANTAGES OF BOTH THE SYSTEM QC MEMBERS CONCLUDED THAT THE
SECOND METHOD IS THE MOST EFFECTIVE FOR THE

SOLUTION OF THE PROBLEM.
SLIDE 64
GRSE
A. 1ST. METHOD
ACTIVITY
ALTERNATIVE METHOD FOR DEVELOPMENT OF SOLUTION

ADVANTAGE 1. NO DISTORTION OF MS FLAT BARS 2. NO WASTAGE OF COSTLY MATERIAL 3 .HIGH INEFFECTIVE TIME FOR REMOVAL OF WELD MATERIAL & STRAIGHTENING THE AL. ANGLES BY FAIRING WORK WILL REDUCED TO ZERO. DISADVANTAGE
DISHARI-S
REMARKS
1. USE MS FLAT BARS IN PLACE OF AL. ANGLE FOR STRONG BACKING THE AL. PANELS. 2 . USE MS/AL. TRANSITION JOINT (BI METALLIC) 3. MS PORTION OF MS/AL TRANSITION JOINT TO BE TACKED WITH MS FLAT BAR AND ALUMINIUM PORTION TO BE TACKED WITH AL.PANEL
1. MS/AL TRANSITION JOINT IS COSTLY AND BROUGHT OUT ITEM. 2. THERE IS A CHANCE OF FAILURE AT PASTED JOINT OF MS/AL TRANSITION JOINT .
NOT ACCEPTABLE
B. 2ND. METHOD
ACTIVITY 1. USE MS FLAT BARS IN PLACE OF AL. ANGLE FOR STRONG BACKING THE AL. PANELS. 2. USE ALUMINIUM LUGS. 3. DRILL HOLES(6mm) ON MS FLAT BARS & AL. LUGS. 4. FITTING THE LUGS WITH MS FLAT BARS BY BOLTING. 5. TACKING/FITTING THE AL. LUGS WITH AL. PANELS FOR STRONG BACKING. 6. AFTER ERECTION OF PANELS REMOVE TACK WELD BY FORK. 7. DISMANTLED LUGS BY REMOVING THE BOLTS, GRIND THE LUG TI REMOVE WELD MATERIAL. 2. NO WASTAGE OF COSTLY MATERIAL. 3. HIGH INEFFECTIVE TIME FOR REMOVAL OF WELD MATERIAL & STRAIGHTENING THE AL. ANGLES BY FAIRING WORK WILL REDUCED TO ZERO. ADVANTAGE 1 . NO DISTORTION OF MS FLAT BARS . DISADVANTAGE PROPER PRESERVATION OF MS FLAT BARS &AL. LUGS IS REQUIRED FOR REUSE IN THE NEXT SHOP. REMARKS
ACCEPTABLE
SLIDE 65
GRSE
A C P D
STEP 8(B)
DISHARI-S
ACTION PLAN FOR DEVELOPMENT OF SOLUTION
While developing the solution of the problem in line with second method of solution, QC members used the Counter Measure Metric technique i.e. an action plan showing time bound and responsibility shared by the member as shown below :ACTION PLAN FOR DEVELOPING SOLUTION (TIME BOUND & RESPONSIBILITY SHARED)
ROOT CAUSE ACTION PLAN FOR DEVELOPMENT OF SOLUTION TARGET DATE FOR COMPLETION 01-04-11 To 07-04-11 RESPONSIBILITY
THE PREVAILING PRACTICE OF USING SOFT, HIGHLY MALLEABLE & LIGHT IN WEIGHT AL. ANGLES FOR STRONG BACKING THE AL PANELS. RESULT:THERE IS 50% WASTAGE OF COSTLY MATERIAL(AL. ANGLE) AFTER REMOVAL OF ALUMINIUM STRONG BACK FROM PANELS
1) PREPARE A SKETCH WITH BILL OF MATERIAL INCL .SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG . 2) COLLECT CUT PIECE MATERIAL AS REQUIRED. 3) DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. LUGS. 4) FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT. 5) TACKING/FITTING AL. LUGS WITH AL, PANELS FOR STRONG BACKING. 6) REMOVE STRONG BACK AFTER ERECTION OF PANELS. 7) DISMANTLE AL. LUGS BY REMOVING BOLTS & NUT FROM FLAT BAR. 8) REMOVE WELDING BARS FROM AL. LUGS BY GRINDING. 9) STRAIGHTENING THE MS FLAT BARS BY FAIRING WORK AS REQUIRED.
MR. S.K.POLLEY MR. A.GHOSH
08-04-11 To 13-04-11
MR. H.ROY MR. S. CHAKRABORTY
MR. A. GHOSH MR. S. BACHAR
SLIDE 66
GRSE
A C
1.
DISHARI-S
P D
DEVELOPMENT OF SOLUTION ACCORDING TO OUR ACTION PLAN

EXECUTION OF ACTION PLAN
ACCORDING TO OUR ACTION PLAN WE PREPARE A SKETCH WITH BILL OF MATERIAL INCL. SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG. COLLECT CUT PIECE MATERIAL AS REQUIRED. DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. LUGS. FITTING LUGS WITH MS FLAT BAR BY BOLT. TACKING/FITTING AL. LUGS WITH AL, PANELS FOR STRONG BACKING. REMOVE STRONG BACK AFTER ERECTION OF PANELS. DISMANTLE AL. LUGS BY REMOVING BOLTS FROM FLAT BAR. REMOVE WELD BARS FROM AL. LUGS BY GRINDING STRAIGHTENING THE AL. ANGLES BY FAIRING WORK.
SLIDE 67
2. 3. 4. 5. 6. 7. 8. 9.
GRSE
EXECUTION OF ACTION PLAN
MS FLAT BAR AND ALUMINIUM LUG
DISHARI-S
ACCORDING TO OUR ACTION PLAN-1, WE PREPARE A SKETCH WITH BILL OF MATERIAL INCL. SIZE & LENGTH FOR MS FLAT BAR & ALUMINIUM LUG
BILL OF MATERIAL FOR FIXTURE

SL.NO 1. 2. 3. NAME OF THE ITEM MS FLAT BAR ALUMINIUM LUG BOLT & NUT SIZE 8000 x 100 x 10, 2000 x 100 x 10, 4800 x 100 x 10, 3400 x 100 x 10, 2100 x 100 x 10, 2400 x 100 x 10 50 x 50 x 6 30 x 8 QTY. 12 100 100
DRAWN BY : DISHARI-S, APPROVED BY : SHRI D K SINHA , M(HOF)
SLIDE 68
GRSE
DEVELOPMENT & SOLUTION
DISHARI-S
FLOW DIAGRAM FOR STRONG BACKING AL PANEL BY MS FLAT BAR

START COLLECT CUT PIECE MATERIAL AS REQUIRED DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. LUGS. FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT. TACKING/FITTING AL. LUGS WITH AL, PANELS FOR STRONG BACKING. REMOVE STRONG BACK AFTER ERECTION OF PANELS.
REMOVE WELDING BURRS FROM ALUMINIUM LUGS BY GRINDING & STRAIGHTENING THE MS FLAT BARS BY FAIRING
CHECK
NOT OK
OK FINISH
SLIDE 69
GRSE
DISHARI-S
DRILL HOLES ON MS FLAT BAR
DRILL HOLES ON AL. LUG
SLIDE 70
GRSE
DISHARI-S
AL. LUGS IS FITTED WITH MS FLAT BAR BY BOLT & NUT.
TACKING/FITTING AL. LUGS ALONG WITH MS FLAT BAR FOR STRONG BACKING.
SLIDE 71
GRSE
DISHARI-S
REMOVE STRONG BACK AFTER ERECTION OF PANELS.
SLIDE 72
GRSE
DISHARI-S
STRAIGHTENING THE MS FLAT BAR BY FAIRING
REMOVE WELDING BURRS FROM AL. LUGS BY GRINDING.
SLIDE 73
GRSE
DISHARI-S
FLOW DIAGRAM FOR STRONG BACKING AL PANEL BY MS FLAT BAR

START COLLECT CUT PIECE MATERIAL AS REQUIRED DRILL HOLES WERE MADE AS PER DRAWING ON MS FLAT BARS & AL. LUGS. FITTING LUGS WITH MS FLAT BAR BY BOLT &NUT. TACKING/FITTING AL. LUGS WITH AL, PANELS FOR STRONG BACKING. REMOVE STRONG BACK AFTER ERECTION OF PANELS.
REMOVE WELDING BURRS FROM ALUMINIUM LUGS BY GRINDING & STRAIGHTENING THE MS FLAT BARS BY FAIRING
CHECK
NOT OK
OK FINISH
SLIDE 74
GRSE A C P D
APPROVAL BY THE MANAGEMENT
DISHARI-S
AFTER COMPLETION OF OUR NEWLY DEVELOPED METHOD FOR STRONG BACKING THE FABRICATED AL. PANELS, WE HAVE EXHIBITED THE SAME FOR MANAGEMENT APPROVAL ON 11.04.11 MANAGEMENT IS PLEASED TO ADVISE YOU TO GO AHEAD WITH THE IMPLEMENTATION OF THE NEWLY DEVELOPED SYSTEM FOR STRONG BACKING THE FABRICATED AL. PANELS.
SLIDE 75
GRSE
DISHARI-S

