About us…..

Napino Auto & Electronics Ltd. is a focused and

dynamic company committed to achieving
enhanced value for its customers in the field of
auto electrical and electronic products.
Our Partners
U.V.,GURGAON
Napino is a joint venture company with
Shindengen Electric Manufacturing Company of
Japan, who are world leaders in the field of Power
and Auto Electronic Products.

IMT,MANESAR HARIDWAR IMT SEC. 8

Our Products

Capacitor Regulator Rectifier Silicon Rectifier Wire Harness for

Discharge Igniter Four Wheeler

Combination Resistor Sub Wiring Main wiring

Switch Assembly Harness Harness
ACHIEVEMENTS, MEMBERSHIPS & STANDARDS

QS 9000 Certified as Direct-On-Line Supplier for HMCL EMS ISO 14001:20004 OHSAS 18001:2007
TS 16949:2009

Membership with ACMA

First Prize – ELCINA IMEA 2005 Platinum Award International Arch of Europe Confederation of Indian Industry.
Presented by Frost & Sullivan Award for Quality & Technology
“BUSINESS CII Membership No: N1044P
in the Gold Category by BID,
EXCELLENCE” AWARD
Spain
2005-06 Membership with CII

QCDDM Award for Best Supplier of

the year 2006-2007 in the Electrical
Award for being the Best Vendor of Hero Honda Membership with
ACMA AWARD Category by HMSI
Presented by President, Honda Motor Co. Japan Gurgaon Industrial Association
 INTRODUCTION QC No. : H-10
FORMATION OF QUALITY CIRCLE TEAM – 10.03.2008
TEAM NAME : SARAL
LEADER MEMBERS

Mr. SANJAY Mr. VINOD Mr. SAHIL Mr. SUNIL Mr. HIMANSHU
GUIDE & FACILITATOR
SLOGAN
To achieve the target by
innovative thinking and
Mr. ANAND ASRANI Mr. ASHISH KULSHRESTHA implementing new ideas
for customer delight
Meeting Day/Time :
COORDINATOR -
WEDNESDAY at 16:00 to 17:00 Hrs
Mr. AMIT
CHAUHAN
 PREVIOUS WORK MAY - 08 TO APRIL - 13
PROBLEM
S. NO. FROM TO TARGET ACHIEVED STATUS
DESCRIPTION

PRODUCTIVITY
1 IMPROVEMENT IN AWP May-09 July-09 2000 PCS 2050 PCS. DONE

6.4 F TERMINAL LOCK

2 REVERCE BEND May-10 Aug-10 0 PCS O PCS DONE
REJECTION ELIMINATION

TO ELIMINAT HIGH
3 CORE & LOW CORE Sep-11 Dec-11 0 PCS OPCS DONE
PROBLEM

PRODUCTIVITY
4 Apr-12 July-12 2125 PCS 2150 PCS DONE
IMPROVEMENT IN AWP

MACHINE PRESS BREAK 50% 50% 50%

5 Apr-13 July-13
DOWN REDUCED Decreased Decreased Decreased
• Regular Implementation &
Standardization
• Follow Up & Review
• Project Reconciliation
• Review Achievement
• Future Plans
• Acknowledgement
A P
• Problem Identification
• Define Problem & Goal
• Problem Analysis
• Identify Probable Causes
• Root Causes & Data Analysis
• Developing Solutions

