Manish engg ppt 26.04.16
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Transcript of Manish engg ppt 26.04.16
TPM – Way Towards Manufacturing Excellence
MANISH ENGINEERING WORKS
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Welcomes All
MANISH ENGINEERING WORKS
K-161, L-33 , MIDC, Waluj, Aurangabad
Vendor Code – CNM0034
Unit - I Unit - II
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Introduction
• Name: Mr. Manish Rawke
• Education: B.E. Mechanical, MIE, Chartered Engineer
• Work Experience: Greaves Cotton Ltd. (4 Years)
• Department: R & D
• Nature of Work: Design of products, Manufacturing process , Prototype
sample to Mass Production
• Firm: Manish Engineering Works established in 1999 at MIDC
Waluj, A’Bad
• Initial Set up: Mechanical presses from 10 to 50 tons ( 6 Press)
• Products: Clamps, Levers, Washers, Brackets & Fabrication Work.
• Customers: Greaves, Videocon & Marathwada Auto
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In 2001-02, • Supply starts for MS and Bakelite Washers, Brackets, and Assembly work.
• Got new orders of Fabrication work & Sub assemblies.
In 2002-03, • OLC Assemblies Started (Mounting Bracket Assy. & Drive Shaft Assy. For Wiper motor).
In 2003-04,• To avoid logistic loss & Mfg. Lead Time OLC Assemblies Converted with Material (Mounting Bracket Assy. & Drive
Shaft Assy. For Wiper motor).
• Got opportunity for Pulsar Yoke Development on Conventional Lathe ( Component Requirement). With special
expanding mandrel achieved run out of spigots in 50µ w.r.t ID.
• Process approved & appreciated by BAL Team & Production Starts.
• After change in design of Yoke, First CNC installed
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Our Products
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Group Revenue
Sales in Cr.Projected
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Customer View
• In-Consistency in Quality• Delivery failures• Repeated customer
complaints• Delay in Development
Management View
• Reduction in Production losses• Reduction in Cost loss• Achieve Zero Breakdown, Zero
Accident, Zero Defect• Low WIP Inventory• Development Lead Time
Reduction
Team View
• Only Fire fighting, Production & Dispatch any how?
• Reactive approach• Lack of discipline• No CFT working• System for Sustenance• Competent Frontline
Initial Challenges
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• Cell Level Ownership of Profit Centre
• Cross Functional Team Working
• Ensure Targeted Profit• Satisfied Customer
• Optimum Utilization of 4M1T Resources
• Basic Restoration• Reactive & Proactive
Improvements• Sustenance• Excellence
• Cell Concept• Unidirectional Material
Flow• Single Piece Flow• Pull System• Operation with
Reduced WIP• Online Control
Streamline Mfg. System
SMS
Total Productive Maint.
TPM Lean Mfg.Lea
n
Methodology
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• Cell Concept• Unidirectional Material Flow• Single Piece Flow• Pull System• Operation with Reduced WIP• Online Control
Streamline Mfg. System
SMS
Approach – Phase I
Final Inspection
Dispatch
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Approach – Phase I
HMSI Cell
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• Optimum Utilization of 4M1T Resources
• Basic Restoration• Reactive & Proactive
Improvements• Sustenance• Excellence
Total Productive Maint.
TPM
Approach – Phase II
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OEE Loss CapturingTPM Track System
Capturing Machine wise Losses
TPM Track System
Capturing 16 Loss Data
Loss Analysis
Identify Loss for Improvement
Countermeasure on Losses
Kaizen Idea
Horizontal Deployment
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OEE – HMSI Cell
BM (Nov-15)
Dec-15 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Target50
55
60
65
70
75
80
85
90
95
100
90
80.480.7 81.3 82.7 83.6
85.83
OEE % (HMSI)
BM OEE Target
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Key Initiative for Zero PPM - Prevention of Customer ComplaintCustomer Complaint - Methodology
Study Product Drawing To identify CTQ Points
Inspection Agreement with Customer
To Know importance of:• Fitment• Functional• AestheticParameters & inspection frequency with checking method.