A C P D
APPROVAL BY THE MANAGEMENT
SLIDE 76
GRSE
STEP 9(A)
DISHARI-S

PLAN
THROUGH BRAINSTORMING
NORMALLY, IF WE TRY A DRASTIC CHANGE IN OUR EXISTING METHOD OF WORKING, THERE MAY BE RESISTANCE TO THAT CHANGE AND OUR FELLOW WORKMEN MAY NOT EASILY ACCEPT SUCH A CHANGE. WE MADE BRAIN STORMING FOR OVER COMING THE RESISTANCE WHICH MAY COME FROM OUR NON MEMBERS & UNION REPRESENTATIVE DURING IMPLEMENTATION OF OUR PROJECT.
SLIDE 77
GRSE
STEP 9(B)
DISHARI-S

DO
ACCORDING TO OUR PLAN, WE MADE A LIVE PRESENTATION ON 19.04.2011 IN PRESENCE OF THEM, DURING PRESENTATION MAJORITY OF THEM IN CONSENSUS WITH US :-
SL. 1
RESISTANT PRODUCTION SUPERVISOR
TYPE OF RESISTANCES PRODUCTION SUPERVISOR WERE NOT AGREED TO SPARE THE TIME FOR STOPPAGE OF WORK DURING EXPERIMENTAL WORK. ANY IDEA FOR BETTERMENT TO BE GIVEN BY OUR HIGHER AUTHORITIES. LOSS OF PRODUCTION DURING TRIAL RUN & IMPLEMENTATION OF PROJECT,AS A RESULT THERE WILL BE TREMENDOUS PRESSURE ON US TO MAINTAIN THE DELIVERY SCHEDULED OF PRODUCTION. INVOLVEMENT OF HUES MAN POWER AS WELL AS HIGH PROJECT COST. MANPOWER MAY BE REDUCED AFTER IMPLEMENTATION OF OUR IMPROVED METHOD SLIDE 78
2. 3
UNION REPRESENTATIVES
FELLOW WORKMEN (PROSPECTIVE MEMBERS)

4 5
GRSE
STEP 9(C)
DISHARI-S

CHECK & ACT
WE OVERCOME THE VARIOUS RESISTANCE RAISED BY THE MINORITY OF THEM BY CONVINCING ABOUT THE BENEFIT OF OUR PROJECT
PROBABLE RESISTANCE & ITS REMEDY

RESISTANCE FACED DURING LIVE PRESENTATION OF OUR PROJECT
1. PRODUCTION SUPERVISOR WERE NOT AGREED TO SPARE THE TIME FOR STOPPAGE OF WORK DURING EXPERIMENTAL WORK, SINCE THERE MAY BE TEMPORARY DELAY IN DELIVERY OF FINISHED PRODUCT. 2. LOSS OF PRODUCTION DURING TRIAL RUN & IMPLEMENTATION OF PROJECT,AS A RESULT THERE WILL BE TREMENDOUS PRESSURE ON US TO MAINTAIN THE DELIVERY SCHEDULED OF PRODUCTION 3. INVOLVEMENT OF HUES MAN POWER AS WELL AS HIGH PROJECT COST. 4. MANPOWER MAY BE REDUCED AFTER IMPLEMENTATION OF OUR IMPROVED METHOD . 5. ANY IDEA FOR BETTERMENT TO BE GIVEN BY OUR HIGHER AUTHORITY.
RESISTANT
COUNTER MEASURE FOR OVERCOMING RESISTANCE

1) DISCUSSED WITH THE NON-MEMBER & UNION REPRESENTATIVE ABOUT THE BENEFITS AFTER IMPLEMENTATION OF OUR NEW PROJECT. 2) THEIR SUGGESTION & VIEWS TO BE NOTED DOWN AND WOULD BE TAKEN INTO CONSIDERATION WHEREVER APPLICABLE BEFORE IMPLEMENTATION OF OUR PROJECT. 3) EXPLAINED THEM THAT THE PROJECT COST IS ONE TIME INVESTMENT AND THE PAY BACK PERIOD IS VERY MINIMUM. THEY WERE ULTIMATELY CONVINCED. 4) WE CAN SATISFY OUR CUSTOMER BY MEETING THE PRODUCTION TARGET IN TIME, RESULTING NEW DOOR WOULD BE OPEN FOR GETTING FRESH ORDER FROM OUR CUSTOMER. 5) CONVINCE THEM THAT QC IS A PLATFORM WHERE WE THE GRASS ROOT LEVEL WORKFORCE CAN EXPLORE OUR GROUP INNOVATIVE IDEAS FOR BETTERMENT OF PRODUCTION & QUALITY
A) NONMEMBER
B) UNION REP.
SLIDE 79
GRSE
STEP 10(B)
DISHARI-S
TRIAL IMPLEMENTATION & CHECKING PERFORMANCE DO

WE CARRIED OUT STRONG BACKING ONE NO ALUMINIUM PANEL(5006 X 2400) BY TACKING/FITTING AL. LUGS BOLTED WITH MS FLAT BARS ON TRIAL BASIS FROM 21.04.11 TO 27.04.11 AFTER ERECTION OF PANEL, WE REMOVED THE STRONG BACK. THE PERFORMANCE & QUALITY OF FINISH PRODUCT WAS CHECKED BY COMPETENT AUTHORITY & FOUND HIGHLY SATISFACTORY.
A C
P D
PERFORMANCE RESULT DURING TRIAL RUN

TRIAL PERIOD - FROM 21.04.11 TO 27. 04. 11
DESCRIPTION SIZE & DRAWING NO. QTY LIST OF MATERIAL INSPECTION BY HOD.
CONDITION OF STRONG BACK AFTER REMOVAL FROM PANEL RE USABLE NOT RE-USEABLE
STRONG BACKING OF ALUMINIUM PANEL
5006 x 2400 x4 mm DRG. NO. 2072796/115201
a) MS FLAT BAR b) ALUMINIUM LUG c) BOLT & NUT
YES
NIL
NOTE : PP&C DEPARTMENT RECOMMENDED US TO REDUCE THE SIZE OF AL LUG FROM 50 X 50 X 6MM TO 40 x 40 x 6 MM TO REDUCE DISTORTION SLIDE 80
GRSE
STEP 10(B)
DISHARI-S
TRIAL IMPLEMENTATION & CHECKING PERFORMANCE CHECK

A
REVISED SIZE OF AL LUG AS RECOMMENDED BY PP&C DEPARTMENT
P
D
SLIDE 81
GRSE
STEP 10(C)
DISHARI-S
TRIAL IMPLEMENTATION & CHECKING PERFORMANCE

CHECK
A C
SL NO
P D
ACTIVITY WISE DATA FOR STRONG BACKING OF AL PANEL WERE COLLECTED DURING TRIAL IMPLEMENTATION BY DIRECT OBSERVATION & WAS COMPARED WITH OBSERVED DATA BEFORE QC
COMPARATIVE STUDY OF ACTIVITY WISE MAN HOUR CONSUMED /PANEL FOR STRING BACKING ALUMINIUM PANELS BEFORE & AFTER QC AS INDICATED BELOW:MAIN ACTIVITIES FOR STRONG BACKING AL. PANELS MAN HOUR CONSUMED / PANEL BEFORE QC 1 2 3 PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS FITTING AL. LUGS WITH MS FLAT BARS TACKING/FTG OF AL. ANGLES ( STRONG BACK) ON AL PANEL TACKING/FTG OF AL. LUGS WITH MS FLAT BARS ( STRONG BACK) ON AL PANEL 4 5 REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS. REMOVE WELD METALS FROM ANGLES BY GRINDING. AFTER QC WASTAGE OF AL ANGLE / PANEL BEFORE QC AFTER QC
2.0 3.0 1.5 2.5
1.0 2.0 1.0 7.5 M NIL
6
7 8
REMOVE WELD METAL FROM AL. LUGS BY GRINDING

