It was a GreenBelt Six Sigma project for Company benefit. The Project was To reduce the warranty complaints in PIX-36 from 47% to 20% by 2009 end.

1. AIS - VADODARA

2. Reduce Warranty Complains in PIX-36
Action Leader : Sudip Dutta
I-Nexus ID : 8999
AIS - VADODARA

3. Project Definition Sheet
D M A I C
BU/PL/UNIT:
Products/PDS/VAIS
Lever:
Process Efficiency
iNexus ID:
8999
ACTION TITLE:
To reduce the warranty complain in PIX-36 from 47% to Y% by 2009 end.
Business Problem: status before change
Action objective: Status after change
The warranty complain in PIX-36 is now 47% of the total
dishpatched job till date leading to increase of cost of non
quality & customer dissatisfaction.
Key Indicator Definition (must be Not Financial)
%Warranty Complaints = (Cumulative Number of
warranty complaints for 18 months) / Cumulative
number of recruitment for 18 months) X 100
47.00%
Indicator Baseline:
Quality, Cost & Delivery
SQCD Impact:
Contributing sites:
Business Impact
KINR
Savings/Benefits
Implementation Costs
Net action impact
on a 12 month basis
Sales
COI
436
435.8
Milestones
x
DEFINE
x
MEASURE
CE
To reduce the warranty complaints in PIX-36 by 15% from existing
47% 2009 end.
In and out of Scope
In scope: PIX-36 MANUFACTURING
Out of scope: , HVX, HWX,HWX-C,PIX-12
<40%
Indicator Target:
Valuation Methodology
Validation (by/when/signature)
Finance validation by Debasish
SQCD % warranty cost before &
Chakraborty
after the project
Amol Phatak
Sponsor:
Action Leader: Sudip Dutta
R. Karthikeyan/Rajan Pothi
Coach (if applicable)
DMAIC
Methodology
Team Members: Ugrasena,Ranjit Mallick,Saibal,Subhajit etc
Deliverables
Target Date
x
Problem Definition, Project scope, Project
Charter, SIPOC, CTQ, Target improvement
value, Benefit estimation, Project Owner
15.07.09
Detailed process mapping, Data collection,
x
ANALYSE
x Prioritization, FMEA, Sigma level, Yield
16.08.09
x
Data analysis, Root cause identification &
validation Brainstorm on X’s, Identification of
X’s affects Y
20.09.09
Solution identification, Piloting solutions, Risk
assessment, Implementation of the
improvement action plan.
15.10.09
x
IMPROVE
x
x
CONTROL
x Auditing
Standardization, Fool-proofing, Inspection,
AIS 30.12.09 VADODARA

4. SIPOC
D M A I C
SUPPLIER
INPUT
TDC/ R&D/COMPETENCY
DESIGN BOM
END CUSTOMER
CUSTOMER NEED,
CORE ENGINEERING
OUTPUT
S2K BOM
CUSTOMER
PRODUCT DETAILS
CENTRE
PROCESS
Assembled
PIX 36 Panels
APPLICATION ENGG
S2K BOM, SAP BOM
APPLICATION ENGG
SAP BOM, DRAWINGS,
PURCHASE
MATERIAL REQUIRED
PRODUCTION
TESTING , QUALITY
CORE
CORE
ENGINEERING
ENGINEERING
PROCESS
PROCESS
PIX-36
MANUFACTURING
END CUSTOMER
PROCESS
PIX-36 READY PANELS
Test Reports
W/O SHORTAGES
TESTED TAGGED
PANELS
APPLICATION
APPLICATION
ENGINEERING
ENGINEERING
PROCESS
PROCESS
PURCHASE
PURCHASE
PROCESS
PROCESS
PRODUCTION
PRODUCTION
PROCESS
PROCESS
TESTING &
TESTING &
QUALITY CHECK
QUALITY
PROCESS
PROCESS
PACKING &
PACKING &
DISHPATCH
DISHPATCH
PROCESS
PROCESS
AIS - VADODARA

5. VOC Tree
D M A I C
NEED
DRIVER
CORE
CORE
ENGINEERING
ENGINEERING
PROCESS
PROCESS
CTQ
Proper Master BOM for
Proper Master BOM for
Pix-36 & in all variant.
Pix-36 & in all variant.
APPLICATION
APPLICATION
Meet Customer
Meet Customer
ENGGINEERING
ENGGINEERING
specifications
specifications
REDUCE
WARRANTY
COMPLAIN
METRICS
No of warranty complains
No of warranty complains
due to non-availability of
due to non-availability of
Material in S2K BOM.
Material in S2K BOM.
No of warranty complains
No of warranty complains
due to fault in SAP BOM &
due to fault in SAP BOM &
Appl Engg output.
Appl Engg output.
No of warranty complains
No of warranty complains
PRODUCTION
PRODUCTION
Quality of products
Quality of products
Related to manufacturing
Related to manufacturing
Fault.
Fault.
IN PIX-36
QUALITY &
QUALITY &
Faith in incoming
Faith
TESTING
TESTING
Checked Materials
Checked Materials
CHECKING
CHECKING
& final tagging.
LOOSE
LOOSE
MATERIAL
MATERIAL
ARRENGEMENT
ARRENGEMENT
PACKAGING &
PACKAGING &
TRANSPORT
TRANSPORT
PROCESS
PROCESS
No of errors in Testing
No of errors
Reliability in arranged
Reliability in arranged
No of errors in loose
No of errors
Loose material box
Loose material box
Material arranging
Material
Standard Packaging &
safe transportation.
safe transportation.
No of warranty complains
No of warranty complains
due to packaging &
due to packaging &
Transportation process
Transportation process
AIS - VADODARA