C D
• Identify Monitor • Design Of Experiment
Process • Implement Corrective
• Check Performance & Actions
Results • Anticipated Probable
• Review Results Resistance
• Confirm Results • Trial Implementation
STEPS FOLLOWED…..
1. Identification of work related problems
2. Selection of Problem
3. Define the Problem
4. Analyze the Problem
5. Identification Of Causes
6. Find Out the Root Causes
7. Data Analysis for root cause validation
8. Developing Solutions
9. Foreseeing Probable Resistance
10. Trial Implementation & check
performance
11. Regular Implementation
12. Follow up / Review
 ACTIVITY PLAN
Quality Circle Name : Department Facilitator MEMBER’S NAME
SARAL Production(AWP) Mr. ASHISH KULSHRESTHA VINOD SAINI
Project : TO INCREASE THE Reason for selection : EXCESS STOPPAGE IN AWP AREA SANJAY
PRODUCTIVITY LEVEL IN SAHIL
AWP
HIMANSHU
Meeting Day : Wednesday SUNIL
Time : 4:00 to 05:00
pm Date of beginning 01/05/2015 Date of completion:31/07/2015

MAY JUNE JULY

No. Activity Responsibility
WK I WK 2 WK 3 WK 4 WK I WK 2 WK 3 WK 4 WK I WK 2 WK 3 WK 4

1 Identification of problems P All Members

2 Selection of problem p All Members

3 Defining the problem P All Members

4 Analysis of problem D All Members

5 Root cause analysis D All Members

6 Finding out the root causes D All Members

7 Data analysis D All Members

8 Developing solution D All Members

Foreseeing probable D All Members

9
resistance

10 PLAN
Trial implementation and
checking performance
C All Members
 IDENTIFICATION OF PROBLEM
1 Improper feeding of material 18 No packing standard of wire 35 Shortage of load tester
Less quantity found in wire and
2 Wastage of terminal 19 36 More sound in awp area
terminal
3 Wastage of wire 20 Terminal plating problem 37 More consumption of feeding wheel
4 Excessive material on line 21 Improper crimping 38 Terminal lock press during process
5 Wastage of water proof seal 22 Terminal face damage 39 Chips cutter not proper work
Wrong identification job card on wire
6 23 Applicator clamping plate tilt 40 Wire stuck during process
bunch
7 Mixing problem in produced wire 24 Improper seal insertion 41 Exclusive spare part inventory
8 Improper storage of raw material 25 Air pressure drop age 42 Awp staff area covered
9 Improper storage of tool 26 Applicator head loose 43 Shortage of skilled manpower
10 Improper setting of tool 27 Encoder failure 44 Automatic printer for job card
11 Wrong size wire use 28 Terminal bend 45 More absenteeism of man power
Winding problem in wire and terminal
12 29 Paper winder not proper work 46 Machine press re-servicing
spool
13 Terminal chain twist problem 30 Seal missing during process 47 Conveyance facility not available.
Facility of Re-creation & library not
14 T.S variation in wire 31 Time loss in changeover 48
available
15 More joint in wire and terminal 32 More breakdown of Press 49 Conical wire spool
16 Low productivity 33 More break down of conveyor 50 Operators not motivated
17 More time in tool setting 34 Improper wire feeding system
  Red Font ( A Category )   Black Font ( B Category )   Blue Font ( C Category )
 SELECTION OF PROBLEM

Current Situation
C- TYPE
10

RELATED TO
B - TYPE 29 29 B- TYPE

A - TYPE
11

0 10 20 30 40 50
NUMBER OF PROBLEMS
 PROBLEM PRIRORITIZATION
MOST IMPROTANT
A Low Productivity
B More breakdown of Press
C More sound in AWP area
D More spare part inventory
E Applicator clamping plate tilt
IMPORTANT
Excessive consumption of feeding
F Q
wheel
G Terminal lock press during process
H Chips cutter not proper work
I Excessive break down of conveyor
J Improper crimping
K Terminal face damage
Winding problem in wire and
L W
terminal spool
M Wire stuck during process
N Seal missing during process
O Applicator head loose
P Terminal chain twist problem
LESS IMPORTANT
Improper feeding of material
Paper winder not proper work
R
Terminal plating problem
S
T Excessive material on line
U Wastage of water proof seal
Wrong identification job card on
V
wire bunch
Mixing problem in produced wire
X Improper storage of raw material
Y Improper storage of tool
Z Improper setting of tool
AA Wrong size wire use
AB Improper feeding of material
AC Wastage of terminal
SELECTION OF PROBLEM
KAWAKITA JIRO METHOD
EVALUATION

