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TQM PROJECT

DEEPAK SPINNERS LIMITED BADDI (H.P.). TQM PROJECT. Group No:- 3. TQM PROJECT TITLE. To increase the utilization of ringframes to 92 %. TQM PROJECT NEED (REASON TO CHOOSE THE PROJECT).

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TQM PROJECT

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  1. DEEPAK SPINNERS LIMITED BADDI (H.P.) TQM PROJECT Group No:- 3

  2. TQM PROJECT TITLE To increase the utilization of ringframes to 92 %.

  3. TQM PROJECT NEED (REASON TO CHOOSE THE PROJECT) Utilization is one of the major factor for survival of any industry specially Textile. It affects over all profitability of the Mill. UTILIZATION IS LIFE LINE OF THE MILL .

  4. UTILIZATION IS LIFE LINE HANDS JOIN TO IMPROVE IT

  5. FACILITATOR,TEAM LEADER & MEMBERS Facilitator : Syt. Shantanuji Daga(Arrangements & Guide lines) Team Leader : Sh. Sudesh Tiwari (Guide lines) Members : Sh. V.B. Shrivastava(Participation- B.S.) : Sh. S.K. Thakur (Participation- B.S.) : Sh. H.S. Sharma (Data collection -”-) : Sh. M.K. Mishra (Data collection -”-) .

  6. .

  7. PROBLEM STATEMENT Utilization is low i.e. 77% since last 12 months, leading to a production loss of 5.5T/day or Rs.25 Lac/month.

  8. MISSION STATEMENT To improve average Ring Frame utilization from 77% to 92% by 30TH Nov.2011 to save the amount of Rs.300Lacs/annum.

  9. Data for validation of problem statement

  10. Validation of problem Statement

  11. QC TOOLS USED Brain storming Flow diagram Cause & effect diagram Pareto

  12. DIAGNOSTIC JOURNEY • .

  13. FLOW/PROCESS DIAGRAM Start Mixing laid Spinning Process Single Ply Processed for Double NO Take issue R/M as per program Yes Not OK Dispatch to customer Packed OK Processed to rectify fault Inspected OK End

  14. BRAIN STORMING .

  15. REFLECTED POINT OF BRAIN STORMING On roll labour shortage Labour negligent. In disciplined labour. Late reporting & early leaving labour. Taking out lighter doffs & delaying doffs. Working idle spindles. Poor training of workers. Poor water quality. Scaling problem. High moisture in the raw material. Higher breakage rate. Higher cuts/ faults at autoconer. Sub standard recipe. Scheduled machine spares delayed. Sub standard spares. Machine setting disturbed. Frequent program change. High turnover of skilled labour. Frequent setup change. Communication gap

  16. Cause & Effect Diagram METHOD MAN Idle Spindle Light Doff Indiscipline Change In Programme Delay Deliberately Slow Down M/C Poor Production Planning Communication Negligency 36 Hour & more Duty Early Leaving Miscommunication Frequent Set Up Change On Roll labor shortage Poor Training Poor charge Lack of ownership at shop floor High Turn Over of Skilled Worker Delay Doff Not Habitual of Night Duty Improper Production Monitoring High Work Load Late Reporting Low Ringframe Utilization LOW R/F UTILIZATION Automation System Failure Poor Working High A/C Cuts High moisture in raw material M/C Setting Disturb Poor Working Scaling Problem Sub Standard Recipe Delayed Supply High Waste Generation Production Loss Poor Working M/C Spares High Breakage Poor Water Quality Non Standard spare Scaling MACHINE MATERIAL

  17. GROUPED BAR GRAPH FACTORS AFFECTING UTILIZATION

  18. STACKED BAR GRAPH FACTORS AFFECTING UTILIZATION

  19. PARETO ANALYSIS VITAL FEW • . • .

  20. REMEDIAL JOURNEY

  21. PRIORITAZATION OF CAUSES SELECTED FROM BRAINSTORMING & GRAPH Labour short Program not available

  22. REMEDY OF CAUSE (TO MINIMIZE L/S) Facilities of workers should be increased & should be reviewed from time to time. Revise wages annually according to industry standard. Strength of female workers should be maintained at 10 % of workforce. Transport facility should be provided for commute of female workers. Search & recruit workers from non – traditional areas such as Nepal & Assam. Implement incentive schemes to increase daily attendance of workers and discourage them from long leaves. Incentive schemes for maintaining on roll are implemented for jobbers. Hostel facility for female workers is provided & new hostel is under construction. Various motivational activities have been started.

  23. REMEDY OF CAUSE Following points are under consideration for remedy of other causes like non availability of Program, recipe change & Program change. • To build customers of big houses to get large orders. • Collaborate with purchase department in order to reduce losses due to change in recipe. • To search new stations for marketing to achieve higher realization.

  24. Validation of gains (After)

  25. GAIN AFTER IMPLEMENTATION

  26. Validation of gains (Aug to Nov. 2010 & 2011)

  27. HOLDING THE GAINS Worker’s retention to be increased by 10% and above. Facilities like residence , hostel will be completed till 31st of march. Various motivational incentives to maintain on roll strength will be continued. Inflow of workers from other areas like Nepal will be continued & new areas like Assam, W.B. will be explored. Strength of female workers 7 to 10% will be maintained. Transport facility will be continued & maintained. Trainee strength will be maintained according to turnover , it would be continuously monitored & and new recruitments will be done regularly. Extra precaution will be taken during festival season & peak labour shortage period.

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