Quality analysis of hmc
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Quality analysis of Machine Shop (HMC)
Presenting:
GROUP # 01
Abu Bakar Siddique ME123009
Shahid Hussain ME123019
Muhammad Ifraheem ME123022
Fahad Akhter ME123082
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Introduction of HMC
• Leading enterprise in a country.
• Two main Production unit
• Mechanical works
• Foundry & Forge works
• Mechanical works starts 1971
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Machine Shop
• Most Important Shop
• Contributes major part in income of industry
• Divided in three categories
• Small Bay
• Medium Bay
• Heavy Bay
• Batch Production
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TurningDrawing Reading
Dimension Correct
Facing
Dimension CorrectMilling
Dimension CorrectDrilling
Store
Dimension Correct
If YES
If YES
• If NO
If YES
If NO
If NO
If NO
If NO If NO
If YES
Flow Chart
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Turning Data
Turning 1 2 3 4 Avg Dia Range
1 420.2 419.6 419.8 420.1 419.925 0.6
2 419.9 420.3 420.1 419.9 420.05 0.4
3 420.8 420.2 420.5 420.3 420.45 0.6
4 420 419.9 419.8 420 419.925 0.2
5 420.4 420 420.3 420.1 420.2 0.4
6 419.5 420.2 419.9 420.1 419.925 0.7
7 420.4 419.8 420.2 419.9 420.075 0.6
8 420.2 419.9 420 420.1 420.05 0.3
9 420.3 419.9 420.2 419.9 420.075 0.4
10 420.2 419.6 420.1 419.7 419.9 0.6
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Charts and Capability
Cp= 0.574 Cpk=
1 2 3 4 5 6 7 8 9 10419419.2419.4419.6419.8
420420.2420.4420.6
X- Bar Chart
Avg. Diameter MeanUCL LCL
Dia
met
er (
mm
)
1 2 3 4 5 6 7 8 9 100
0.2
0.4
0.6
0.8
1
1.2
R-Chart
Range R UCL(R) LCL(R)
Rang
e
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Facing Data
Facing 1 2 3 4 Avg. Width Range
1 36.4 35.8 36.2 35.9 36.075 0.6
2 35.8 36.2 36 36.1 36.025 0.4
3 36.5 35.5 36.2 35.3 35.875 1.2
4 36.3 35.9 36.1 35.8 36.025 0.5
5 35.7 36.2 35.9 36 35.95 0.5
6 35 36.5 36.4 36.1 36 1.5
7 35.8 36.4 36.2 35.9 36.075 0.6
8 36.2 35.7 35.9 36.2 36 0.5
9 36.8 36.4 35.9 36 36.275 0.9
10 35.6 36.3 36.3 35.8 36 0.7
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Charts and Capability
Cp= 1.66 Cpk=
1 2 3 4 5 6 7 8 9 1034.8
35.2
35.6
36
36.4
36.8
X- Bar Chart
Avg, Width MeanUCL LCL
Wid
th (
mm
)
1 2 3 4 5 6 7 8 9 1000.20.40.60.8
11.21.41.61.8
R-Chart
Range R UCL(R) LCL(R)
Rang
e
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Milling DataMilling 1 2 3 4 Avg Depth Range
1 24.4 23.8 24.2 23.7 24.025 0.7
2 24.6 24.2 24.3 24.6 24.425 0.4
3 23.7 24.2 24.1 23.9 23.975 0.5
4 24.4 23.6 23.9 24.2 24.025 0.8
5 24.2 23.9 23.9 24.1 24.025 0.3
6 23.9 24.7 24.5 23.9 24.25 0.8
7 24.2 23.7 23.9 24 23.95 0.5
8 24.3 23.7 23.9 24.1 24 0.6
9 23.8 24.1 24 23.9 23.95 0.3
10 24.5 23.6 23.7 24.4 24.05 0.9
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Charts and Capability
Cp= 1.15 Cpk=
1 2 3 4 5 6 7 8 9 1023.223.423.623.8
2424.224.424.6
X- Bar Chart
Avg. Depth MeanUCL LCL
Dep
ht (
mm
)
1 2 3 4 5 6 7 8 9 1000.20.40.60.8
11.21.4
R-Chart
Range R UCL(R) LCL(R)
Rang
e
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Drilling Data
Drilling 1 2 3 4 Avg. Depth Range
1 15.8 16 15.9 15.8 15.875 0.2
2 16.4 16.5 16.1 16.2 16.3 0.4
3 15.9 16 16 16 15.975 0.1
4 16.5 16.2 16.3 16.4 16.35 0.3
5 15.8 15.9 16 15.9 15.9 0.2
6 15.8 15.9 15.9 15.9 15.875 0.1
7 16.1 15.8 15.9 16.1 15.975 0.3
8 16.3 16.1 16.2 16.1 16.175 0.2
9 16 16 15.9 15.9 15.95 0.1
10 16.4 16.1 16.3 16.4 16.3 0.3
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Charts and Capability
Cp= 0.877 Cpk=
1 2 3 4 5 6 7 8 9 101515.215.415.615.8
1616.216.416.6
X-Chart
