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Six Sigma: Modification of Qa Procedure of FRP Shelter' Against Op Task Orders For Issue of Inspection Note
Six Sigma: Modification of Qa Procedure of FRP Shelter' Against Op Task Orders For Issue of Inspection Note
PROJECT TITLE :
MODIFICATION OF QA PROCEDURE OF
FRP SHELTER AGAINST OP TASK ORDERS
FOR ISSUE OF INSPECTION NOTE
PROJECT BY : COL VV KADAM
SIX SIGMA
PROJECT TITLE :
MODIFICATION OF QA PROCEDURE OF
FRP SHELTER AGAINST OP TASK ORDERS
FOR ISSUE OF INSPECTION NOTE
PROJECT BY : COL VV KADAM
AND
TEAM FROM
SQAE (E)
MUMBAI
CONTENTS
*
Introduction
*
Define Phase
*
Measure Phase
*
Analyze Phase
*
Improve Phase
*
Control Phase
*
Benefits & Future
Recommendations
D MAI C
Introduction & Define
Project Charter
D MAI C
D MAI C
D MAI C
Currently the average total time for issue of I-note
on completion of QA of FRP shelters from date of
offer / receipt of QA call letter by SQAE (E) Mumbai
is 34 days which has been obtained from data held.
The order placing authority i.e. HQ 15 Corps /
HQ 14 Corps and Engineer Regiments used to
express their urgency due to their programme and
climatic condition prevailing and insisted to shorten
the QA check and clear the lot at the earliest, so the
stores can reach them before the road gets blocked
at high altitudes due to winter snow fall. Moreover,
they further require some time for erection of these
shelters before winter sets in.
D MAI C
The procedure of manufacturing of FRP shelters are is
as follows :
Preparation of moulds as per drawing.
The 4-6 men shelter requires 69 moulds and
8-10 men shelters requires 75 moulds.
Mobilisation of Raw material like Resin, Gel Coat,
Chop strand Mat (CSM), Woven Roving (WR), etc.
Procurement of accessories like a) Flower picket duly heat treated at show end
b) Hardware / Fasteners duly galvanized
c) Repair kit
d) Electrical installations
D MAI C
e) Bath room / Toilet Chamber accessories and
fittings
f) Various tools
Hand Laying of Male/Female moulds of panels
as per S/o requirements.
D MAI C
QA OF BULK SUPPLY :
The procedure of QA check for Bulk supply,
carried out before issue of I-note, as under :
Quantity Check : Total qty of panels as per shelter as
offered are required to be checked.
Visual Inspection : Completeness , workmanship,
proper fitment after sealing are checked.
Dimensional Check : Dimensional check as per
drawing.
Checking of panels in erected condition for delamination, and splits.
Weighment check
Repair of panels where there are rejection due to delamination and splits.
Recheck of repaired panels.
Checking of spares , accessories & tools.
Release and despatch of shelters and Quality
Assurance records.
D MAI C
If the checks are found to conform as per governing
drawings and specification, the panels are required to be
stamped by concerned QA staff. Thereafter , preparation of
QA report and finally issue of acceptance Inspection Note.
D MAI C
PROJECT CHARTER
Source : Customer i.e. consignee / user complaints
External customer (firms) complaints
Directive from Higher HQs
Potential savings from the project :
Characteristics : Total clearance time (TCT)
Measures : Time in days for TCT ( LC = 1 day )
Defect Definition : Any clearance letter / issue of I-note
taking more than 10
days is
considered as a
defect.
