Mechanical Engineering

7QC TOOLS What are 7QC tools? Stratification (Divide and Conquer) Histogram. Check Sheet (Tally Sheet) Cause-and-effect diagram (“fishbone” or Ishikawa diagram) Pareto chart (80/20 Rule) Scatter diagram (Shewhart Chart) Control chart. Who invented? Japanese professor of engineering Kaoru Ishikawa Why 7QC tools? The 7 QC tools are fundamental instruments  to enhance  the method  and merchandise  quality.  they're  wont to  examine  the assembly  process, identify the key issues, control fluctuations of product quality,  and provides  solutions to avoid future defects

 Rejection Analysis flow in Industry  This is the process flow for rejection analysis 1. Team Formation   -  Create a team with Production, Quality, and Required persons 2. 5W2H   - Details of rejection should be filled in this format 3. Process Flow   - Where defective parts are produced in a flow ( Stations) 4. Containment action for Produced parts - Check all stocks in the company and  included customer ends stock if required 5. 4M Analysis - Man, Machine, Method, Material - Check which "M" got deviated from Specification 6.  Root cause analysis  - WHY WHY analysis  - Find the root cause for deviated process 7.  Reproduce the failure - Once you found the root cause, revalidate and confirm the deviation 8.   Action Plan - Take a permanent action plan to avoid the root cause 9. Monitor the result - A minimum of 3 months need to monitor the rejection trend 10. Sign off the process with solution and Result - If the resu...

  Escalation Process Through Mail The escalation process is used to communicate the issues to next-level management people. You are a supervisor of an area. Most of the problems are solved by you.  Some issues required additionals support like other function help, Cost impact. So you are tried up to your best level and things are not happening means, you can seek help from your higher-level people. This is called escalation. Process Flow for Escalation  1. First Mail to concern Person and Talking directly 2.  If no Improvement, Then Add the Incharge of that person in CC 3. If no Support Still, Address to that Incharge directly in TO and Talk directly to Him 4. If no support again, Then you put Gentle Reminder 5. Still you are getting any response, then Type Escalation 1 - To mark CC with Plant Head.

 SOP - Standard Operating Procedure SOP is a document to ensure the process is in a correct and defined method. Commonly it will contain 3 Major Parts 1. Incoming Quality Check 2. Work Content 3. Outgoing Quality check 1. IQC - Incoming Quality Check This is the first checking method for any start of work You need to check the correct part no, Correct Fixtures, Correct Tool, Basic checking required before assembly. Previous customer claims, Special and critical parameters should be checked before assembly 2. Work Content This part will contain,  How to assemble the part?  How to do the sequence of processes? How to do an in-process check? Mainly, This will say how to produce the part in a defined method 3. OQC - Outgoing Quality Check After assembly what are the checkpoints before being sent to the next station? Commonly mating parts should be correct. Apart from this, the SOP should have the following things also 1. Work Station No.................. 2. Work Centre Name ....

 How to make a report on 5S in the industry? The following procedure will help to make report on 5S in the industry 1. 5S Awarance training to all people across the industry 2. Prepare the 5S checksheet based on location like store, market, assembly, etc., 3. Schedule a audit plan and share to everyone 4. Audit the line / Place 5. Calculate the score after the audit and publish to all 6. Schedule a meeting to discuss about points and closure commitment 7. Re audit the line . Weekly once a audit in mondetary. Minimun Score - 85 %

 Salient features of Shitsuke in 5S The aim of the step is to transform the concept of 5S into the enduring culture Top Management organizes communication, education, and training on 5S Cultural transformation takes place: Efficiency, responsiveness, speed, and punctuality improve perceptibly Exactness is everything is seen throughout the organization in all the activities The cultural transformation is brought about by rewards, recognition, and celebrations Gifts, rolling shields, display of photographs of achievers and public adulations are some of the initiatives to foster the culture 5S culture is the foundation for all other practices of TQM and by practicing 5S, employees are becoming efficient and getting ready to adopt other elements of TQM to improve their effectiveness

Shitsuke( Sustain) in 5S and Its Benefits This is the final step in the 5S methodology. This step is to do the right thing as a matter of course( Routine). Shitsuke is an effective way of sustaining the 5S movement . The top management's commitment is a must for this activity Key Strategy for Shitsuke:  " Promote and Motivate in order to entrench 5S culture through  Top management's involvement  Constant Communication and Training Competitions Rewards/ Recognitions/Celebrations Benefits: The entrenched culture of 5S across the organization Top Management's commitment demonstrated Rewards and Recognition bring forth enthusiasm and happy Sustained activities of 5S in all areas of the organization

5S audit check sheet  5S audit check sheets are used to confirm the 5S level and improvement in your workplace. Checkpoints may vary based on the workplace. So here we will see the guideline for how to create a 5S check sheet. Steps to create 5S audit check sheet, 1. First, go to the real workplace 2. Check  and capture what are the things used to do the work like a machine, computer, table, tools, etc 3. Check what are the standards followed in the place 4. Keep 5's in your mind and take a plain A4 paper 5. Make 5 S as a separate column as Seiri, Seiton, Etc., 6. Every column must have 5 points each, so that put together it will come 20 and each point have score range 1 - 5 ( 1 - Poor, 2 - Fair, 3- Good, 4 - Excellent, 5- Outstanding) 6. Write down the points Seiri column which is about unwanted things removal ( eg: Removal of unwanted materials) 7. Like that write down the points for other 4 S based on the reality to improve ...