COMPLETED WITH
PROJECT CAN BE
SOLVED BY THE
INVOLVEMENT

WHETHER THE
WHETHER THE
CATEGORY

CIRCLE ON ITS
IMPORTANCE

EVALUATION
PROB CAN BE
DEGREE OF

ECONOMIC
URGENCY

FACTOR

IN SPECIFIC

TOTAL

SCORE
TEAM

TIME
PROBLEM

A 28 1
B 8 4
C 10 3
D 18 2
E 6 5
S.No. PROBLEM SYMBOL MARKS
A LOW PRODUCTIVITY AT AWP MACHINE 1
D MORE SPAR E PART INVENTORY 3
C MORE SOUND IN AWP AREA
5
B MORE BREAK DOWN OF PRESS
E APPLICATOR CLAMPING PLATE TILT
SELECTION OF PROBLEM

LOW PRODUCTIVITY
OF AWP MACHINE
PROBLEM

LOW PRODUCTIVITY OF AWP MACHINE

THEME

TO INCREASE PRODUCTIVITY OF AWP MACHINE

IMPACTS OBJECTIVES

1. Increasing manufacturing cost 1. To reduce manufacturing cost

of product. of product.

2. Time and Monetary Losses. 2. To Save Time & Money.

3. Operator Fatigue. 3. Reduce operator fatigue

4. Loss of Overall Efficiency. 4. Increase Overall Efficiency.

5. Depletion of Natural
5.To Save the Natural Resources .
Resources
 PROCESS FLOW AWP A P
CD

RAW MATERIAL WIRE FEED TOOLING LOADING TERMINAL FEED

CRIM. HEIGHT
& WIDTH
MEASURING

GO TO NEXT STAGE WIRE INSPECTION PROGRAMMING LOAD TESTING

AUTOMOTIVE WIRE PROCESSING MACHINE
AUTOMOTIVE WIRE PROCESSING MACHINE

WIRE FEEDING C.S UNIT WIRE FEEDER WIRE CUTTING

BOTH SIDE CRIMP SEAL INSERTION & ONE SIDE CRIMPING SEAL FEEDER

DISPLAY UNIT

WIRE TREY
BEFORE IMPROVEMENT
Monthly Avg. Minor stoppage of AWP machine
AVOIDABLE NON AVOIDABLE

S.NO MONTH TERMIN TOTAL PRODUC

CHIPS BOX SEAL WIRE MACHIN WIRE TIVITY
SEAL FEED AL
EMPTY STUCK STUCK E ERROR JOINT
JOINT

1 Jan-15 19.8 8 16 13 16 8 5.8 86.6 2178

2 Feb-15 19.8 8 15.5 15 15 7.5 5.7 86.5 2180
3 Mar-15 19.5 8 16 13.5 16 7.8 5.8 86.6 2175
4 Apr-15 19.6 8 16.5 14.5 15 7.6 5.5 86.7 2185
Avg. time /stoppage 2 min.
Total Avg. stoppage time /day 175 min

STOPPAGE PRODUCTIVITY

19
PROBLEM ILLUSTRATION

STOPPAGE PROBLEM

Wire was feeding out from pulley.

Wire stuck in feeding unit.

Water proof seal stuck in Seal conveyor.

 
PROBLEM ILLUSTRATION

STOPPAGE PROBLEM

Machine stop every 3 hrs. due to clean

up the chips cutter box.
 

Machine show Center stripping error

frequently.
 

Machine show Acopos Error (66001)

frequently .
 
TARGET SETTING JUSTIFICATION

To increase
productivity
through reduce
minor stoppage

OBJECTIVE

To increase productivity through

reduced minor stoppage.

PRESENT STATUS
Total Minor stoppage
per day 87