D MAI C
TOTAL CLEARANCE TIME
T C T (Y) = Detailment of QA Team for Raw material check
( T1)
+ Time required for Lamination preparation ( T2)
+ Forwarding of samples to Lab (T3)
+ Receipt of Test Results (T4)
+ Detailment of QA Team (T5)
+ Returned of stores for repair (T6)
+ Detailment of QA Team (T7)
+ Second / Third Tier QA (T8)
+ Stamping & sealing (T9)
+ Preparation of QA report and Issue of I-note
(T10)
D MAI C
SIPOC
Supplier
Input
Process
Output
Customer
Firm
Delivery
Schedule
QA of Bulk
Supply
Issue of
I -Note
Firm
QA Staff
Availability
Laboratory
Test Results
HQs /
AHSP
Authorisation /
Directives /
Tech Specn
AHSP / DGQA
Offer of
Raw
Material
Raw
Material
testing
Offer
of bulk
QA
check
2nd Tier/
3rd Tier
QA check
Preparation
of QA
Report
Issue of
I-Note
CTQ Tree
Need
Reduce the
Total Time
for
clearance
of FRP
Shelters
Drivers
Total
Clearance
Time
D MAI C
Sub-Drivers
CTTs
Time (T1)
Lamination Preparation
Time (T2)
Time (T3)
Time (T4)
Time (T5)
Time (T6)
Time (T7)
Time (T8)
Time (T9)
Issue of I/Notes
Time (T10)
QA STAFF
D MAI C
D MAI C
Start
DETAILMENT OF QA TEAM
COMENCEMENT OF QA
QA CHECK
TESTING OF SAMPLES
SECOND/THIRD TIER QA CHECK
STAMPING OF BUNDLES
PREPARATION OF QA REPORT & ISSUE OF I/NOTE
End
End
DMAIC
MEASURE
D MAI C
DETAILS OF DELIVERY SCHEDULES OF S/Os OF
2006
Srl
No.
Recd.
On
Item
DD of
Bulk
Total
No. of
days
1011/14CORPS/60/O
T DT. 18.07.06
27.07.
06
FRP Shelter 8 10
Men 01 No.
24.08.20
06
29
1011/14CORPS//OT
DT. 22.07.06
11.09.
06
FRP Shelter 4 6
Men
11 No.
09.10.20
06
29
1400/Job 537/SO/15/
OW DT. 18.07.06
28.07.
06
FRP Shelter 8 10
Men 03 Nos
30.08.20
06
34
1011/14CORPS/58/O
T DT. 18.07.06
28.07.
06
FRP Toilet
28 Nos.
30.08.20
06
34
50298/SO/05-06/21/
OPW DT. 27.02.06
21.03.
06
25.04.06
36
1011/14CORPS/147/
OT DT. 23.02.06
21.03.
06
FRP Shelter 8 10
Men 15 Nos.
20.04.06
31
1011/14CORPS/73/O
T DT. 23.07.06
11.09.
06
FRP Toilet
84 Nos
09.10.06
29
1011/14CORPS/72/O
T DT. 23.07.06
11.09.
06
FRP Shelter 8 10
Men
09.10.06
29
50298/SO/06-07/84/
OPW DT. 26.07.06
11.09.
06
20.10.06
40
D MAI C
2007
Srl
No.
Recd. On
Item
DD of Bulk
Total No.
of days
1011/14CORPS/06/OT DT.
28.05.07
10.07.07
FRP Toilet
20 Nos
29.09.07
81
50298/SO/07-08/63/
OPW dt. 13.07.07
24.08.07
FRP Toilet
19 Nos
25.09.07
32
1011/14 Corps/10/OT
Dt. 14.06.07
10.07.07
FRP Toilet
82 Nos
29.09.07
81
50298/SO/07-08/85/
OPW dt. 11.08.07
17.09.07
10.10.07
24
10.07.07
13.10.07
96
50298/SO/07-08/86/
OPW dt. 11.08.07
17.09.07
10.10.07
24
50298/SO/07-08/18/
OPW dt. 10.06.07
24.08.07
15.09.07
23
1011/14 Corps/04/OT
Dt. 28.05.07
10.07.07
13.10.07
96
1011/14 Corps/12/OT
Dt. 14.06.07
10.07.07
29.09.07
81
D MAI C
DETAILS OF DELIVERY SCHEDULES OF S/Os OF
2008
Srl
No.