6. Defect Definition of CTQ
D M A I C
CTQ METRICS
No of warranty complains
due to non-availability of
due to non-availability of
Material in S2K BOM.
Material in S2K BOM.
No of warranty complains
due to fault in SAP BOM &
due to fault in SAP BOM &
Appl Engg output.
Appl Engg output.
No of warranty complains
Related to manufacturing
Related to manufacturing
Fault.
Fault.
DEFECT definition
Any one or more components
That are missed in S2K BOM
Any required components that are
Missed in SAP Bom & Engg output.
Any fault remains in the offered
Completed panels for tagging
No of warranty complaints
Any fault remains in inspected
due to errors in Testing
due to errors in Testing
Materials & tagged Panel
No of errors in loose
No of errors in loose
If any loose material component
Material arranging
Material arranging
Missed to put in the BOX
No of warranty complains
due to packaging &
due to packaging &
Transportation process
Transportation process
Packaging is not as per AREVA spec
& transportation practice is not good
AIS - VADODARA

7. Measure
Measure
7
AIS - VADODARA

8. Data Collection Plan
D M A I C
COLOR INDICATE PNL EXECUTED IN 2007
COLOR INDICATE PNL EXECUTED IN 2008
COLOR INDICATE PNL EXECUTED IN 2009
ALL THE DATAS ARE FOUND AFTER DISSCUSSION WITH Mr. Amit pyne , Mr Amol phatak
The Service team-Kotambi & me.
SL NO
SO NO
PNL
QTY
CUSTOMER
1
2
3
4
5
6
7
8
9
10
11
12
127
3106700638
3106700638/02/01
3106700638/01/01
3106700638/01/02
3106700240/02/01
3106700463/01/01
3106700463/01/02
3106700463/01/03
3106700240/03/01
3106700647/01/01
3106700616/01/02
3106700616/01/03
3106700616/01/04
3107700221/01/01
1
1
1
1
1
1
1
1
1
1
1
1
1
VENKATESH ELECTRICALS
VENKATESH ELECTRICALS
VENKATESH ELECTRICALS
JOYPRAKASH ASSOCIATES
MARUTI CLEAN COAL & POWER
MARUTI CLEAN COAL & POWER
MARUTI CLEAN COAL & POWER
JOYPRAKASH ASSOCIATES
POWER & INSTRUMATION LTD
ESSAR CONSTRUCTION LTD
ESSAR CONSTRUCTION LTD
ESSAR CONSTRUCTION LTD
R.R. ISPAT LTD
3107700221/01/02
3107700221/01/03
3107700397/01/01
3107700397/01/01
3107700336/01/01
3107700336/01/02
3107700336/01/03
3107700336/02/01
3107700336/02/01
3107700484/01/01
3107700470/01/01
3107700470/01/02
3107700470/01/03
3108710001/099/02
3108710001/099/03
3108710001/099/04
3108710001/099/05
3108710001/099/06
3108710001/099/08
3108710001/099/12
3108710001/099/16
3508701551/01/01
3508701551/01/02
3508701551/01/03
3108700138/01/01
3108700138/01/02
3108700138/01/03
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
R.R. ISPAT LTD
R.R. ISPAT LTD
POWERLINE CABLE
POWERLINE CABLE
GOVINRAJ - POWER DRIVE
GOVINRAJ - POWER DRIVE
GOVINRAJ - POWER DRIVE
GOVINRAJ - POWER DRIVE
GOVINRAJ - POWER DRIVE
VENKATESH ELECTRICLAS-AAI AURANGABAD
AJITA TRADING
AJITA TRADING
AJITA TRADING
JSPL
JSPL
JSPL
JSPL
JSPL
JSPL
JSPL
JSPL
ATIBIR
ATIBIR
ATIBIR
LARSEN & TOUBRO LTD
LARSEN & TOUBRO LTD
LARSEN & TOUBRO LTD
128
129
130
131
132
133
134
135
136
137
138
139
140
397
398
399
400
401
402
403
404
405
406
407
408
409
410
3106700240
3106700463
3106700240
3106700647
3106700616
3107700221
3107700397
3107700336
3107700484
3107700470
3508701551
3108700138
1
1
1
SITE COMPLAINT
RECEIVED
YES
YES
NOT KNOWN
YES
YES
YES
YES
YES
NOT KNOWN
YES
NOT KNOWN
NOT KNOWN
NO
SOURCE
YEAR
MONTH
TAG DATE
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2007
2008
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
MARCH
MARCH
MARCH
FEBRUARY
01.02.2007
02.02.2007
05.02.2007
08.02.2007
09.02.2006
09.02.2006
10.02.2006
15.02.2007
27.02.2007
22.03.2007
22.03.2007
23.03.2007
13.02.2008
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
AEIW
SLW
SLW
SLW
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2008
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
2009
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
FEBRUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
JANUARY
VADU
VADU
VADU
2009
2009
2009
JANUARY
JANUARY
JANUARY
13.02.2008
13.02.2008
14.02.2008
14.02.2008
19.02.2008
19.02.2008
19.02.2008
20.02.2008
20.02.2008
22.02.2008
28.02.2008
28.02.2008
28.02.2008
30.01.2009
30.01.2009
30.01.2009
30.01.2009
30.01.2009
30.01.2009
30.01.2009
30.01.2009
29.01.2009
29.01.2009
29.01.2009
18/01/2009
18/01/2009
18/01/2009
TOTAL NO OF DEFECTED(CUSTOMER COMPLAINED) ORDERS DATASHEET
AIS - VADODARA