SEGREGATION THE REJECTED ANGLES , FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING. STRAIGHTENING THE MS FLAT BARS TOTAL
9.0 18.0
1.0
4.0 9.0
SLIDE 82
GRSE
DISHARI-S TRIAL IMPLEMENTATION & CHECKING PERFORMANCE 59 CHECK
STEP 10(D)
WITH THE HELP OF ACTIVITY WISE MAN HOURS. CONSUMED BEFORE QC AFTER QC DURING TRIAL RUN, WE PREPARED A LINE AND BELT GRAPH TO SHOW THE IMPROVEMENT AFTER QC AS INDICATED BELOW :ACTIVITIES WISE COMPARATIVE MAN-DAYS. SPENT BEFORE & AFTER QC
18.0
LINE & BAR DIAGRAM
LENGTH IN Mtr.
9.0
6 4 2 0 BEFORE QC AFTER QC
7.5
TOTAL MAN HOUR CONSUMED / PANEL IMPROVEMENT AFTER QC. (BASED ON LINE & BELT GRAPH) 1. 2.
WASTAGE OF AL ANGLE / PANEL
WASTAGE OF COSTLY AL ANGLE HAS COME DOWN TO ZERO LEVEL. TOTAL PRODUCTION TIME IS REDUCED FROM 18.0 MAN HOURS. TO 9.0 MAN HOURS. (54%) SLIDE 83
GRSE
STEP 11 (A)
REGULAR IMPLEMENTATION
PLAN
A C P D
DISHARI-S
AFTER ACHIEVING HIGHLY SATISFACTORY RESULTS DURING TRIAL RUN, QC MEMBERS DECIDED TO GO FOR REGULAR IMPLEMENTATION OF THE NEWLY DEVELOPED METHOD FOR STRONG BACKING ALL THE ALUMINIUM PANELS BY TACKING/FITTING AL. LUGS WITH PANELS, AND THE LUGS ARE BOLTED WITH MS FLAT BARS. DURING REGULAR IMPLEMENTATION QC MEMBER PLANNED TO FOLLOW THE FOLLOWING STEPS : AFTER COMPLETION OF TRIAL RUN WE WILL REVIEWED EVERY ACTIVITIES & UPDATED THE SAME & A REVISED MILE STONE CHART WILL BE PREPARED FOR THE BALANCE ACTIVITIES LIKE REGULAR IMPLEMENTATION & FOLLOW UP ACTION ACTIVITY WISE DATA WILL BE COLLECTED FOR STRONG BACKING AL. PANELS BY NEWLY DEVELOPED METHOD AFTER ITS REGULAR IMPLEMENTATION (AFTER QC) AND THE SAME WILL BE COMPARED WITH THE DATA BEFORE QC TO OBSERVE THE IMPROVEMENT ACHIEVED AFTER QC. THE SAME WILL BE SENT TO IE&P DEPT.FOR AUDITED & NECESSARY CERTIFICATION.
FIND OUT TANGIBLE & INTANGIBLE BENEFITS DURING OUR QC PROGRESS.
SLIDE 84
GRSE A C P D
STEP 11(B)
DISHARI-S
REGULAR IMPLEMENTATION DO
REVISED MILESTONE CHART AFTER TRIAL IMPLEMENTATION
AFTER COMPLETION OF TRIAL RUN WE HAVE REVIEWED EVERY ACTIVITIES & UPDATED THE SAME & A REVISED MILE STONE CHART IS PREPARED ON 26.05.10 FOR THE BALANCE ACTIVITIES LIKE REGULAR IMPLEMENTATION & FOLLOW UP ACTION.
D. O. START.: 24-01-11 D.O. COMP-:01-06-11 QC MEMBERS: S. K. POLLEY, H. ROY, A. K. GHOSH, S.BACHAR
QC TEAM : DISHARI ( S ) / STRUC. SHOP (FOJ)

PROJECT: ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
QC STEP 3 TO 10 11 ACTIVITIES
1 2 3 4 5
TIME SCHEDULE IN WEEKS

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
FROM DEFINING THE PROBLEM TO TRIAL IMPLEMENTATION

REGULAR IMPLEMENTATION A) PREPARE A MILE STONE CHART FROM REGULAR IMPLEMENTATION TO FOLLOW-UP ACTION & REVIEW B) DATA COLLECTION & COMPARISON OF IMPROVEMENT (BEFORE & AFTER QC), TANGIBLE GAIN & INTANGIBLE GAIN.
12
FOLLOW-UP ACTION & REVIEW
PLANNED
ACTUAL
SLIDE 85
GRSE A C P D
STEP 11(C)
DISHARI-S
DO
DATA COLLECTION & COMPARISON WITH THE CORRESPONDING DATA BEFORE QC AFTER REGULAR IMPLEMENTATION
COMPARATIVE STUDY OF ACTIVITIES BEFORE & AFTER QC IS EXHIBITED HERE IN A TABLE AS INDICATED BELOW :
SL. NO. 1 2 3 MAN HOUR CONSUMED /PANEL MAIN ACTIVITIES FOR STRONG BACKING AL.PANELS PREPARATORY WORK FOR STRONG BACK OF FABRICATED PANELS . FITTING AL. LUGS WITH MS FLAT BARS TACKING/FITTING OF AL. ANGLES ( STRONG BACK) ON ALUMINIUM PANEL TACKING/FITTING OF AL. LUGS WITH MS FLAT BARS (STRONG BACK) ON ALUMINIUM PANEL BEFORE QC 2.0 3.0 AFTER QC 1.0 1.5 52.06% PRODUCTION TIME IS SAVED DUE AVOIDANCE OF SEGREGATION THE REJECTED ALUMINIUM ANGLES , FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING REMARKS
4
5 6 7 8
REMOVING THE TEMPORARILY FITTED STRONG BACK AFTER ERECTION OF PANELS.

REMOVE WELD METALS FROM ANGLES BY GRINDING. REMOVE WELD METAL FROM AL. LUGS BY GRINDING SEGREGATION THE REJECTED ANGLES , FAIRING THE DISTORTED ANGLES FOR STRAIGHTENING. STRAIGHTENING THE MS FLAT BARS TOTAL
1.5
2.5 9.0 18.0
1.0
1.5 4.0 9.0
SLIDE 86
GRSE
DO
DISHARI-S
FURTHER DATA WERE COLLECTED FOR REQUIREMENT AS WELL AS REJECTION OF AL. ANGLE PER SHIP BEFORE QC AND REQUIREMENT AS WELL AS REJECTION OF MS. FLAT BARS PER SHIP BEFORE QC
A C
P D
COMPARATIVE STUDY OF REQUIREMENT AS WELL AS REJECTION OF AL. ANGLE PER SHIP BEFORE QC AND REQUIREMENT AS WELL AS REJECTION OF MS. FLAT BARS PER SHIP AFTER QC .
BEFORE QC.( STRONG BACKING BY ALUMINIUM ANGLES) SHIP/CONST. NO. DESCRIPTION OF WORK REQUIRED AVERAGE LENGTH (75 X 50 X 6mm) PER SHIP FOR STRONG BACKING THE PANEL REJECTION OF AL. ANGLE AFTER QC. .( STRONG BACKING BY MS FLAT BAR BOLTED WITH AL. CLIT) REQUIRED AVERAGE LENGTH (100X 10 mm) PER SHIP FOR STRONG BACKING THE PANEL REJECTION OF MS FLAT BARS SAVINGS OF 67 METER ALUMINIUM ANGLE PER SHIH (49.2% OF TOTAL REQUIRED LENGTH ) AFTER QC. REMARKS
WJ FAC/2062 WJ FAC/2063 IPV/2074 APV/2075
STRONG BACKING OF AL. PANELS FOR TRANSPORTATION & ERECTION OF WHEEL HOUSE.
132
67 (50.8%)
132
SLIDE 87
GRSE
REGULAR IMPLEMENTATION CHECK
DISHARI-S
AUDITED /CERTIFICATION OF VARIOUS DATA FOR FABRICATION OF ALUMINUM BEAMS & GIRDERS BEFORE QC. & AFTER QC
A C
P D
SLIDE 88
GRSE
STEP 11(E)
DISHARI-S
REGULAR IMPLEMENTATION CHECK

A C P D
1. REDUCTION IN PRODUCTION TIME( INEFFECTIVE TIME)
PRODUCTION TIME (MAN-DAYS.) FOR STRONG BACKING THE 12 NOS. OF PANELS OF EACH WHEEL HOUSE BEFORE QC STRONG BACKING OF AL. PANELS 27.0 AFTER QC SAVING OF PRODUCTION TIME. AFTER QC (%)
COMPARISON OF IMPROVEMENT BEFORE QC & AFTER QC DURING REGULAR IMPLEMENTATION
LINE & BAR DIAGRAM

30
PRODUCTION TIME
DESCRIPTION OF WORK
25 20 15 10 5 0
27
13.5
13.5
50%
BEFORE QC AFTER QC
SLIDE 89
GRSE
DISHARI-S
COMPARISON OF IMPROVEMENT BEFORE QC & AFTER QC DURING REGULAR IMPLEMENTATION 2. SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP
DESCRIPT ION OF WORK TOTAL LENGTH OF MATERIAL FOR STRONG BACKING AL. PANEL.PER SHIP BEFORE QC (STRONG BACKING BY ALUMINIUM ANGLES) AFTER QC ( STRONG BACKING BY MS FLAT BAR BOLTED WITH AL. LUG)
REQUIRED WASTAGE
SAVING OF COSTLY AL ANGLES. AFTER QC (%)

LENGTH IN Mtr.
LINE & BAR DIAGRAM

80 60 40
REQUIRED
WASTAGE
67
20 0
STRONG BACKING OF AL. PANELS
132 MTR.
67 MTR.
132 MTR.
NIL
50.8%
BEFORE QC
AFTER QC
IT IS OBSERVED FROM THE LINE & BAR DIAGRAM THAT :
REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP
= 50% = 50.8%
SLIDE 90
GRSE
STEP 11(G)
DISHARI-S
TANGIBLE GAIN
REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) = 50%
SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP COST SAVING PER YEAR a) b) LABOUR COST SAVING MATERIAL COST SAVING = = 2.44 LAKHS 1.34 LAKHS = 50.8%
TOTAL COST SAVING PER YEAR
3.78 LAKHS
THE MAN HOURS SAVED IS USED FOR FABRICATION OF VARIOUS SEATS FOR EQUIPMENTS OF SHIP WHICH WERE PREVIOUSLY OUTSOURCED
SLIDE 91
GRSE
DISHARI-S
PROJECT COST 1. LABOUR COST FOR MAKING ALUMINIUM LUGS
AND DRILLING HOLES ON MS FLAT BARS IS APPROX RS 20,000/-, WHICH IS ONE TIME. 2. COST OF CUT PIECE MATERIAL IS NOT
CONSIDERED.
SLIDE 92
GRSE
DISHARI-S
INTANGIBLE BENEFITS
RATIONAL THINKING FOR PROBLEM SOLUTION