Recd. On
Item
DD of Bulk
Total
No. of
days
8040/SO/2008-09/02/
OPW Dt. 14.06.08
21.07.08
10.08.08
21
8040/SO/2008-09/01/
OPW Dt. 14.06.08
21.07.08
10.08.08
21
3531/SO/28 ID/08-09/
13/Engrs dt. 16.05.08
06.06.08
20.08.08
76
3531/SO/28ID/12/Engrs
dt. 16.05.08
06.06.08
20.08.08
76
3531/SO/19 ID/08-09/
03/Engrs dt. 16.05.08
06.06.08
20.08.08
76
3531/SO/CT/08-09/ 2/
Engrs dt. 16.05.08
30.05.08
20.08.08
83
3531/SO/CT/08-09/01/
Engrs dt. 16.05.08
30.05.08
FRP Shelter 4 6
Men
07 Nos
20.08.08
83
D MAI C
TIME TAKEN FOR ISSUE OF I/NOTE FOR S/Os IN 2006
Sr
N
o.
Call
Letter
Recd on
Raw
material
sent to
Lab on
Test
Report
received
on
Days
taken for
clearance
of Raw
material
Stores
offered on
( Qty )
Stores
insp. On
2 Tier /
3 Tier Insp
completed
on
I Note
issued on
28.02.06
10.03.06
19.03.06
24.02.06
10.03.06
28.07.06
Days
taken for
issue of
I-Note
20
19.03.06
(05)
23.03.06
(05)
23.03.06
(05)
22.03.06
25.03.06
29.03.06
24.03.06
29.03.06
01.04.06
24.03.06
31.03.06
03.04.06
06/25
13/31
16/35
19.03.06
24
23.03.06
(03)
25.03.06
26.03.06
27.03.06
09/32
02.08.06
14.08.06
18
05.10.06
(28)
11.10.06
13.10.06
13.10.06
09/50
28.07.06
02.08.06
14.08.06
18
27.12.06
(03)
05.01.07
08.01.07
08.01.07
13/147
21.09.06
05.10.06
13.10.06
23
20.11.06
(06)
02.12.06
(05)
23.11.06
06.12.06
28.11.06
11.12.06
29.11.06
11.12.06
10/47
10/59
28.07.06
02.08.06
14.08.06
18
12.09.06
(01)
19.09.06
22.09.06
22.09.06
11/40
D MAI C
TIME TAKEN FOR ISSUE OF I/NOTE FOR S/Os IN 2006
7 21.09.06
05.10.06
13.10.06
23
18.10.06 (01)
30.10.06 (10)
20.11.06 (15)
02.12.06 (15)
19.12.06 (10)
26.12.06 (24)
19.10.06
09.11.06
24.11.06
07.12.06
14.12.06
27.12.06
23.10.06
14.11.06
28.11.06
11.12.06
20.12.06
29.12.06
23.10.06
15.11.06
29.11.06
11.12.06
21.12.06
29.12.06
06/33
17/56
10/70
10/82
03/92
04/100
8 12.09.06
21.09.06
18.09.06
05.10.06
26.09.06
13.10.06
15
23
12.09.06 (04)
05.10.06 (10)
30.10.06 (10)
02.12.06 (06)
19.12.06 (05)
26.12.06 (06)
27.12.06 (12)
18.09.06
16.10.06
03.11.06
14.12.06
19.12.06
27.12.06
01.01.07
22.09.06
21.10.06
15.11.06
18.12.06
20.12.06
29.12.06
03.01.07
22.09.06
23.10.06
15.11.06
19.12.06
21.12.06
29.12.06
04.01.07
11/00
19/33
16/56
18/90
03/92
04/100
09/105
9 21.09.06
05.10.06
13.10.06
23
27.12.06 (08)
02.01.07
04.01.07
05.01.07
10/106
D MAI C
Sr
l
N
o.