Fixed Point Photography in 5S Fixed Point Photography is the system of comparing the status of the workplace on two different occasions and learn from what we see. How to do?.... 1. Take photographs on different occasions but the same place / position / angle 2. Understand the difference and make a score in your 5S audit board ( Integrate with 5S checksheet and not sand-alone practice) 3. Improve and confirm improvement by taking photograph later 4. Photograph freezes the status and it is for everyone to see.

The salient features of Seiketsu in 5S Seiketsu means Standardize and used to follow 1S,2S and 3S regularly The salient features of Seiketsu in 5S is, 1. The aim, as stated above, is to standardize. For this purpose, self-evaluation check sheets are used 2. Fixed point photography : It is used to freeze the status for everyone to reflect in order to improve continuously 3. Poka-yokes are used to lock the habits 4. 1S, 2S, and 3S activities are carried out, as a part of the daily routine activities 5. The practices are structured by defining them in the 5S manual and involving all employees 6. Keeping in mind the dictum: 'whats get measured, gets done' 7. Inspiring but realistic targets are fixed for score 8. The trend is monitored and the status is improved by rotating the PDCA

Seiketsu in 5S and Benefits This the fourth step in 5S . In English called as Standardize The objective of the step is to make 1S, 2S, 3S a habit through standardization Benefits of Seiketsu: 1. Practicing 5S becomes a routine for everyone, 5S becomes a habit 2. Practice makes things perfect 3. By practicing every day, the time taken becomes lesser and lesser 4. Everybody gets the eye for 5S 5. Workplace looks neat, clean and efficient always 6. Standardization of all practices of 1S,2S, and 3S

The salient features of Seiso in 5S Seiso is the third step in 5S , in English called Shine The salient features of  Seiso in 5S is, 1. Keep everything shining and keep it that way always! 2. Cleaning activity becomes as 'inspection' 3. By frequent cleaning, you can identify small issues which are capable to create a big crisis later 4. Seiso tags are used to identify the issues 5. The aim is to beget a work-place that is spotless to took at and faultless to work with. What is the Key Strategy for Seiso? 1. Identify abnormalities while cleaning, find out causes abnormalities 2. Adopt preventive maintenance to prevent the occurrence of abnormalities in future

Seiso and benefits in 5S This is the third step in 5S .  This seiso step is to eliminate trash, filth, and foreign matter for achieving a cleaner workplace. Cleaning is done as a form of inspection. To maintain a machine, cleaning is very important. Benefits of Seiso: 1. Clean environment 2. Prevention of major breakdown by early detection 3. Improvement in productivity by better upkeep of equipment 4. Cost reduction by improving the reliability of equipment 5. Healthy and cheerful workplace 6. Support to 1S (Seiri) - Cleaning will support to identify unused items 7. Support to 2S (Seiton) - Cleaning will support to arrange the items neatly

Examples of Seiton in 5S The following examples of seiton is for your reference 1. Gangway marking 2. Use of dedicated containers 3. Visual control charts with plan and target 4. Gauge stand with fixed pockets for each gauge 5. Document / Record files with Poka - Yoke marks 6. Push-Pull signs in the door 7. All mobile items with set-limits

Visual Work place in 5S The visual work place is used to maintaining 5S in place. This is one the method uses in Seiton "A place for everything and everything in its place" 1. Name everything         ---- Provide Visible Indicators ---- Provide arrows, Lamps, Signs, Colors,                                                                                                      Codes, Etc. 2. Use 3 keys for storage ---- Provide Address  --- Use logic city/Street/House(Racks/Floor/Location)                                          ---- Identify Parts       --- Use...

Key strategy for Seiton in 5S The key strategy for Seiton is to provide a place for everything in order to  - Identify and fix locations to eliminate orphans - Find out the root cause for no location and ensure a place for everything which is already existing (or) arriving new.

NVA and VA NVA - Non Value added  - unnecessary time which is doing by mistake VA     - Value-added         -   This is the necessary time to do that process

Salient features of Seiton in 5S Seiton means A place for everything and everything in its place 1. Seiton is achieved by providing a place for all necessary items 2. While providing a place for things, safety and speedy retrieval are ensured 3. By Practising Seiton, the Workplace becomes efficient, Productive and safe 4. The aim is to achieve Zero search time 5. The ultimate aim is to achieve inventory less workplace and paperless office

Good Seiton in 5S means, Zero Counting Zero Searching Zero unwanted movements Zero Transfer Zero Damage Zero Accidents Zero Wastes Zero Losses

Seiton(Sorting out) in 5S This is the second tool in 5S Seiton means A place for everything and everything in its place Provide a neat layout so that you can always get just as much of what you need when you need it. What are the benefits of Seiton in 5S? 1. Search time elimination 2. NVA time reduction 3. Productivity improvement  4. What is needed is kept properly 5. Frequently needed kept nearer 6. Heavy items at a lower level  and lighter at a higher level 7. Containerization for eliminating damage /counting / searching, etc.