THE JOB WAS COMPLETED TO THE SATISFACTION OF ALL CONCERN JOB SATISFACTION ON ITS ACHIEVEMENT INCREASED EMPATHICALLY RELATIONSHIP INCREASED WORK COMMITMENT INCREASED QC KNOWLEDGE SELF DEVELOPMENT & MUTUAL DEVELOPMENT SELF REALISATION IN COMPLICATED TECHNOLOGY INCREASED GROUP HARMONY CARING AMONG THE WORKGROUP
INCREASED TEAM SPIRIT

SLIDE 93
GRSE A C
SL
1
STEP 12
DISHARI-S
P D
FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION

TO ENSURE THAT THE SOLUTIONS ARE ADOPTED & MAINTAINED. WE CONDUCTED FOLLOW-UP ACTION & REVIEW OF OUR NEWLY DEVELOPED PROJECT AS INDICATED HERE :-
CHECK SHEET
CHECK POINT ACTION PLAN FOR RECURRENCE PREVENTION REVIEW PERIOD RESULT
1. 50% WASTAGE OF COSTLY ALUMINIUM ANGLES USED FOR STRONG BACKING THE ALUMINIUM PANELS BEFORE ITS ERECTION HAS COME TO ZERO LEVEL BY REPLACING MS FLAT BARS IN PLACE OF AL. ANGLES. 2. FINISHED PRODUCTS ARE DELIVERED IN TIME.
STRONG BACKING 1. ALWAYS KEEP CLOSE CONTACT THE ALUMINIUM WITH THE GROUP OF PANELS BY MS OPERATIVES WHO ARE FLAT BARS DEPLOYED FOR STRONG INSTEAD OF BACKING THE ALUMINIUM ALUMINIUM PANELS BEFORE ITS ERECTION. ANGLES TO AVOID & CONVEYED THEM TO FOLLOW WASTAGE OF AL. THE IMPROVED METHOD. ANGLES. MAINTAIN THE DELIVERY SCHEDULE OF FINISHED PRODUCT IN TIME. 3. MAINTAINING A PROGRESS REVIEW CHART FOR MONITORING THE MONTHLY WASTAGE OF MATERIAL USED FOR STRONG BACKING THE AL. PANELS AND MAN HR.CONSUMED
ON DAILY BASIS & SUMMARIZED ON MONTHLY BASIS .
SLIDE 94
GRSE
STEP 12 (A)
DISHARI-S

A P
WE ARE MAINTAINING A PROGRESS REVIEW CHART FOR MONITORING THE MONTHLY MAN HRS. CONSUMED FOR STRONG BACKING THE ALUMINIUM PANELS AS WELL AS THE WASTAGE OF COSTLY ALUMINIUM ANGLES.
SHIP WISE PROGRESS REVIEW CHART FOR MAN HRS. CONSUMED FOR STRONG BACKING AND WASTAGE OF COSTLY ALUMINIUM ANGLES
CONST. NO. ALUMINIUM ANGLES/MS FLAT BARS (LENGTH IN METER) USED FOR STRONG BACKING THE PANEL ALUMINIUM ANGLES USED 2063 (WJ-FAC) 2064 (WJ-FAC) 2065 (WJ-FAC) 2075 (IPV) 2076 (IPV) 136 138 137 WASTAGE 69 70 66 125 126 0 0 MS FLAT BAR USED WASTAGE TOTAL MANDAYS CONSUMED/SHIP FOR STRONG BACKING THE ALUMINIUM PANELS AND REMOVAL INCL. FAIRING 27.0 28.0 26.0 13.0 14.0
NOT USED BECAUSE MS CAN NOT BE FITTED WITH ALUMINIUM BY TACKING
REPLACED BY MS FLAT BARS
SLIDE 95
GRSE
DISHARI-S
SHIP WISE PROGRESS REVIEW CHART FOR MAN HRS. CONSUMED FOR STRONG BACKING AND WASTAGE OF COSTLY ALUMINIUM ANGLES
BEFORE QC
140 120 100 80 60 40 20 27 28 26 69 70 66 136 138 137 125
AFTER QC
126
WASTAGE OF COSTLY AL .ANGLE = 68 Mtr. /SHIP
WASTAGE OF COSTLY AL. ANGLE = NIL
13 0 0 2076
14
0 2063 2064 2065 2075
STRONG BACK USED (Mtr.)

OBSERVATION :
STRONG BACK REJECTED(Mtr.)
MANDAYS)
WASTAGE OF COSTLY ALUMINIUM ANGLE (USED AS STRONG BACKING THE AL. PANELS) CAME DOWN FROM 68 Mtr. /SHIP TO ZERO LEVEL AFTER QC. THE MANDAYS SPENT FOR STRONG BACKING INCL. REMOVAL & FAIRING FOR STRAIGHTENING THE AL ANGLE/MS FLAT BARS CAME DOWN FROM 27.0 MANDAYS /SHIP TO 13.5 MANDAYS LEVEL AFTER QC.
SLIDE 96
GRSE A C
SL. NO.
1 2 3 4 5 6 7 8 9 10
FOLLOW UP ACTION/REVIEW & DISHARI-S RECURRENCE PREVENTION STEP 12(B)

STANDARDISATION
P D
AFTER SUCCESSFUL REGULAR IMPLEMENTATION OF OUR PROJECT & SUBSEQUENT DISCUSSION WITH PLANNING DEPT. AS A FOLLOW UP ACTION WE HAVE STANDARDIZED MS FLAT BARS & AL. LUGS TO BE USED FOR STRONG BACKING THE VARIOUS SIZES AL.PANELS FOR FABRICATION & ERECTION OF WHEEL HOUSE OF WJFAC/IPV CLASS OF SHIPS.
STANDARDISATION OF VARIOUS SIZES MS FLAT BARS AND ALUMINIUM LUGS

DESCRIPTION OF ITEMS
SIDE BHD.(S&P) SIDE BHD.(S) SIDE BHD.(P) FORD. BHD. AFT. BHS. PARTITION BHD. PARTITION BHD. PARTITION BHD. PARTITION BHD. PARTITION BHD.
ALUMINIUM PANELS
SIZE IN mm QTY
MS FLAT BAR
SIZE IN mm QTY
ALUMINIUM LUG
SIZE IN mm QTY
8300 X 2400 5250 X 2400 3800 X2400 5006 X 2600 2500 X 2400 1400 X 2400 2500 X 2400 1450 X 2400 940 X 2400 1560 X 2400
2 1 1 1 1 2 1 1 1 1
8000 x 100 x 10 2000 x 100 x 10 4800 x 100 x 10 2000 x 100 x 10 3400 x 100 x 10 2000 x 100 x 10 4600 x 100 x 10 2000 x 100 x 10 2100 x 100 x 10 2000 x 100 x 10 1000 x 100 x 10 2000 x 100 x 10 2100 x 100 x 10 2000 x 100 x 10 1100 x 100 x 10 2000 x 100 x 10 500 x 100 x 10 2000 x 100 x 10 1100 x 100 x 10 2000 x 100 x 10
4 4 2 2 2 2 2 2 2 2 4 4 2 2 2 2 2 2 2 2
40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6 40 x 40 x 6
80 40 48 20 34 20 44 20 20 20 20 40 20 20 10 20 05 20 10 20
SLIDE 97
GRSE
STEP 12 (C)
DISHARI-S

COMPARATIVE MILESTONE CHART
ACTIVITY WISE REVIEW & UPDATE AND COMPARE THE ACTUAL TIME TAKEN WITH THE ESTIMATED TIME QC TEAM : DISHARI ( S ) / STRUC. SHOP (FOJ) PROJECT: ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM QC STEP 3 &4 ACTIVITIES
1 2 3 4 5 6 7 8
D. O. TART.:06.01.11 D. O COMP.: 22.06.11
QC MEMBERS:
S. K. POLLEY, H. ROY,A. K. GHOSH, S BACHAR