Call
Letter
Recd
on
Raw
material
sent to
Lab on
Test
Report
received
on
Days
taken
for
cleara
nce of
Raw
materi
al
Stores offered
on
(Qty )
Stores
insp. On
2 Tire /
3 Tire
complet
ed on
I Note
issued
on
Days
taken
for
issue
of INote
10.07.07
17.07.07
01.08.07
22
29.08.07 (05)
07.09.07
08.09.07
10.09.07
13/63
10.07.07
17.07.07
01.08.07
22
04.09.07 (10)
11.09.07
13.09.07
14.09.07
11/67
10.07.07
17.07.07
01.08.07
22
12.09.07 (10)
17.09.06
19.09.07
19.09.07
08/72
10.07.07
17.07.07
01.08.07
22
24.09.07 (30)
29.09.07
0510.07
05.10.07
12/88
10.07.07
17.07.07
03.08.07
24
12.09.07 (05)
25.09.07
27.09.07
27.09.07
16/80
10.07.07
17.07.07
03.08.07
24
25.09.07 (06)
28.09.07
01.10.07
01.10.07
07/84
10.07.07
17.07.07
03.08.07
24
24.08.07 (05)
05.09.07
06.09.07
07.09.07
14/60
10.07.07
17.07.07
03.08.07
24
04.09.07 (10)
15.09.07
17.09.07
18.09.07
15/71
10.07.07
17.07.07
03.08.07
24
12.09.07 (10)
25.09.07
26.09.07
27.09.07
16/80
D MAI C
TIME TAKEN FOR ISSUE OF I/NOTE FOR S/Os IN 2008
Sr
N
o.
Call
Letter
Recd on
Raw
material
sent to
Lab on
Test
Report
received
on
Days
taken for
clearance
of Raw
material
Stores
offered on
(Qty)
Stores
insp. On
2 Tire /
3 Tire Insp
completed
on
I
Note
issued
on
Days
taken for
issue of
I-Note
29.05.08
06.06.08
20.06.08
23
20.07.08
(07)
22.07.08
30.07.08
31.07.
08
12/64
29.05.08
06.06.08
20.06.08
23
15.07.08
(09)
18.07.08
19.07.08
21.07.
08
07/54
29.05.08
06.06.08
20.06.08
23
17.07.08
(02)
18.07.08
19.07.08
21.07.
08
05/54
06.06.08
06.06.08
20.06.08
15
20.07.08
(06)
22.07.08
30.07.08
31.07.
08
12/56
06.06.08
06.06.08
20.06.08
15
21.07.08
(14)
22.07.08
25.07.08
26.07.
08
06/51
11.07.08
25.07.08
04.08.08
25
05.08.08
(10)
06.08.08
09.08.08
11.08.0
8
07/67
24.07.08
25.07.08
04.08.08
11
05.08.08
(15)
06.08.08
09.08.08
11.08.0
8
07/67
D MAI C
PROCESS FLOW CHART
Start
D MAI C
D MAI C
5.15 days
1 day
5 days
1 day
1 day
34.15 = 34 days
D MAI C
DESCRIPTIVE STATISTICS
D MAI C
EVALUATION
Process
Inspection of Bulk Store
Product of the process I-Note
Metric
No. of days taken for issue of
Standard
Max 10 days
No. of I-Note issued
25
No. of I-Note issued within 7 days
Nil
No. of potential action leading 10
to/create defect
The Yield for process 0/25 =0
Defect Rate
I-Note
D MAI C
Sample
Size (n)
25
PPM
Sigma
Level
Zero
D MAI C
DMAIC
ANALYSE
DMAIC
DMAIC
Overloading of QA Staff
Task allocation non systematic
TOOLS
MAN
Overloading of
available
manpower.
High
Clearance
Time for
Issue of INote for
bulk Supply
DMAIC
BRAIN STORMING
A detailed brain storming was done
with the following present
Firm Management Rep and Manager QC
SQAO
QAO
QA Staff ( 12 Nos )
BRAIN STORMING
DMAIC
DMAIC
DMAIC
DMAIC
DMAIC
D MAI C
3.5 days
1 day
Nil
3 days
1 day
1 day
9.5 = 10 days
D MAI C
EVALUATION
Process
Inspection of Bulk Store
Product of the process I-Note
Metric
No. of days taken for issue of
Standard
Max 10 days
No. of I-Note issued
25
No. of I-Note issued within 10 days
14
No. of potential action leading 10
to/create defect
The Yield for process 14/25 =0.56
Defect Rate
1-0.56 = 0.44
I-Note
D MAI C
Sample
Size (n)
PPM
Sigma
Level
25
4400
3.2
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