Quality Circle

5 STAR
1
Vision Mission Core value

Location – Maraimalai nagar

BUSSINESS TYPE – Auto Ancillary

MD - MR. RAM VENKATARAMANI

MAIN PRODUCT – Hot forging

IP RINGS LTD
PRODUCTION CAPACITY – 1 Million / Month

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 Company Brief Introduction

Company Name IP RINGS LTD. (OCF – Division)

Location Maraimalai Nagar, Chennai.
Established ( Year) 1991

Bevel Gear Pole wheel Synchrocone Cam Ring Gear shift sleeve Shaft Bevel Gear

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 CUSTOMERS

Hyundai Tata Motors FORD Maruti Ashok Leyland Eicher

Simpson Enfield Mahindra & Mahindra Hindustan Motors TVS Motors

ILJIN TATA BAJAJ Man Truck India: HCV TAFE

Daimler DANA PIAGGIO Kurushethra Agriking

After Market STANADYNE

India Pistons

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5
 v QUALITY CIRCLE CFT

KUMARAN K ATHIBAN V

COORDINATOR FACILITATOR

SURESH S

LEADER

ALWIN
J SATHISH SATHISH DHARMA RANJITH CHANDRU
PETER

TEAM MEMBERS
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v Steps in Quality circle methodology
Identification
of Problems
Selection of
1 the Problem
Follow Up and
review
12 2 Define the
Problem
3
Regular
implementatio
11
n Analysis of the
4 Problem

Identification
5 of Causes
LOGO
10
Trial
implementation &
Check performance

6
Finding out the
Root causes

9
Foreseeing
Probable
Resistance
8 7
Developing Data Analysis
Solution 7
 JULY‘23 AUG’23 SEPTEMBER’23
SI NO Action Plan
1W 2W 3W 4W 1W 2W 3W 4W 1W 2W 3W 4W
P
1 Identification of Problems
a
P
2 Selection of the Problem
A
P
3 Define the Problem
A
P
4 Analysis of the Problem
A
P
5 Identification of Causes
A
P
6 Finding out the Root causes
A
P
7 Data Analysis
a
P
8 Developing Solution
A
P
9 Foreseeing Probable Resistance
A

Trial implementation & Check P

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performance A
P
11 Regular implementation
A
P 8
12 Follow Up and review
A
Morning Market Meeting (Quality)

Team Brainstorming

Identification of the problem

By In-House data

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IDENTIFY & CATEGORY OF PROBLEMS – Part No.328

Category
S.NO. Problem Description
A B C
1 Bore over size P
2 Datum under size P
3 Bore Line Mark P
4 Bore Unclear P

v “A” category is the Problems which can be solved by SGA Members.

v “B” Category is the Problems which needs other department help

to solve.
v “C” Category is the Problems which requires management help
to solve.

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11
 HARDTURN PART NO.328 – DEFECT WISE

BORE OVER SIZE DATUM UNDER SIZE BORE LINE BORE UNCLEAR
325
290 294

149

105

55

10 4 20 16

Apr-23 May-23 Jun-23 Jul-23

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Part No.328 is a low tolerance component (Bore Spec:12.002 - 12.015 mm) and in that
bore over size rejection is a major problem.So we have chosen 328 bore over size as our
problem.
99% 100% 100% 100%
1200
83% 90%

1000 80%
70%
800 60%
50%
600
1058 40%
400 30%
20%
200
196 10%
10 4
0 0%
BORE OVER SIZE DATUM UNDER SIZE BORE LINE BORE UNCLEAR

HARDTURN PART NO.328 – DEFECT WISE-PARETO ANALYSIS (APRIL 2023-JULY-2023)

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 WHAT ? Bore oversize in Part no.328

HOW MUCH ? 13,388 PPM

WHEN ? JUNE-2023

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Process Flow Diagram – Gear &Pinion Manufacturing – OCF Plant 2
Shot blasting Deburring Hard Turn

Selected Area
for
Heat Improvement
Treatment

Despatch Packing PDI Final

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 Brainstorming on Possible causes

After brainstorming session, we have identified the following possible causes.

