“Quality Goal towards

Six Sigma”
 Sigma Level DPMO Defects % Competitive Level

1σ
691462 69% Non-Competitive

2σ
308538 31% Industry Average

Sigma 3σ
66807 6.7% Industry Average

Scale.
4σ
6210 0.67% High Quality

5σ
233 0.023% World Class

6σ
3.4 0.00034% World Class
 Sigma Level DPMO Defects % Competitive Level
1σ 691462 69% Non-Competitive

Our
2σ 308538 31% Industry Average
3σ 66807 6.7% Industry Average

Present 4σ

5σ
6210

233
0.67%

0.023%
High Quality

World Class

Process 6σ 3.4 0.00034% World Class

Level. * Highlighted row is our current sigma level. This level

error range is DPMO 66807 to 6211 which is very wide
range. So we want to cross this comfortable wide range
towards 4 sigma within running financial year.
 Target Year Process Accuracy % Sigma Level
Jul 22- Jun 23 93.300% 3σ

Long Jul 23- Jun 24

Jul 24- Jun 26

99.330%

99.977%
4σ

5σ

term
Jul 26- Jun 27 99.9997% 6σ

102.000%

Plan for
100.000%

98.000%

Quality
96.000%

94.000%

Goals.
92.000%

90.000%

88.000%
3σ 4σ 5σ 6σ

Jul 22- Jun 23 Jul 23- Jun 24 Jul 24- Jun 26 Jul 26- Jun 27
 Process Average DPMO Sigma Level
Incoming Rejection PPM 6607 3σ

In process Rejection PPM 146 5σ

Present
In process Rework PPM 33704 2σ

Final Testing PPM 5570 4σ

Situation Final Inspection PPM 59 5σ

 Analysis
In-process
0.00
5.00
10.00
15.00
30.00
35.00

20.00
25.00
40.00

Tank Fabrication-Core Frame

Tank Fabrication-Conservetor

Tank Fabrication-Main Tank

Laser Cutting Shop

Tank Fabrication-Top Cover

Switchgear-Component Assly

Powder Coating
Shop wise Rework Generation %

Pretreatment-Phosphating

Panel Fabrication-Welding

Panel Fabrication-Bending
 Section Cause
Total rework VS Particular
40.00 process contribution %
Laser cutting Burr on cutting
35.00
edge.

30.00 Powder coat Improper

Coating.
25.00

In-process
Pretreatment Uncoated
20.00 metal surface
with oil & stain.

Analysis
15.00

SB Comp Ass Wrong ACB kA,

10.00
Wrong MFM &
False plate
5.00
modification
0.00
during Comp
Assembly.
Laser Cutting Shop

Powder Coating

Tank Fabrication-Top ...

Pretreatment-Phosph...

Switchgear-Componen...

Tank Fabrication-Cor...

Panel Fabrication-Wel...
Panel Fabrication-Ben...

Tank Fabrication-Cons...

Tank Fabrication-Mai...
TF Core Frame Cutting section
error.
 Shop wise Defect Generation %
25.00

20.00

Final Test 15.00

Analysis
10.00

5.00

0.00
Power Txr Switch Board Instrument Txr
 Section Cause
Total Defect VS Particular
shop contribution %. Switch Board PFI Panel control
90.00 wiring connection
80.00 error.
70.00

60.00 Power Txr Dry Txr Hi-pot test

Final Test
50.00 fail.
40.00

30.00
Instrument Txr Hi-pot test fail

Analysis
20.00
after casting.
10.00

0.00
Switch Board Power Txr Instrument Txr

* If SB & Dry Txr fail in final test it can be repairable. But in the case of Instrument
txr not possible to repair which induced sever impact on our bottom line.
 Total Cost of non Quality month
wise

Non
80000

70000
Month Value
60000

Quality 50000

40000
Jul 23
Aug 23
15356
55269

Cost
30000
Sep 23 67246
20000

Analysis
10000

0
Jul Aug Sep

* It is alarming that non quality cost is increasing every month.

 August Month
60000
Section Value
50000
Switchboard 49222

Non
40000

30000 Instrument Txr 0

20000
Fabrication 6047

Quality Shop
10000

0
Switchboard Fabrication Shop Instrument Txr

Cost
September Month
40000 Section Value
35000

Analysis
30000 Switchboard 35413
25000

20000 Instrument Txr 28000

15000

10000
Fabrication 3833
5000
Shop
0
Switchboard Instrument Txr Fabrication Shop
 Most significance process for rework in In-process-

• Tank fabrication Shop

• Laser Cutting Shop
• Switch Board Component Assembly Shop.

Summary Most significance process for rejection at Final Test-

of • Switchboard
• Power Txr

Analysis Most significance process for increasing Cost of non Quality-

• Switchboard
• Instrument Txr
 War Against Defect

One
First Kill the big one and continue the
Simple process.
Strategy
 Let me know

Thank you for actively if you have

any

listening. question.