This presentation helps you to create live presentation by your own.

1. QUALITY CIRCLE
Systematic Approach To Problem Solving
Prepared By
Mohamed Yusuff
Operations U & A
together we can
Quality Circle!

2. Introduction to Quality Circle
• It is a small group of frontline operators who
continually control and improve the quality of their
work, products and services.
• They voluntarily meet together on a regular basis to
identify improvements in their respective work areas
using proven techniques for analyzing and solving
work related problems.
• QC Circle activities are carried out as part of Total
Quality Management(TQM),
Operations U & A
together we can
Quality Circle!

3. QUALITY CIRCLE FROM TQM
• Continuous Process Improvement – Kaizen, Six
Sigma
• Employee Empowerment – Quality Circle
• Benchmarking – Legally stealing other people’s ideas
• Customer-Supplier Partnerships – JIT concept
• Management by fact.
Operations U & A
together we can
Quality Circle!

4. WHY WE NEED QUALITY CIRCLE
• Its provides an opportunity for members to
develop their creative thinking
• As the members study and learn together, their
full potential is realized
• To contribute to the improvement and
development of an Organisation.
Operations U & A
together we can
Quality Circle!

5. OBJECTVES OF QC
• Establishment of a pleasant workplace
• Establishment of a state of control
• Enhancement of morale
• Establishment of sound human relations
• Better income
• Improvement in Quality Assurance
Operations U & A
together we can
Quality Circle!

6. POTENTIAL BENIFITS
• Increased productivity
• Improved quality of work life
• Boost employee morale
• Enhances creativity
• Improved teamwork
• Employee involvement
Operations U & A
together we can
Quality Circle!

7. ORIGIN OF QC
• The first Quality Circle was organized in 1962,
by Japan Nippon Telegraph company.
• It was supervised by Mr.Deming and Dr.Juran.
• Japan Started JUSE (Union of Japan
Scientists and Engineers) to spread Quality
control circle.
Operations U & A
together we can
Quality Circle!

8. Asian Productivity Organization
•
•
•
•
•
•
•
•
•
•
•
•
Japan
South Korea
Taiwan
Singapore
Malaysia
the Philippines
Hong Kong
India,
Indonesia
Thailand
Sri Lanka
Pakistan and Vietnam
Operations U & A
together we can
Quality Circle!

9. QUALITY CIRCLE IN COIL SHOP
• In Coil shop Quality Circle successfully started
on 30th March 2013.
• Total 13 team formed on 24th March 2013.
• Booklet and training provided 8 th April 2013.
• Currently successfully continuing the Improve
phase.
Operations U & A
together we can
Quality Circle!

10. QC Team Formation-Coil shop
Line/Area
Assy
Brazing
CAC-1
1 Team
13 Members
2 Team
26 Members
CAC-2
1 Team
6 Members
1 Team
7 Members
AHU
1 Team
9 Members
1 Team
10 Members
Chiller
1 Team
10 Members
1 Team
9 Members
Tubing
Coating
2 Team
16 Members
1 Team
9 Members
1 Team
10 Members
Resistec
Total Team :13
Operations U & A
together we can
Quality Circle!

11. QUALITY CIRCLE IN COIL SHOP
• Assigned Leaders and sub leaders for each
team.
• Team name selected by each team members
• Each team took each project from their own
area. Total 13 project in progress.
Operations U & A
together we can
Quality Circle!

12. Team list with Project
Area
Team name
Team
Leader
Sub Leader
M/C Shop
Success
Renji
Wassil
To Reduce Fin & Cu Tube damages in all
stages
Current Level is 3 NCN/Month
Target- 1 NCN/Month
Brazing-1
Rose Riders
Girish
Manoj
To Reduce Return Bend Leak rate below 0.5%
Current return bend leak rate is 2.1%
Target- 0.5 %
3
Brazing-2
Speed Riders
Ilyas
Mohsin aalam To Reduce Return Bend Leak rate below 0.5%
Current return bend leak rate is 2.1 %
Target- 0.5 %
4
M/C Shop
Fire Crackers
Raj kamal
Emilio
To Eliminate wrong Coil assembly
Current Level is 3 NCN/Month
Target- 1 NCN/Month
5
Brazing
Seven Star
Brazers
Varghese
Ansar
To Reduce Brazing Leak rate Below 1%
Current leak rate is 3 %
Target - 1 %
6
Parts
Perfect
Jahangir
Mahroof
To Reduce InProcess scraps of copper tubes
Current scrap is 12 Lbs
Target to below 4 Lbs
Assy
Brazing Bullets
Monir
Akbar,
Sabbir
To Reduce InProcess scraps of copper tubes
Current scrap is 12 Lbs
Target to below 4 Lbs
M/C Shop
YIPS Express
Azziz
Blitz
,Iliyas
To Increase Per day production by 30%
Avg daily production is 11
Target to 14
9
Brazing
Courage
Abdul
Khader
Fakrudeen To Reduce Brazing Leak rate Below 1%
Current leak rate is 4.6 %
Target- 1 %
10
M/C Shop
S.N
Line
1
2
CAC-1
CAC-2
7
CAC
Tube shop
8
AHU
Chiller
11
12
13
PSDOS
(P ro blem so lving, Develop in g o f
skill)
Resistec
Target description
Krishna
Current scrap is 1.8 Lbs
Erwin,Malick To Reduce In Process scraps of Copper tubes
Kumar Jha
Target to below 0.5 Lbs
Royal
Challengers
Anas
Professional
Aquil
Hassan
To Reduce In Process scraps of Copper tubes
Current scrap is 7 Lbs
Target to below 4 Lbs
Resistec X1
Thaisen
Jackson
To Improve Efficiency of coating line
Current Level is 2 NCN/Month
Target- 0 NCN/Month
Brazing
Chiller
Parts&Assy
Tube shop
Project description
Coating
Operations U & A
Ashraful
To Reduce Brazing Leak rate Below 1%
,Ajay Kumar
together we can
Current leak rate is 3.1 %
Target- 1 %
Quality Circle!