Avg. Dia UCL LCL Mean
Dia
met
er
1 2 3 4 5 6 7 8 9 1000.10.20.30.40.50.6
R-Chart
Range UCL(R) LCL(R) R
Rang
e
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Cause and effect diagram
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Flow Process ChartProcesses Time ⃝� → □ D ∇
Drawing Reading 05 min √
Transfer to Turning machine 02 min √
Machine checking 02 min √
Turning 12 min √
Transfer to Grinding machine 02 min √
Tool Grinding 01 min √
Check dimensions 02 min √
Transfer to another machine for facing 03 min √
Facing 10 min √
Check dimensions 02 min √
Transfer to Grinding machine 01 min √
Tool Grinding 01 min √
Supervisor inspection 05 min √
Transfer to Milling 02 min √
Wait for completing job 14 min √
Milling 40 min √
Check dimensions 05 min √
Supervisor inspection 05 min √
Transfer to Drilling 02 min √
Drilling 10 min √
Check dimensions 02 min √
Transfer to QC Department 05 min √
Quality Inspection 07min √
Transfer to store 05 min √
Store ---- √
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Calculations
Total Time= 143 min
Operation Time= 79 min, Transport Time=22 min, Inspection Time= 30 min,
Delay Time =14 min
Efficiency % = =%
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Questionnaire
Questions SA A N D SD
Material quality of HMC products is good enough. 1 5 2 2 1
Dimensional accuracy is within specified limits. 2 4 3 1 1
HMC is able to ship out products in a given time period. 2 4 1 3 1
Are all design reviewed tested and verified? 1 3 5 2 0
HMC products are reliable. 3 5 3 0 0
HMC manufacture products are low cost as compared to other firms. 4 2 2 2 1
latest technology is being used in HMC. 0 3 4 4 0
HMC has a good benchmark for other relevant firms. 1 4 5 0 1
HMC is meeting all customer requirements. 3 5 3 0 0
Is HMC fulfilling ISO standards? 2 2 1 4 2
19 37 29 18 7
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Importance Performance Matrix
IMPORTANCE
HIGHHMC
LOW
LOW HIGH
PERFORMANCE
Total Value=
11x (1+2+3+4+5+6+7+8+9+10)x5=3025
Total obtained=2071
Our Target Value =3
On scale 5=
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Cost per Month
Labor cost 104,000 Rs 36.62%
Electricity 150,000 Rs 89.70%
Maintenance 20,000 Rs 96.57%
Others 10,000 Rs 100.00%
Total 284,000 Rsele
ctricit
y
labor
cost
mainten
ance
others
020000400006000080000
100000120000140000160000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
Cost per Month
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Cost of Quality
Years External Cost
Internal Cost
Prevention Cost
Appraisal Cost
Total Quality Cost
1 4.5 2 1 0.55 8.05
2 4.5 2.5 1.2 0.55 8.75
3 4.25 3 1.2 0.54 8.99
4 3.75 3.5 1.3 0.53 9.08
5 2.75 3 1.6 0.52 7.87
6 2.5 2.7 1.5 0.51 7.21
7 2 2.5 1.25 0.5 6.25
Note: Each cost * 100,000 Rs
0 1 2 3 4 5 6 7 802468
10
Cost Of QualityExternal Cost Internal CostPrevention Cost Apperasial CostTotal Quality Cost
Years
Cost
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Current Sigma Level
Number of units Nu 5,000Number of opportunities No 04
Number of defects Nd 85
Number of defective units Ndu 53
• 4250 defects per million opportunities.• This corresponds to the 3.2 sigma level.
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ISO Standard
• ISO 9001 certified
• Authorized to use 4 ASME stamps U, U2, S & PP for equipment manufacturing
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Conclusion
HMC management has to take some decisions.
• Buy new machinery
• Shift machines from manual to Computer Numerical Control
• Hire highly skilled people
• Follow Six sigma principles
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Questions???