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
DEFINING & ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES AND DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE & TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION
6&7
9 & 10
11
12
PLANNED 20 WEEKS
ACTUAL 24WEEKS SLIDE 98
GRSE
DISHARI-S
COMPARISON BETWEEN ACTUAL TIME TAKEN WITH THE ESTIMATED TIME AS PER MILS STONE CHART WITH REASONS OF VARIATION
QC STEP ACTIVITY TIME ESTIMATED ( IN NO. OF MEETING) 4-WEEKS 2-WEEKS 3-WEEKS ACTUAL TIME TAKEN (IN NO. OF MEETING) 4-WEEKS 2-WEEKS 4-WEEKS ADDITIONAL TIME TAKEN (IN NO. OF MEETING) + 1-WEEK
ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION DURING DATA ANALYSIS.
REASON
3&4 5 6&7
DEFINING & ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES AND DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE & TRIAL IMPLEMENTATION REGULAR IMPLEMENTATION
8 9 & 10
4-WEEKS 4-WEEKS
4-WEEKS 4-WEEKS
11
2-WEEK
4-WEEKS
+ 2-WEEK
ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION FOR AUDIT &CERTIFICATION OF GAINS FROM IE&P. DEPT.DURING REGULAR IMPLEMENTATION ADDITIONAL ONE WEEK TIME WAS SPENT FOR DATA COLLECTION DURING PREPARATION OF PROGRESS REVIEW CHART
12
1-WEEK
2-WEEK
+ 1-WEEK
SLIDE 99
GRSE
STEP 12 (D)
DISHARI-S
FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION EFFECTIVENESS OF THE REMEDY ON IMPLEMENTATION OF OUR NEWLY DEVELOPED METHOD
COMPARATIVE PARETO DIAGRAM IS USED TO CHECK THE EFFECTIVENESS OF THE REMEDY ON ITS IMPLEMENTATION
COMPARATIVE PARETO DIAGRAM

BEFORE QC
CUMULATIVE % LINE
AFTER QC
SOLVED PROBLEM A CUMULATIVE % LINE
IT IS OBSERVED FROM THE COMPARATIVE DIAGRAM THAT AFTER TAKING PROPER REMEDIAL MEASURE THE PROBLEM A IS SOLVED
SLIDE 100
GRSE
SL. 1 2 12-QC. STEPS PROBLEM IDENTIFICATION PROBLEM SELECTION
DISHARI-S
TOOL & TECHNIQUE USED BRAINSTORMING. STRATIFICATION , A-B-C ANALYSIS, BAR-DIAGRAM, DATA COLLECTION , ECT- OPTION CHART & PARETO CHART. FLOW DIAGRAM 4-W & 1-H TECHNIQUE, DATA COLLECTION , RUN CHART, LINE & BAR DIAGRAM. BRAINSTORMING, 5W-1H TECHNIQUE, CAUSE & EFFECT DIAGRAM. WHY- WHY ANALYSIS. VALIDATION OF PROBABLE CAUSES. DATA COLLECTION, STRATIFICATION, PARETO DIAGRAM, PIE CHART. BRAINSTORMING, 5W-1H TECHNIQUE. BRAINSTORMING, 5W-1H TECHNIQUE. DATA COLLECTION, LINE & BELT GRAPH . DATA COLLECTION,BAR DIAGRAM, LINE & BAR DIAGRAM. DATA COLLECTION, BAR DIAGRAM, PROGRESS REVIEW CHART.
QUALITY CIRCLE TOOL & TECHNIQUE USED
3 4
DEFINE THE PROBLEM ANALYSIS THE PROBLEM
5 6 7 8 9 10 11 12
IDENTIFICATION THE PROBABLE CAUSES OF THE PROBLEM IDENTIFICATION THE ROOT CAUSES OF THE PROBLEM DATA ANALYSIS FOR ROOT CAUSE DEVELOPING SOLUTION FORESEEING PROBABLE RESISTANCE TRIAL IMPLEMENTATION & CHECK PERFORMANCE REGULAR IMPLEMENTATION FOLLOW UP ACTION/REVIEW & RECURRENCE PREVENTION
SLIDE 101
GRSE
DISHARI-S
PRODUCTION LOSS DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE WE MADE A MILESTONE CHART OF 18 WEEKS TO COMPLETE OUR FUTURE PROJECT.
SLIDE 102
GRSE
DISHARI-S MILESTONE CHART FOR FUTURE PROJECT
WE MADE A MILESTONE CHART OF 18 WEEKS TO COMPLETE THE PROJECT MILESTONE CHART IS HANDED OVER TO OUR CO-ORDINATOR FOR REGISTRATION OF THE PROJECT
QC TEAM : DISHARI ( S ) / STRUC. SHOP (FOJ )
PROJECT:PRODUCTION LOSS ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE
QC STEP ACTIVITIES
STARTING DATE --- 07.07.2011 DURING COMPLETION DATE 09.11.2011
QC MEMBERS: S. K. POLLEY, H. ROY, A. K. GHOSH, NIZAMUDDIN, S. CHAKRABORTY, S BACHAR
1
PLAN 3 4 5 DO DEFINING THE PROBLEM ANALYSIS OF THE PROBLEM IDENTIFICATION OF PROBABLE CAUSES FINDING OUT ROOT CAUSES DATA ANALYSIS DEVELOPMENT OF SOLUTION FORESEEING PROBABLE RESISTANCE
10
11 12 13 14 15 16 17 18
6
7 8 9
CHECK
10
11 ACT 12
TRIAL IMPLEMENTATION
REGULAR IMPLEMENTATION FOLLOW-UP ACTION & REVIEW
SLIDE 103
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DISHARI-S
We extend our gratitude and thanks to the following agencies for their wholehearted co-operation & support for the completion of our project.
1.
2. 3.
Our Management.
G. R. S. E. Trade Union. IE &P Department
4.
All The Non-Members Of Our Shop.

SLIDE 104
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CASE STUDY AT A GLANCE

DEFORMED ANGLES
DISHARI-S
STRONG BACKING THE ALUMINIUM PANELS ( BEFORE QC.)

DISTORTED ANGLES
TACKING/FITTING OF AL. ANGLES (75X50X6) ON 4-SIDES OF EACH FABRICATED PANELS FOR STRONG BACK THE PANELS.
PROBLEM:-ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM. IMPACT OF THE PROBLEM : ADDITIONAL TIME (INEFFECTIVE TIME) IS ADDED TO PRODUCTION TIME TO REMOVE THE DISTORTION. WASTAGE OF ABOUT 50% COSTLY ALUMINIUM ANGLE DUE TO DEFORMATION AND / OR DISTORTION AFTER ITS REMOVAL. DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB.
STRAIGHTENING THE AL. ANGLES BY FAIRING
SLIDE 105
GRSE

STRONG BACKING THE ALUMINIUM PANELS ( AFTER QC.)
DISHARI-S
AL. LUGS IS FITTED WITH MS FLAT BAR BY BOLT & NUT

REMOVE WELDING BURRS FROM AL. LUGS BY GRINDING.
TACKING/FITTING AL. LUGS ALONG WITH MS FLAT BAR FOR STRONG BACKING.
STRAIGHTENING THE MS FLAT BAR BY HAMMERING
SOLUTION OF THE PROBLEM:- STRONG BACKING THE ALUMINIUM PANELS BY MS FLAT BARS BENEFIT: REDUCTION IN PRODUCTION TIME (INEFFECTIVE TIME) = 50% SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP = 50.8% COST SAVING PER YEAR a) LABOUR COST SAVING = 2.44 LAKHS, b) MATERIAL COST SAVING =1.34 LAKHS
SLIDE 106
GRSE
DISHARI-S
OUR THEME SONG ON QC

QUALITY CONCEPT FOR SUSTAINABLE DEVELOPMENT
SOLVE THE PROBLEMS IN SMALL GROUPS, COME ON BROTHER, DO NOT BE SHY TORCH-BEARER OF NEW INDIA FLY THE BANNER FOR QC HIGH
DISHARI - S
SLIDE 107
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DISHARI-S

TITLE OF CASE STUDY (PROBLEM) IMPACT OF THE PROBLEM ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM 1) HIGH IN-EFFECTIVE TIME 2) 50% WASTAGE OF COSTLY ALUMINIUM ANGLES WHICH IS USED FOR STRONG BACKING THE ALUMINIUM PANEL. 3) DIFFICULT TO MAINTAIN THE DELIVERY SCHEDULE OF JOB DUE TO INVOLVEMENT OF ADDITIONAL WORK 1) OPERATOR, 2) MATERIAL USED FOR STRONG BACK, 3) TACKING/FITTING PROCEDURE OF STRONG BACK, 4) TRANSPORTATION OF AL. PANELS, 5) ERECTION PROCEDURE. THE ROOT CAUSE BEHIND THE PROBLEM ARE THE PREVAILING PRACTICE OF USING SOFT, HIGHLY MALLEABLE AND LIGHT IN WEIGHT AL. ANGLES FOR STRONG BACKING THE AL PANELS. 1) FITTING LUGS WITH MS FLAT BAR BY BOLT & NUT. 2) TACKING/FITTING AL. LUGS WITH AL, PANELS FOR STRONG BACKING. 1) REDUCTION IN PRODUCTION TIME ( INEFFECTIVE TIME) = 50% 2) SAVINGS OF COSTLY ALUMINIUM ANGLE PER SHIP = 50.8% 3) COST SAVING PER YEAR = a) LABOUR COST SAVING = 2.44 L b) MATERIAL COST SAVING =1.34 L
PROBABLE MAIN CAUSES OF THE PROBLEM ROOT CAUSE OF THE PROBLEM SOLUTION OF THE PROBLEM BENEFIT
PROJECT DURATION
DATE OF STARTING - 06. 01.11 DATE OF COMPLETION - 22. 06.11