Prepare FinalInspection Check Sheet
Facilities at Final Inspection Stage
• Inspection Table• Gauges (in line with Customer) • Place for gauges • Lights with illumination level • Display Document• Reference samples OK / Not OK • Red lockable bin for not Ok• Monitor Records for arrested defect
Skilled Inspector
• Train Inspector with OJ T• Give Ownership• Monitor Performance as Zero
Customer Complaint• Contribute for Corrective action
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IHR Methodology
Defect Phenomenon Killed
Key Initiative for Zero PPM – Elimination of In-house Rejection
Make Kaizens & Pokayoke for arresting the defects at source
C Type Defect• Process not ok, (while initial setup)
corrective action taken. • Process become ok, jobs ok
Make Kaizens & Pokayoke for identified causes
Capture Defect Phenomena of the Process
Categorize defect into A, B & C Type Wise
Prepare QA Matrix to understand the generating point
Analyze by doing FTA Approach, identify 4M1T Condition
Make Sustenance plan for ensuring zero defect status with help of QM Matrix
Analyze by doing Why Why Analysis
A Type Defect• Process OK, in between not ok comes, • causes is known action taken process
becomes ok
B Type Defect• Process ok, suddenly not ok comes• Cause not known, no action taken yet
next job ok
IHR – HMSI Cell
Total De-fect
A Type B Type C Type0123456789 8
3 2 35
2 1 2
Mar. 15
Jun. 15 (Past)
Mar. 16 (Present)
020000400006000080000
100000120000140000160000
33378
145073
830 260
Suppled Qty. IHR PPM
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IPO - Methodology Control PlanVQS/CQA/FM/1
0/19-Aug-2014
1/1
Date(Rev.): -
Rev. No.: 0 Core Team:
Mod No.: E 06/07/2015
Supplier/Plant: Supplier code: CNM-0034 Cust. Name:
Operator Inspector Engineer MFG
QC/QASpecial
Char. Product /Process Evaluation Control Class Specification/ Measurement Method
Tolerance Technique
10 Receiving inspection ------//----- 1) Dent/Damage - Free from Dent & Damage Digital vernier caliper 5 nos. Each lot Inward inspetion
report
If parameter not in limit then inform to supplier & send back
the material1) Diameter-13.0 ±0.10 Snap gauge 100% 100%2) Length-9.90 - 0.3 Height gauge 1:50 1:503) Total Length-58.0 +1.0 DVC 100% 100%4) Diameter- 24.00 +0.2 Snap gauge/Mic 100% 100%5) Chamfer-1.0x10° ±0.3x±3° Profile projector 1:100 1:1006) OD Chamfer-0.5x45° ±0.2x±3° Profile projector 1:100 1:1007) Ra-2.5 Max Roughness tester Once in a shift Once in a shift8) Length-36.00 Min. DVC Once in a shift Once in a shift9) Length-0.5 +0.3 Height gauge 1:100 1:10010) Diameter-17..0 ±0.3 DVC 1:100 1:10011) Radius- 0.5 ±0.3 Radius Gauge 1:100 1:100
1) Length-25.80 +0.3 DVC 100% 100%
2) Outer Diameter-14.80 +0.050 Snap gauge 100% 100%
3) Outer Diameter-12.90 -0.060 Snap gauge 100% 100%
4) Length- 11.00 +0.5 Height gauge 1:50 1:50
5) Total Length-57.00 -0.5 Digital vernier caliper 100% 100%
6) Radius-0.5 ± 0.3 Radius Gauge 1:50 1:50
7) Ra-1.6 Max Roughness tester Once in a shift Once in a shift
8) Chamfer-0.5x45° ± 0.2 Profile projector 1:100 1:100
9) Radius- 2 ± 0.5 Profile projector 1:100 1:100
10) Chamfer-1x10° ±0.3x3° Profile projector 1:100 1:100
11) Diameter-13.50 ±0.1 Profile projector 1:100 1:100
12) Diameter-14.70 +0.05 Profile projector 1:100 1:100
13) Length-2.80 +0.3 Profile projector 1:100 1:100
14) Radius-1.50 ±0.5 Profile projector 1:100 1:100
15) Angle- 70° +4° Profile projector 1:100 1:100
16) Runout-0.1 Max V Block & Dial 1:100 1:100
17) Angle-20° ±2° Profile projector 1:200 1:200
1 Burr. Dent & Damage 1:200 Each 3 Hr
2 Rusty 1:200 Each 3 Hr
Packing Bins 1) Partion Bin -96 nos - 96 nos Bins Physical Count 100% 100% Packing Standard If not ok Reject the lot
Oiling Rustnil 2) Rustnil-214 - Rustnil oil dip Visual 100% 100% Oil Sta If not ok Reject the lot
60 Dispatch Vehicle Condition 1) Visual - Vehicle should not be open Visual 100% 100% Packing Standard If not ok Reject the lot
Note:- 1 Special characteristic to be denoted by this symbol.2 Wherever special characteristic are variable type & tool dominant control method to be
indicated as record of above variables in first piece & Last piece report before mould unloading for 5 Nos.3 For Variables type of special characteristic control method should be (X - R chart).4 Lay out Inspection - all dimensions specified in the drawing will be checked.5 In process Inspection is termed as stage product audit.6 Product Audit / Process Audit to be conduct as per plan.
