“ A STUDY ON UPSHOT OF LEAN SIX SIGMA IN THE NEGATIVE

DOWNTIME REDUCTION IN TI ROLLFORMING MILL”

PROJECT REPORT

SUBMITTED TO UNIVERSITY OF MADRAS

IN PARTIAL FULLFILLMENT FOR THE DEGREE OF
MASTER OF BUSINESS ADMINISTRATION
Submitted By

NAME: S.JEYAKUMAR

ENROLMENT NUMBER: A17101PBO6322

Under the guidance of

Prof. K.RAVIKUMAR, M.COM, M.B.A, M.Phil, (Ph.D)

ASSISTANT PROFESSOR
DEPARTMENT OF MANAGEMENT STUDIES
SRM ARTS AND SCIENCE COLLEGE
KATTANKULATHUR-603203

INSTITUTE OF DISTANCE EDUCATION

UNIVERSITY OF MADRAS

JUNE- 2019
Prof. K.RAVIKUMAR, M.COM, M.B.A, M.Phil(Ph.D)
ASSISTANT PROFESSOR
DEPARTMENT OF MANAGEMENT STUDIES
SRM ARTS AND SCIENCE COLLEGE
KATTANKULATHUR-603203

BONAFIDE CERTIFICATE
INSTITUTE OF DISTANCE EDUCATION
UNIVERSITY OF MADRAS

Certified that this is the bonafide project work done by S.JEYAKUMAR with enrolment
number A17101PBO6322 of final year of M.B.A (Operation Management) degree
course in the institute of distance Education, University of madras Chennai-600005
during the year 2019

DATE: Guide
(Signature with seal)
 DECLARATION

I hereby declare that the dissertation entitled ““ A STUDY ON UPSHOT OF

LEAN SIX SIGMA IN THE NEGATIVE DOWNTIME REDUCTION

IN TI ROLLFORMING MILL”submitted for the degree of Master of business
administration is my original work and the dissertation has not formed the basis for
the award of any degree ,diploma, associate ship, fellowship, or similar other titles. It
has not been submitted to any other university or institution for the award of any degree
or diploma.

Date: S.JEYAKUMAR

Place: A17101PBO6322
 ACKNOWLEDGEMENT

First and foremost, I thank almighty for enabling me to continue my M.B.A course
under THE DIRECTOR, INSTITUTE DISTANCE EDUCATION, UNIVERSITY
MADRAS, CHENNAI.

I extend my gratitude and profound thanks to Dr B. DEVAMAINDHAN, B.E., M.B.A,

ASSOCIATE PROFESSOR, MANAGEMENT STUDIES IDE, UNIVERSITY OF
MADRAS for providing a great opportunity to do this project.

I extend my gratitude and profound thanks to my guide and supervisor

Prof.K.RAVIKUMAR, M.COM, M.B.A, M.Phil (Ph.D), ASSISTANT PROFESSOR,
DEPARTMENT OF MANAGEMENT STUDIES, SRM ARTS AND SCIENCE
COLLEGE, KATTANKULATHUR-603203, who encouraged me for shaping up this
project.
I sincerely thank TI ROLLFORMING MILL for providing me an opportunity to
undertake this project in the organization.

I sincerely thank to my wife Dr.V.KIRUTHIGA for supporting me to complete this

project successfully.

S.JEYAKUMAR
A17101PBO6322
 TABLE OF CONTENTS

S.NO TITLE Page No

ABSTRACT 1
CHAPTER 1 INTRODUCTION 2
1.1 INDUSTRY PROFILE 3
1.2 COMPANY PROFILE 6
1.3 STATEMENT OF THE PROBLEM 10
1.4 SCOPE OF THE STUDY 10
1.5 OBJECTIVE OF THE STUDY 11
1.6 NEED FOR THE STUDY 11
1.7 LIMITATION OF THE STUDY 11
CHAPTER 2 PRODUCT OVERVIEW 12
2.1 ROLLING MILL DEFINATION 13
2.2 PROCESS TERMINALOGY 14
2.3 CLASIFICATION OF ROLLING MILL 15
CHAPTER 3 RESEARCH METHODOLOGY 21
3.1 AREA 22
3.2 TIME SPAN 22
3.3 HYPOTHESIS 22
3.4 DATA COLLECTION 23
3.5 INSTRUMENT 24
3.6 TOOLS USED FOR ANALYSIS 24
CHAPTER 4 DATA ANALYSIS AND INTERPRETATION 26
4.1 DEFINE 27
4.2 MEASURE 28
4.3 ANALYSE 34
CHAPTER 5 INTERPRETATION & FINDINGS 46
5.1 DATA INTERPRETATION 47
5.1.1 IMPROVE 47
5.2 MAJOR FINDINGS 49
CHAPTER 6 SUGGESTIONS & CONCLUSION 54
Table No. List of Tables Page No.
4.1 Downtime month wise overall 27
4.2 Brainstorming 28
4.3 Analysis of rolling mill downtime 29
4.4 Downtime for last three months 30
4.5 Control Impact Matrix for Rolling Mill for Shaft broken 32
Control Impact Matrix for Rolling Mill for Lip
4.6 waviness 33
Control Impact Matrix for Rolling Mill for Cutting tool
4.7 breakdown 33
4.8 Housing bush worn out –T Test 34
4.9a ANOVA 35
4.9b ANOVA 35
4.9c ANOVA 35
4.10 Shaft Broken-High manual setting pressure 36
4.11a Heavy load act- Box plot chart 37
4.11b Heavy load act- Box plot chart 37
4.12a Re usage of broken rollers - Box plot 38
4.12b Box plot 38
4.13 Excess gate clearance Cp & Cpk calculator 39
4.14a Lip waviness – Operator skill—ANOVA 40
4.14b ANOVA 40
4.14c ANOVA 40
4.15 Cutting tool b/d – Slug / burr sticking-T test 41
4.16 Cutting tool b/d – cutting dent-Cp & Cpk calculator 42
Cutting tool b/d – Punch & die clearance problem--: T
4.17 test 43
4.18a Cutting tool b/d– Operator skill -ANOVA 44
4.18b ANOVA 44
4.18c ANOVA 44
4.19 Cutting tool b/d – Depreciation of Punch broken-T test 45
5.1 Summary of analysis 47
Table No. List of Figures Page No.
2.1 Type of Rolling 19
2.2 Flat rolling process 19
2.3 a TI Mudguard rolling mill 20
2.3b TI Mudguard rolling mill 20
4.1 Downtime month wise overall 27
4.2 Fishbone Diagram 28
4.3 Analysis of rolling mill downtime 29
4.4 Down time for last three months 30
4.5 Fish bone diagram for Shaft Broken diagram 31
4.6 Fish bone diagram for cutting tool diagram 31
4.7 Fish bone diagram for Lip Waviness diagram 32
4.8 Matrix 34
4.9 Box plot chart 37
4.10 Box plot chart 38
5.1 Shaft broken-Manual pressure high 47
5.2 Shaft broken-heavy load 47
5.3 Shaft broken-Re-usage of broken rollers 48
5.4 Root cause analysis for Lip waviness 48
5.5 Root cause analysis for cutting b/d 49
5.6 Negative downtime reduction 49
5.7 Downtime reduction 50
5.8 Shaft Broken-Reduction trend 50
5.9 Cutting tool b/d Reduction 51
5.10 Downtime reduction-lip waviness-Reduction trend 51
5.11 Rolling scrap Reduction 51
5.12 OEE Improvement 52
5.13 Productivity Improvement 52