SLIDE 108
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DISHARI-S
SLIDE 109
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DISHARI-S
QUESTION & SUGGESTION PLEASE
GRSE
REGULAR IMPLEMENTATION DISHARI-S

TANGIBLE GAIN (COST BENEFIT )
MAN HRS. SPENT /BEAM &GIRDER BEFORE QC AFTER QC 9.0 LABOUR COST / BEAM &GIRDER BEFORE QC 18.0 RS 194 2.90 (190 % OH) = RS 10126.80 AFTER QC 9.0 RS 194 2.90 (190% OH) = RS 5063.40 LABOUR COST SAVINGS /BEAM &GIRDER
DESCRIPTION OF WORK
FABRICATION OF 8 M 2.4 M A PANEL
18.0
RS 5063.40
NO OF PANELS FOR EACH WJFAC & IPV VESSEL = 12 TOTAL LABOUR COST SAVING FOR EACH WJFAC/ FPV VESSEL := Rs. 5063.40 X 12 NOS =Rs. 0.61 LAKHS
a) YEARLY LABOUR COST SAVING FOR 4-NOS. WJFAC/ IPV VESSEL

= Rs. 2.44 LAKHS (APPROX) YEARLY MATERIAL COST SAVING FOR 4-NO.WJFAC/IPV VESSEL =Rs.500 x 67 Mtr. X 4 no. vessels =Rs. 1.34 LAKHS
GRSE
STEP 1( A)
DISHARI-S
SL. NO. MAJOR PROBLEM AREA SL. NO.
1 2
WORK RELATED PROBLEMS IN THE AREA OF REWORK REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC.
EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. PRESS BENDING MACHINE. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL.
SLIDE 11
REWORK
4 5 6
GRSE
STEP 1(A)
DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO. 9 WORK RELATED PROBLEMS IN THE AREA OF REWORK
REWORK
EXCESSIVE DISTORTION DURING FABRICATION OF AL. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIPS SUPERSTRUCTURE
WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS
10
SL NO
MAJOR PROBLEM AREA
SL. NO.
1
2 3
PRODUCTION LOSS
PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS.
SLIDE 12
GRSE
DISHARI-S
SL NO MAJOR PROBLEM AREA
PRODUCTION LOSS
SL. NO. 5
WORK RELATED PROBLEMS IN THE AREA OF PRODUCTION LOSS PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG.
WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. GASKET CUTTING FOR PLUMBING WORK. PRODUCTION LOSS DUE TO UNEVEN LEVEL OF BLACK SMITH FLOOR.
6 7
8
9 10 11
PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH.

PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS. UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
SLIDE 13
GRSE
STEP 1( A)
DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO 1 2 3 3 HOUSE KEEPING/ SPACE WORK RELATED PROBLEMS IN THE AREA OF HOUSE KEEPING / SPACE DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE. PERSONAL/ OUTSIDERS. KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME. DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION. IMPROPER STORING ARRANGEMENT CAUSES PROBLEM FOR IDENTIFICATION OF REUSABLE MATERIAL. PROBLEM DUE TO NON AVAILABILITY OF PROPER STORE FOR KEEPING PERSONAL BELONGINGS OF OPERATIVE AT GATE - NO 2. HUGE AMOUNT OF UNUSED / OBSOLETE TOOLS / MACHINE / MATERIALS OF TOOL STORE ARE KEPT IN A UN SYSTEMATIC WAY.
SLIDE 14
4 5 6
7
8
GRSE
DISHARI-S
SL NO 3 MAJOR PROBLEM AREA HOUSE KEEPING/ SPACE SL. NO. 9 WORK RELATED PROBLEMS IN THE AREA OF HOUSE KEEPING / SPACE NO SHOPS NAMEPLATE ON TOP OF MAIN ENTRANCE GATE FOR IDENTIFICATION OF SHOP.
10
PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF TIG /MIG & PLASMA WELDING MACHINE OF DIFFERENT MAKE.
WORK RELATED PROBLEMS IN THE AREA OF DISSATISFACTION INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR, ESPECIALLY WHERE PRECISION WORK TAKE PLACE. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. INADEQUATE LIGHT & FAN IN DRESS CHANGING ROOM. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. COMMUNICATION PROBLEM DUE TO NON AVAILABILITY OF PUBLIC TELEPHONE BOOTH NEAR THE GATENO 2. INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION.
SL NO
MAJOR PROBLEM AREA
SL. NO. 1 2
DISSATISFACTION 3 4
5
6
SLIDE 15
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DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO. 1 2 5 FACILITY 3 4 SL NO MAJOR PROBLEM AREA SL. NO. 1 2 3 WORK RELATED PROBLEMS IN THE AREA OF FACILITY
EXISTING SHOP FLOOR CONDITION CAUSES PROBLEM OF FABRICATION OF HEAVY STRUCTURE. PROBLEM OF WORKING OUTSIDE SHOP FLOOR (OPEN AIR) FOR FABRICATION & ERECTION SPECIALLY DURING SUMMER & RAINY SEASON. BUS STAND SHED OUTSIDE THE GATE NO-2 ARE BROKEN FOR A LONG TIME. INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION. WORK RELATED PROBLEMS IN THE AREA OF DELAY A.M.C. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH, OXYGEN AND D.A. REGULATORS. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. IN SITU PREPARATION OF C-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL.
DELAY
SLIDE 16
GRSE
DISHARI-S
SLN O MAJOR PROBLEM AREA SL NO 1 2 7 ACCIDENTAL HAZARD / SAFETY HAZARD 3 4 5 WORK RELATED PROBLEMS IN THE AREA OF ACCIDENTAL HAZARD / SAFETY HAZARD CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING.. WELDING HOLDER CAUSING LOSS OF PRODUCTION AS WELL AS SAFETY HAZARD. BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPING OF DAMAGE CABLE. ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED. ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR . FREQUENT DAMAGE OF HEAD SCREEN FOR WELDING CAUSES WASTAGE. FREQUENT DISLOCATION OF ASBESTOS SHED OF SHOP DURING HEAVY STORM CAUSING SAFETY HAZARDS & WASTAGE OF MATERIALS DUE TO RAIN. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM.
6 7 8
SLIDE 17
GRSE
STEP 1( A)
DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO. 9 10 WORK RELATED PROBLEMS IN THE AREA OF ACCIDENTAL HAZARD / SAFETY HAZARD HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING ITS OPERATION CAUSES SAFETY HAZARDS. NON AVAILABILITY OF ALARM BELL IN EOT CRANE MAY CAUSES ACCIDENTAL HAZARD. INADEQUATE INSULATION OF MMAW HOLDERS CAUSES ACCIDENTAL HAZARD. CHANCES OF SAFETY HAZARD FROM VARIOUS LIFTING TACKLES LIKE WIRE SLING, VERTICAL CLAMPS, D SHACKLES ETC. WHICH ARE USED WITHOUT LOAD TESTING. GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER.
SLIDE 18
ACCIDENTAL HAZARD / SAFETY HAZARD
11 12
13
14
GRSE
DISHARI-S
SL NO MAJOR PROBLEM AREA SL. NO. 1 2 8 POLLUTION / HEALTH HAZARD 3 4 5 WORK RELATED PROBLEMS IN THE AREA OF POLLUTION / HEALTH HAZARD STAGNANT DRAINAGE WATER CAUSES UNHYGIENIC ENVIRONMENT CONDITION IN SHOP FLOOR. FLOODING OF DRESS CHANGING LOBBY ATTACHED TO SHOP DURING RAINY SEASON CAUSING LOSS OF PRODUCTION & UNHYGIENIC ATMOSPHERE. BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. FRONT SPACE OUTSIDE THE ENTRANCE GATE OF SHOP REMAINS UN CLEANED.
SL NO
9
MAJOR PROBLEM AREA