Prepared By: Mr V.T.Gosavi Checked By: Mr. Kishor Dukare Approved By: Mr Shaikh
Manish Engg. Works Doc No
Manish Quality System Rev No/ Dt
Title: - Control Plan Page No
Prototype Pre-launch Production Key contact /Phone:9225306431
Control Plan Number: 01 Mr. M.D. Rawake, Mr. L.N. Shaikh, MrV.T. Gosavi, Mr. KSD
Manish Engineering Works Varroc Engineering Pvt. Ltd.( WP-5)
Customer Engineering Approval /Date (If Reqd.):Part No./Latest Change Level: 10231141 Supplier/Plant Approval/Date: Customer Quality Approval/Date (if Reqd.):
Part Name/Description: Counter Shaft Other Approval/ Date(if reqd): Other Approval/Date (If Reqd.):
Symbols For Person In charge
Part/Process Number
Process NameOperation
Description
Machine DeviceJig, ToolsFor Mfg.
Characteristic Methods
Responsibility Reaction Plan No. Product Process
Sample
Size Freq.
If parameter not in limit then inform to
supervisor. Put NC tag & segregate the lot
30 CNC M/C 2 nd set up
CNC M/c Tool holder-MTJNL X 2 , Insert-TNMG-
0.4/0.8
Jaw boring
↗, 0.010,
RPM, 3200,FEED 0.09 DPIR
If parameter not in limit then inform to
supervisor. Put NC tag & segregate the lot
20 CNC M/C 1 St Set Up
CNC M/cTool holder-MTJNL X 2.Insert-TNMG-
0.4/0.8
Jaw boring
↗, 0.010,
RPM, 3200,FEED 0.09 .DPIR
Approved By
Reject & seggregate the lot
REVISION STATUS
Visually
50
Revision No. Date Change
PDIR40 Final Inspection Visually Visually Component should be free
from dent, damage& rust
√
Sustenance of In-house Rejection
• To understand ‘I’ Dimensions• To identify CTQ PointsStudy Drawing
QM Matrix(Control Plan / IPO Doc.)
IPO Linkage toCheck Sheet
Follow Activities as per Control Plan / IPO • Work on Abnormalities
Monitor Result• If not OK• Revisit IPO Document• Revisit 4M1T Condition
• J H / PM / Tool Fix. Maint / Process Quality / Material Handling / SOP / Gauges Calibration
QA Matrix• Happen and May Happen Study : Defect Possibilities
Corr. Action on happen & May happen Defects
• Cause Side Action:- Kaizens- Pokayoke
• Insp. Side Action: - Q Alerts - Check Points / OPL- Process Parameter
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P
Q
Plant PQCDSM Result
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D
S
M
Plant PQCDSM Result
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Recognition by Varroc
CII Kaizen Competition - 2014
2014
IVKC - 2013
Achievements
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We have celebrated this moment with our employees
Recognition For Front Line
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Progress – Cell Formation
HMSI CellREML Cell Crank Pin Cell
BSC CellYoke Cell
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Challenges FY 2015-16
• Development lead time high
• High In-house Rejection
• Start up delay
• Product cost high
• High Investment in same category
To develop the Component:
• With minimum lead time
• To ensure product functions as well as to achieve:
“Ease of Quality assurance”
“Ease of Manufacturing”
“Achieve Vertical start-up during volume
production”
• To meet the anticipated needs of Users/ Customer
• Capacity enhancement by productivity improvement & by
addition of new machines
Background Aim
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No. Challenges Activity
1 Sustenance of In-House Rejection • Implementation of IPO With Daily Work Management
2 Minimum Development Lead Time • Implementation of MP Generation System & Used while NCDS
3 Fast Ramp up volume• Capacity enhancement by Production
per hour improvement with existing set up &
• By Addition of new machine
4 Elimination of Non value added activity• Small Automation• Multi - Gauging• Process upgradation
5 Manpower Retention• Empowerment of Frontline Team• Fatigue free Processes• Healthy Work Environment
Forecast Challenges FY 2016-17
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Future Approach – Phase III
DWM Approach:
Benefits:
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Thanks for Timely Support & Guidance by
Journey Continues…
dtj Team&Team