13. GANT CHART-Full Program
-Planned
Description
Intro+ education+ team
formation
Define phase Training +
project assign
Measure phase training +
data collection+
Brainstorming
Analyze(Training+
Pareto chart)
Improve
Phase(Implementation)
Control Phase training+
implement
Operations U & A
-Completed
Plan/
Actual
WK-12
WK13,14
WK15,16,17
WK18,19,
WK
20-48
WK48-52
WK-52
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
ACTUAL
together we can
Quality Circle!

14. ABOUT PROJECTS
• Format used – DMAIC
Define, Measure, Analyze, Improve & Control
• Periodical training & meeting conducted.
• Internal meeting conducted by team leaders in
work place every month to define their own
stage problems.
Operations U & A
together we can
Quality Circle!

15. ABOUT PROJECTS
• Tools used
- Pareto chart
- Cause and Effect diagram
- FDM(Function Deployment Matrix)
- Brainstorming
- Check sheets
Operations U & A
together we can
Quality Circle!

16. Improvements observed
• Each Project working on minimum 2 problems
which is to improve on their stage.
• Total 32 improvements related to their own
stage is in progress.
Operations U & A
together we can
Quality Circle!

17. Major improvements
Return Bend Leak rate reduction in
CAC-1
(Team-Rose riders & speed riders)
Brazing Leak reduction in AHU &
Applied Coil shop
(Team-Seven star brazers, Courage&
Royal challengers)
Leak rate-2.1%
Leak rate-1.1%
Action Taken:
1.Check sheet displayed to monitor the
leak from every stage.
2.Input Butane pressure regularized by
placing adjustable pressure gauge.
3.Practicing Pre heat to reduce oil level in
flare.(if found more oil on flares)
4.Continual feed back system by internal
operator itself.
Leak rate-3.0%
Operations U & A
Leak rate-1.0%
together we can
Quality Circle!

18. IMPROVEMENTS
Location:CAC-1 Brazing Area
Team-Rose riders
Type: Quality Improvement (Leak rate reduction)
Before Improvement
N2 IN
After Improvement
Return bend
storage box
Return bend
storage box
Return bend
storage box
N2 OUT
In progress
Dust and moisture accumulate
on return bend which is stored in
box can creates corrosion and
cause leak
Return bend stored box will arrange and
N2 gas will insert in serial to all box, so
that external moisture will not enter.
Effect on implementation: Return bend leak rate will be reduce
18
Improve
Operations U & A
together we can
Quality Circle!

19. IMPROVEMENTS
Location: CAC2 Machine shop
Team- Fire Crackers
Type: Productivity Improvement
Before Improvement
After Improvement
Photos attached
on next slide
Photos attached
on next slide
Process In progress
After Process sheet obtain from scheduling, in
coil shop there exist manual editing for coil
size and hair pin Qty which creates wrong coil
due to wrong entry.
With the help of Scheduling
process sheet changed with required
data to produce coil without manual
editing
Effect on implementation: Wrong coil assembly will reduce
19
Improve
Operations U & A
together we can
Quality Circle!

20. Process sheet-Current
Operations U & A
together we can
Quality Circle!

21. Modified Process sheet
Operations U & A
together we can
Quality Circle!

22. IMPROVEMENTS
Location: AHU Brazing Area
Team-Royal Challengers
Type: Quality Improvement (Leak rate reduction)
Before Improvement
Gas pressure was not proper due
to flux blockage ,lengthy hose
and hose frequent damage.
After Improvement
Brazing hose arranged and standardized
by extending steel pipe up to brazing
stage to make hose length short and
constant gas pressure.
Effect on implementation: Constant gas pressure obtain thus leak rate will reduce
22
Improve
Operations U & A
together we can
Quality Circle!

23. IMPROVEMENTS
Location: Resistec
Team-Resistec 11
Type: Productivity Improvement
Before Improvement
Coils were coated by keeping on
drums. Coating done on one face and
hold it for drying about 6 hrs and then
coating on the opposite side..
After Improvement
Moving trolley made with hanging
system, Now coils will coat/spray and
directly move to the oven without lifting
the coils
Effect on implementation: Process time reduction with improved Quality
23
Improve
Operations U & A
together we can
Quality Circle!

24. IMPROVEMENTS
Location: Chiller
Team-Courage
Type: Productivity and Quality Improvement
Before Improvement
After Improvement
In Progress
During Crimping for valve insertion in
Evap coil, there no flare exist, which
cause difficulties in brazing tends to
leak occur
Design of crimping tool need to alter by
cutting a slot in tool of flare rest area.
Effect on implementation: Process time reduction with improved Quality
24
Improve
Operations U & A
together we can
Quality Circle!

25. IMPROVEMENTS
Location: CAC Tube Shop
Team-Perfect Type
Productivity and scrap reduction Improvement
Before Improvement
In straight tube cutting machine roll
end tube not able to cut due to
machine limitation
After Improvement
Manual cutting machine ordered so as to
cut roll end tube at instant, by this
minimum length can be cut according to
our process requirement.
Effect on implementation: Cu tube Scrap due to roll end will totally eliminate.
25
Improve
Operations U & A
together we can
Quality Circle!

26. Various improvements
• CU Scrap reduction by introducing
– Tube clamping system to standardize the cutting angle.
• Process improvement
– AHU brazing carried out in sequence table to increase
productivity
Operations U & A
together we can
Quality Circle!

27. Operations U & A
together we can
Quality Circle!