UTILIZATION
SL. NO.
1 2
WORK RELATED PROBLEMS IN THE AREA OF UTILIZATION

IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES, DRILLS, TAPS ETC. IMPROPER UTILIZATION OF CUT PIECE MATERIAL.
SLIDE 19
GRSE
DISHARI-S
SLN O MAJOR PROBLEM AREA SL. NO. WORK RELATED PROBLEMS IN THE AREA OF UTILIZATION
UTILIZATION
3
4
UNDER UTILIZATION OF HUGE QUANTITY OF SCRAP MATERIALS LIKE PLATES, ANGLE, CHANNEL ETC.
UN UTILIZATION OF BROKEN /OVER USED DRILL BITS & TAPS.
SLN O
MAJOR PROBLEM AREA
SL. NO. 1 2
WORK RELATED PROBLEMS IN THE AREA OF WASTAGE / DAMAGE DAMAGE OF WELDING TRANSFORMER, RECTIFIER MACHINES ETC. FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS. FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. DAMAGE OF ELECTRODE CARTOONS DUE TO STORING OUTSIDE FLOOR OF THE SHOP. DAMAGE OF COLUMN POST FROM CONTROLLING DRINKING WATER WASTAGE IN FRONT OF THE DEPARTMENT.
10
WASTAGE/ DAMAGE
3 4 5
WASTAGE OF END PORTION OF FILLER ROD USED IN TIG WELDING. SLIDE 20
GRSE
DISHARI-S
74 PROBLEMS IN 10- MAJOR WORK RELATED PROBLEM AREA OF A,B, C & A/K CATEGORIES (THROUGH BRAINSTORMING)
SL 1 2 PROBLEMS CHANCES OF ACCIDENTAL HAZARD FROM WELDING CABLE DURING WELDING. INSUFFICIENT LIGHT & VENTILATION IN SHOP FLOOR, ESPECIALLY WHERE PRECISION WORK TAKE PLACE. PROBLEM DURING ROLLING THE PLATE IN SHEARING MACHINE FOR SHEARING THE PLATE. REWORK FOR REMOVING DISTORTION OF HEAVY STRUCTURAL ITEMS BY PRIMITIVE MANUAL METHOD. A.M.C. SERVICE CAUSES DELAY FOR REPAIRING OF GAS CUTTING TORCH, OXYGEN AND D.A. REGULATORS. PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE. IM PROPER UTILIZATION OF HUGE QUANTITY OF UNUSABLE FILES, DRILLS, TAPS ETC. IN SITU PREPARATION OF FABRICATED CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. PROBLEM AREA ACCIDENTAL HAZARD / SAFETY DISSATISFACTION RATINGS A B
3 4
PRODUCTION LOSS RE WORK
A C
DELAY
6 7 8
PRODUCTION LOSS UTILIZATION DELAY
A C A
SLIDE 22
GRSE
DISHARI-S
SL 9 10 11 12 13 14 15 16 PROBLEMS IMPROPER UTILIZATION OF CUT PIECE MATERIAL. MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC. REWORK & FAILURE OF WELDING JOINTS FROM IMPROPER PLATE PREPARATION. WELDING HOLDER CAUSING LOSS OF PRODUCTION AS WELL AS SAFETY HAZARD. DAMAGE OF WELDING TRANSFORMER, RECTIFIER MACHINES ETC. BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPING OF DAMAGE CABLE. STAGNANT DRAINAGE WATER CAUSES UNHYGIENIC ENVIRONMENT CONDITION IN SHOP FLOOR. FLOODING OF DRESS CHANGING LOBBY ATTACHED TO SHOP DURING RAINY SEASON CAUSING LOSS OF PRODUCTION & UNHYGIENIC ATMOSPHERE. EXISTING SHOP FLOOR CONDITION CAUSES PROBLEM OF FABRICATION OF HEAVY STRUCTURE. PROBLEM OF WORKING OUTSIDE SHOP FLOOR (OPEN AIR) FOR FABRICATION & ERECTION SPECIALLY DURING SUMMER & RAINY SEASON. PROBLEM AREA UTILIZATION RE WORK RE WORK ACCIDENTAL HAZARD / SAFETY DAMAGE ACCIDENTAL HAZARD / SAFETY HEALTH HAZARD HEALTH HAZARD RATINGS A A/K A C B A/K B B
17 18
FACILITY FACILITY
C C
SLIDE 23
GRSE
DISHARI-S
SL 19 20 21 22 23 24 25 PROBLEMS UNDER UTILIZATION OF HUGE QUANTITY OF SCRAP MATERIALS LIKE PLATES, ANGLE, CHANNEL ETC. DIFFICULTY IN IDENTIFYING OUR SHOP FROM OUTSIDE BY UNKNOWN GRSE. PERSONAL/ OUTSIDERS. ACCIDENT MAY CAUSE FROM DAMAGED COLUMN BASE OF STRUCTURAL SHOP SHED. BUS STAND SHED OUTSIDE THE GATE NO-2 ARE BROKEN FOR A LONG TIME. BAD WORKING ENVIRONMENT OUT SIDE THE SHOP & UN CLEANED ROAD SIDE ADJACENT TO OUR SHOP. DIFFICULTY IN FINDING EMERGENCY TELEPHONE NUMBERS DURING ANY EMERGENCY REQUIREMENT. CRANE GIRDER OF EOT CRANE OF SHOP CAUSES SOUND POLLUTION & VIBRATION RESULTING FUSE OF FOCUSING BULBS. KIRLOSKAR MAKE GENERATOR TYPE WELDING MACHINE IS KEPT IN UN-USED FOR A LONG TIME. EXCESSIVE ENTRAPMENT OF WATER INSIDE COMPRESSED AIR HOSE PIPE, SPECIALLY DURING RAINY SEASON. INADEQUATE LIGHT & FAN IN DRESS CHANGING ROOM. PROBLEM AREA UTILIZATION HOUSE KEEPING ACCIDENTAL HAZARD/ SAFETY FACILITY HEALTH HAZARD DISSATISFACTION POLLUTION RATINGS C A/K A C A A/K B
26 27 28
HOUSE KEEPING PRODUCTION LOSS DISSATISFACTION
A A C
SLIDE 24
GRSE
DISHARI-S
SL 29 30 PROBLEMS FREQUENT DAMAGE OF FLOW METER FOR TIG WELDING BY ARGON GAS. ACCIDENTAL HAZARD & PRODUCTION LOSS MAY OCCUR FROM WELDING CABLE LINE & GAS PIPE LINE ETC. INSIDE SHOP FLOOR . FREQUENT DAMAGE OF ELECTRIC EXTENSION BOARD CAUSES ACCIDENTAL HAZARD. VOLTAGE FLUCTUATION IN WELDING MACHINE CAUSES PRODUCTION LOSS. PROBLEM FOR TACKING OF CU-NI PIPE WITH FORGED BENDS BEFORE FINAL WELDING BY TIG. INSUFFICIENT LIGHTING ARRANGEMENT NEAR RADIAL DRILLING MACHINE. EXCESSIVE ROOT GAP DURING FITTING BEFORE WELDING CAUSES REWORK. DISCONNECTION OF POWER CABLE NEAR SOLDERING JOINT DUE TO HEAT GENERATION DURING TIG WELDING CAUSES ACCIDENTAL HAZARD. PROBLEM AREA DAMAGE ACCIDENTAL HAZARD/ SAFETY DAMAGE PRODUCTION LOSS PRODUCTION LOSS DISSATISFACTION RE WORK HOUSE KEEPING RATINGS A A
31 32 33 34 35 36
B B A A/K A A
37
38
FREQUENT DAMAGE OF HEAD SCREEN FOR WELDING CAUSES WASTAGE.