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CAUSE & EFFECT DIAGRAM

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S. No Possible Causes Validation / Verification Result

Verified during production and found Significant

1
three numbers defects

Using re-lapped inserts during Gemba

2 Usage of Significant
visit.

Inspection might be Skipped at any Significant

3 Inspection Skipped
shift

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S. No Possible Causes Validation / Verification Result

Verify the clamping process and found

4 Insignificant
ok.

During Gemba visit, insert was found Insignificant

5
to be in good condition

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S. No Possible Causes Validation / Verification Result

Verified the ring master with Air Insignificant

6
gauge.

VerifIed the before stock and found

7 Insignificant
Ok.

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 Why - Why Analysis for Wrong Offset

Wrong offset given by operator 0.050 instead of

0.005

Operator was not aware of offset.

Insufficient training

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 Why-Why Analysis for using Re-lapped inserts

Low tolerance component (12 Microns)

Size variation is coming while the machine is

running.

Operator couldn’t give offset as like fresh inserts.

Re-lapped insert not fitting properly inside the tool

holder

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 Why – Why Analysis for Operator Skipping Inspection

Operator has Skipped inspection

Operator has not followed Quality plan

Operator has low skills

Insufficient Training

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 BORE OVERSIZE QUANTITY FROM MARCH,2023 TO JULY,2023
350 325
290 294
300
250
250
QUANTITY

200
149
150

100

50

0
Mar-23 Apr-23 May-23 Jun-23 Jul-23
MONTH 25
• Macro Implementation to control offsets ( Max 10 microns at a time adding up
to 30 microns maximum)
• Using Fresh inserts instead of Re-lapped inserts.
• Implementing Auto Offset Correction(AOC).
• Machine should only be run by regular operator and the adequate training must
be given to new operators.

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 SOLUTIONS PROBABABLE RESISTANCES

NO RESISTANCES AND WE HAVEN’T

AUTO OFFET CORRECTION(AOC) FACED ANY PROBLEMS RELATED TO
QUALITY AND PRODUCTIVITY.

NO RESISTANCES AND WE HAVEN’T

FACED ANY PROBLEMS RELATED TO
MACRO IMPLEMENTATION
QUALITY AND PRODUCTIVITY.

NO RESISTANCES AND WE HAVEN’T

FACED ANY PROBLEMS RELATED TO
FRESH INSERTS
QUALITY AND PRODUCTIVITY.

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 Macro Implementation

• Macro has implemented to control offsets • An alarm has been set to indicate if the given
(Max 10 microns at a time adding up to 30 offset is more than 10 microns(0.01 mm)
microns maximum)

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 Auto Offset Correction(AOC) Implementation

• Auto Offset Correction(AOC) has been implemented to give auto offsets based on the previous job
that ran on the machine and the CNC machine is interlocked with AOC.

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RE-LAPPED INSERT FRESH INSERT

NO GAP
GAP

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 BORE OVERSIZE QUANTITY FROM JUNE,2023 TO OCTOBER,2023

QUANTITY
325
264
149
63
9
JUN-23 JUL-23 AUG-23 SEP-23 OCT-23
MONTH

BEFORE QC AFTER QC

vFrom the above graph, the bore oversized jobs was 9 Nos for the month of
October and the PPM for the month of October has came down to less than 400
PPM.
vAnd from the above graph we can notice the significant reduction in bore over
size defects due to the implementations we have done.
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• Auto Offset Correction (AOC) & Macro offset are implemented in the CNC
machine and training has given to the concerned CNC operators, Cell leaders,
Quality department and Production team .

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• Implemented solutions are being monitored continuously through Daily trend
graph and data’s are being recorded on a daily basis.

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Cost benefits:-
PRICE OF A 328 PINION :- Rs.48

August Month Bore over size scrap value :- 264(Quantity) * 48(Price) = Rs.12,672 (A)
September Month Bore over size scrap value :- 63(Quantity) * 48(Price) = Rs.3024 (B)
October Month Bore over size scrap value :- 9(Quantity) * 48(Price) = Rs.432 (C)

Cost savings = A-C = Rs.12,672 – Rs.432 = Rs.12,240 per month

The projected cost savings per year will be Rs.1,46,480.

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Intangible benefits:-

1. Opportunity to attain knowledge

2. Self-development
3. Leadership
4. Organizational benefits.
5. Healthy working environment

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