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TQM PROJECT TITLE

TQM PROJECT TITLE. Additional shifting of finished goods resulting in higher cost due to extra work. FACILITATOR & TEAM . Facilitator : Sh.Shantanu Daga ji Team leader : Sh.P.C .Mittal Member : Sh.Rachhpal Singh Sh.Purshottam Singh.

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TQM PROJECT TITLE

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  1. TQM PROJECT TITLE Additional shifting of finished goods resulting in higher cost due to extra work.

  2. FACILITATOR & TEAM Facilitator : Sh.Shantanu Daga ji Team leader : Sh.P.C .Mittal Member:Sh.Rachhpal Singh Sh.Purshottam Singh

  3. ATTENDENCE OF MEETING

  4. PROBLEM STATEMENTThe finished goods are shifted from one place to another resulting in a loss of Rs. 20000/mth.

  5. MISSION STATEMENT To reduce loss incurred due to shifting of material to Rs.5000/month by 31 Mar, 2012

  6. EXPENSES ON SHIFTING

  7. EXPENSES ON SHIFTING

  8. QC TOOLS USED 1.Process/Flow diagram 2.Cause & Effect Diagram 3.Stacked graph/Line graph

  9. Start FLOW DIAGRAM Packing Lifting of final yarn Godown Space available In yarn godown Shifting in Deptt. Gallery Stored in Deptt. Final shifting to yarn Godown Re-check Space availability Storage Dispatch

  10. BRAIN STORMING 1. Insufficient space in godowns 2. Wide dispatch fluctuations on daily basis. 3. Godowns far off from packing deptt. 4. Manual movement to first floor of consumes time & labor. 5. Untimely dispatch advice. 6. Unavailability of canter for material shifting 7. Road congestion on the way to Godown IV. 8. Difficulty in material identification due to poor lighting. 9. Loading delays due to uncovered shed during monsoons 11. Contractor workers – delay in work, delay in reporting, etc 12. Labor less than requirement provided by contractor. 13. Stock stored inside department is damaged by workers. 14. Stock at various places causes delays during loading – truck owners complain. 15. Delays in arrival of transport – container for export 16. Repacking because sample is required after packing. 17. Pallet machine faulty. 18. Uncovered shed cause delay in shifting during rain.

  11. LOCOMOTION METHOD Small forklift unavailable Godown too far Lifts unavailability CAUSE EFFECT DIAGRAM Packing at different places Internal movement Pallet lifting Machine faulty Storage Production not as per plan Shifting delay Manual shifting causes broken cases Vehicle not available Manual shifting & extra time Poor planning Canter breakdown Canter availability Additional shifting of FG resulting in higher cost due to extra work. Uncovered shed causes delay during rain Advice delay Irregular dispatch Loading mistake Undefined timings Reloading Heavy work Stock Labour Wrong loading Wage structure Tired/sick Excess form export/short wt. Rechecking Contract labour irregular CUSTOMER MAN

  12. Ranking of brainstorming points

  13. PRIORITIZATION OF CAUSES • Insufficient space in go-downs. • Fluctuations in monthly dispatch. • Manual movement to first floor of consumes time and labor. • Untimely dispatch advice. • Contractor workers - delay in work ,delay in reporting, etc. • Unavailability of canter for material shifting. • Labor less than requirement provided by contractor.

  14. LABOUR SHORT

  15. LABOUR SHORT

  16. PRODUCTION VS DESPATCH

  17. PRODUCTION VS DESPATCH Qty. in MT. Months & Years

  18. CAUSES EFFECT DELAY SHIFTING & LOADING FG.

  19. CAUSES EFFECT DELAY SHIFTING & LOADING FGS. MONTH & YEAR

  20. REMEDY OF CAUSES 1. Fix inventory levels of finished goods according to production level. 2. Install a lift to facilitate handling of excess stock. 3. Revise wages of contract labour annually. 4. Old canter should be replaced in order to avoid breakdowns. 5. Pallet machine should be serviced as per maintenance schedule in order to avoid breakdowns. 6. Store finished goods inventory according to lot, shade and counts. 7. Marketing should provide dispatch advice one day in advance. 8. One vehicle, dedicated for shifting goods is required at all times.

  21. IMPLIMENTATION • Lift under construction, would come in operation till 15th Jan 2012. • Storage of finished goods in lot wise. • Contractor labour rates revised. • Pallet machine maintenance scheduled for prevention of faults.

  22. VALIDATION OF GAINS Project is under progress…………..

  23. HOLD THE GAINS • Check to see that elevator is serviced regularly and maintained according to schedule • Monthly check to ensure that pallet machine is being serviced according to schedule • Check daily that F.G. inventory is stored systematically

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