HOUSE KEEPING PROBLEM OF HANDLING TIG /MIG WELDING ACCESSORIES IN DISTANT PLACE.
ACCIDENTAL HAZARD/ SAFETY

HOUSE KEEPING
C
A
SLIDE 25
GRSE
DISHARI-S
SL 39 PROBLEMS WASTAGE OF MAN POWER AS WELL AS LOW OUT PUT DURING MANUAL HUES NO. GASKET CUTTING FOR PLUMBING WORK. REWORK EXCESSIVE DEFORMATION OF STRUCTURAL PANEL AFTER WELDING. DAMAGE OF ELECTRODE CARTOONS DUE TO STORING OUTSIDE FLOOR OF THE SHOP. IMPROPER DEMARCATION FOR MATERIAL CAUSE DELAY FOR IDENTIFICATION. IMPROPER STORING ARRANGEMENT CAUSES PROBLEM FOR IDENTIFICATION OF REUSABLE MATERIAL. DAMAGE OF COLUMN POST FROM CONTROLLING DRINKING WATER WASTAGE IN FRONT OF THE DEPARTMENT. PRODUCTION LOSS DUE TO UNEVEN LEVEL OF BLACK SMITH FLOOR. FREQUENT DISLOCATION OF ASBESTOS SHED OF SHOP DURING HEAVY STORM CAUSING SAFETY HAZARDS & WASTAGE OF MATERIALS DUE TO RAIN. CHANCES OF ACCIDENTAL HAZARDS DURING HANDLING OF MATERIAL BY EOT CRANE DUE TO NON-AVAILABILITY OF ANY ALERT SYSTEM. COMMUNICATION PROBLEM DUE TO NON AVAILABILITY OF PUBLIC TELEPHONE BOOTH NEAR THE GATENO 2. PROBLEM AREA PRODUCTION LOSS RATINGS A
40 41 42 43 44
RE WORK DAMAGE HOUSE KEEPING HOUSE KEEPING DAMAGE
A C A/K A B
45 46 47
PRODUCTION LOSS SAFETY HAZARD
C B A/K
ACCIDENTAL HAZARD DISSATISFACTION
48
SLIDE 26
GRSE
DISHARI-S
SL
49
PROBLEMS
PROBLEM DUE TO NON AVAILABILITY OF PROPER STORE FOR KEEPING PERSONAL BELONGINGS OF OPERATIVE AT GATE - NO 2. PRODUCTION LOSS DUE TO FREQUENT DAMAGE OF TIG TORCH. FRONT SPACE OUTSIDE THE ENTRANCE GATE OF SHOP REMAINS UN CLEANED . HANDLES FOR HORIZONTAL ROLLER BENDING MACHINE DURING ITS OPERATION CAUSES SAFETY HAZARDS. REWORK FOR AS WELL AS WASTAGE OF MATERIAL DUE TO CONVENTIONAL METHOD OF EDGE PREPARATION & BACK GOUGING WORK FOR WELDING JOINTS. HUGE AMOUNT OF UNUSED / OBSOLETE TOOLS / MACHINE / MATERIALS OF TOOL STORE ARE KEPT IN A UN SYSTEMATIC WAY. NO SHOPS NAMEPLATE ON TOP OF MAIN ENTRANCE GATE FOR IDENTIFICATION OF SHOP. HIGH VOLTAGE SWITCH BOARDS KEPT IN A ROOM NEAR THE OUTSIDE WORKING FLOOR MAY BE DAMAGED / SHORT CIRCUITED DUE TO FALLING OF RAIN WATER THROUGH ROOF. UN UTILIZATION OF BROKEN /OVER USED DRILL BITS & TAPS.
PROBLEM AREA
SPACE
RATINGS
C
50 51 52 53
PRODUCTION LOSS HEALTH HAZARD SAFETY HAZARD REWORK
A C A/K A
54
HOUSE KEEPING
55 56
HOUSE KEEPING UTILIZATION
B B
57
UTILIZATION
SLIDE 27
GRSE
SL
58
PROBLEMS
REWORK
DISHARI-S
RATINGS
A
PROBLEM AREA
REWORK AS WELL AS DETERIORATION OF QUALITY FOR MASS PRODUCTION OF CLEATS DUE TO MANUAL BENDING DURING BREAKDOWN OF HYD. PRESS BENDING MACHINE. WASTAGE OF END PORTION OF FILLER ROD USED IN TIG WELDING. PROBLEMS DUE TO IMPROPER STORING ARRANGEMENT OF VARIOUS SPARES PARTS OF TIG /MIG & PLASMA WELDING MACHINE OF DIFFERENT MAKE. IN-SITU PREPARATION OF DOUBLERS PLATES CAUSING RE WORK & DELAY IN LAYING OF PIPES ON BOARD THE VESSEL. NON AVAILABILITY OF ALARM BELL IN EOT CRANE MAY CAUSES ACCIDENTAL HAZARD.
59 60
WASTAGE HOUSE KEEPING
B A
61
REWORK
62
ACCIDENTAL HAZARD
63
PROBLEM DUE TO SHORTER LENGTH OF REMOTE CONTROLS OF MIG & PLASMA WELD CAUSES P0RODUCTION LOSS.
UNEVEN WORKING FLOOR AREA CAUSES ACCIDENTAL HAZARD & P0RODUCTION LOSS. INADEQUATE INSULATION OF MMAW HOLDERS CAUSES ACCIDENTAL HAZARD. CHANCES OF SAFETY HAZARD FROM VARIOUS LIFTING TACKLES LIKE WIRE SLING, VERTICAL CLAMPS, D SHACKLES ETC. WHICH ARE USED WITHOUT LOAD TESTING,
PRODUCTION LOSS
PRODUCTION LOSS ACCIDENTAL HAZARD SAFETY HAZARD
64 65 66
A B B
SLIDE 28
GRSE
DISHARI-S
SL
67
PROBLEMS
EXCESSIVE DISTORTION DURING FABRICATION OF AL. PANEL FOR SUPER STRUCTURE FOR SHIP AFFECTS PRODUCTION FOR REWORK AS WELL AS QUALITY. INSUFFICIENT EXHAUST FAN AT WORKING AREA CAUSES LOSS OF PRODUCTION. GENERATION OF EXCESSIVE HEAT TO THE WELDING HOLDER WHILE WELDING WITH HIGHER GAUGE OF ELECTRODE CAUSES ACCIDENTAL HAZARD. CHANCES OF ACCIDENTAL HAZARD IN FRONT OF BOTH MAIN GATES OF OF OUR UNIT IN ABSENCE OF SPEED BREAKER. INADEQUATE CRAIN FACILITY CAUSES LOSS OF PRODUCTION. IN SITU PREPARATION OF C-CLAMP CAUSING DELAY IN LAYING OF PIPE ON BOARD THE VESSEL. REWORK AS WELL AS LOSS OF PRODUCTION DUE TO EXCESSIVE DISTORTION DURING FABRICATION OF BEAMS & GIRDERS FOR ALUMINUM PANELS OF SHIPS SUPERSTRUCTURE. ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM
PROBLEM AREA
REWORK
RATINGS
A
68 69
DISSATISFACTION ACCIDENTAL HAZARD
B B
70
ACCIDENTAL HAZARD
71 72 73
FACILITY DELAY REWORK
B A A
74
PRODUCTION LOSS
SLIDE 29
GRSE
DISHARI-S
LIFT AND TRANSPORT INDIVIDUAL PANELS BY MOBILE CRANE AND PLACED VERTICALLY AS PER POSITION ON DECK HEAD AT SITE .
ALIGN THE PANELS IN ACCURATE MARKED POSITION ON DECK HEAD, THEN TACKING/FITTING/RUNNING WELDING AND COMPLETE ERECTION OF PANELS ON DECK HEAD BLOCK.

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WELCOME QUALITY CIRCLE

CENTURY OLD GLORIOUS SHIPBUILDING ORGANISATION IN EASTERN REGION OF INDIA

FAST PATROL VESSEL

DECK MACHINERY EQUIPMENT

DIESEL MARINE ENGINE

PORTABLE BAILEY BRIDGE

DISHARI-S BRIEF HISTORY OF THE QUALITY CIRCLE

NO OF QC TEAM IN GRSE NAME / QUALITY CIRCLE NO.

NAME OF CONTACT PERSON

: SHRI K S VERMA, GM(IE&P)

AVERAGE ATTENDANCE IN THE MEETING IN THIS PERIOD

FOR VARIOUS EQUIPMENTS ETC. INCLUDING

RANKED- OUTSTANDING / EXCELLENT

RANKED- PAR EXCELLENCE /EXCELLENT

APPRECIATED RANKED- GOLD

DISHARI-S PDCA CYCLE WITH TWELVE STEPS FOR PROBLEM SOLVING

MAJOR PROBLEM AREA

PRODUCTION LOSS RE WORK

PRODUCTION LOSS UTILIZATION DELAY

DISSATISFACTION ACCIDENTAL HAZARD

FACILITY DELAY REWORK

IDENTIFICATION OF PROBLEM OUT OF 75 PROBLEMS WE HAVE ALREADY SOLVED 13 A CATEGORY PROBLEMS

(EXCLUDING CURRENT PROBLEM) & 08 NOS

5. 9. 21. 26. 33. 39. 50. 53.

MARKING CHALK CAUSES MARKING PROBLEM ON PLATES/ANGLES ETC.

BLACK TAPE CAUSES ACCIDENTAL HAZARD DURING TAPEING OF DAMAGE CABLE.

SOME OF THE IMPORTANT SOLVED PROBLEM

EXCESSIVE MANPOWER CONSUMPTION AND WASTAGE OF MATERIAL FOR GASKET CUTTING

FREQUENT DAMAGE OF TIG TORCH DURING WELDING

TOTAL NO. OF PROBLEM = 53

SELECTION OF THE PROBLEM

LIST OF A CATEGORY PROBLEM

SELECTION OF THE PROBLEMS

IMPROPER STORING ARRANGEMENT IDENTIFICATION OF REUSABLE MATERIAL.

RATING SCALE FOR E.C.T. ANALYSIS

STEP 2(C) SELECTION OF PROBLEM CHECK SHEET

DATA COLLECTION FOR THE PERIOD OF 26.11.10 TO 30.12.10

PRODUCTION LOSS WHILE WORKING AT HIGH ALTITUDE IN SHOP & SITE.

FROM SHOP & SITE

SELECTION OF PROBLEM PARETO DIAGRAM

ALUMINIUM ANGLES AS STRONG BACK OF FABRICATED ALUMINIUM PANELS CAUSES PROBLEM

TIME SCHEDULE IN WEEKS 8 9 10 11 12 13 14 15 16 17 18 19 20

FORESEEING PROBABLE RESISTANCE

11 REGULAR IMPLEMENTATION ACT 12 FOLLOW-UP ACTION & REVIEW

DEFINING THE PROBLEM

DEFINING THE PROBLEM

FINALLY WHEEL HOUSE ERECTED ON BRIDGE DECK OF SHIP

DEFINING THE PROBLEM

ERECTION OF ALUMINIUM PANELS / PARTITION WALL OF WHEEL HOUSE BLOCK AT SHIPSITE

TACKING/FITTING OF AL. ANGLES ON 4-SIDES OF FABRICATED PANELS FOR STRONG BACKING

CHECK THE DEFORMATION / DISTORTION OF ANGLE

MARKED THE DISTORTED ZONE

GRINDING & STRAIGHTENING THE AL. ANGLES BY FAIRING.

CHECK THE STRAIGHTNESS

DEFINING THE PROBLEM

DEFINING THE PROBLEM

DEFINING THE PROBLEM

DEFINING THE PROBLEM

STRAIGHTENING THE AL. ANGLES BY FAIRING.

DISHARI-S DEFINING THE PROBLEM BY FLOW DIAGRAM DISHARI-S

CHECK THE DEFORMATION / DISTORTION OF ANGLE

MARKED THE DISTORTED ZONE

GRINDING/FILING/DRESSING & STRAIGHTENING THE AL. ANGLES BY FAIRING.