9. D M A I C
Data Collection Plan
CCH S
NO
CU S TO MER
SO
CO MPL A I N
S O U RCE
DIS P
D ATE
COM PL A IN
D A TE
CO MM EN TS
M A TERIA L
A FFECTED
CO MPL A I N
TYPE
1
SYAD-0003
power & instrumenation
3106700647
CCHS
27.02.2007
18/04/2007
Bkr on-off sticker reversely sticked
Breaker
Mechanical
2
NDAS-0273
Essar Power limited
3106700616
CCHS
12/07/2007
Rack in-out handle not engaging.
Breaker
Mechanical
3
NDAS-0273
Essar Power limited
3106700616
CCHS
12/07/2007
Shutters are not operating properly
Shutter
Mechanical
12/07/2007
PNL Interlock are not functioning
Interlock
Mechanical
12/07/2007
E.Switch aslly disturbed
EarthSwitch
Mechanical
12/07/2007
Faulty Transducer
Transducer
Electrical
12/07/2007
Busber sleeve (Raychem) scratched in transit
Sleeving
Mechanical
SL
22.03.2007
22.03.2007
22.03.2007
4
NDAS-0273
Essar Power limited
3106700616
CCHS
5
NDAS-0273
Essar Power limited
3106700616
CCHS
22.03.2007
22.03.2007
6
NDAS-0273
Essar Power limited
3106700616
CCHS
22.03.2007
7
NDAS-0273
Essar Power limited
3106700616
CCHS
3106700281
CCHS
24.08.2007
28/10/2007
BKR stucked in Pnl
Breaker
Mechanical
3106700281
CCHS
24.08.2007
28/10/2007
Auxiliary Drive fault
Breaker
Mechanical
10
BHUTAN POWER CORPORATION
DEVELOPMENT & CONSTRUCTION
DEPT.
NDAS-0277
BHUTAN POWER CORPORATION
DEVELOPMENT & CONSTRUCTION
DEPT.
NDAS-0277
BHUTAN POWER CORPORATION
DEVELOPMENT & CONSTRUCTION
DEPT.
NDAS-0277
3106700281
CCHS
24.08.2007
28/10/2007
Energy-meter defective
Meter
Electrical
11
VSAL-0001
DANCO ENTERPRISES
3107700110
CCHS
22.09.2007
11/10/2007
Emergency push-trip rod not entering
Machining Items
Mechanical
12
VSAL-0001
DANCO ENTERPRISES
3107700110
CCHS
22.09.2007
11/10/2007
BKR not getting off through rod
Breaker
Mechanical
13
VSAL-0001
DANCO ENTERPRISES
3107700110
CCHS
22.09.2007
11/10/2007
Control wiring broken
LV Wiring
Electrical
14
VSAL-0001
DANCO ENTERPRISES
3107700110
CCHS
22.09.2007
11/10/2007
BKR stucked in Pnl
Breaker
Mechanical
15
PBIJ-0028 larsen & toubro ltd, ecc division , chennai
3107700153
CCHS
30.11.2007
08/01/2008
Front door opening problem
Pnl assly
Mechanical
8
9
FROM DISPATCHED DATE & COMPLAIN RECEIVE DATE, THE CONCLUSION CAME THAT THE ALL
COMPLAINTS ARE WITHIN EITHER 18 MONTH FROM DELIVERY OR 12 MONTH AFTER INSTALLATION .
SO ALL THE CUSTOMER COMPLAIN FOR PIX-36 A/C WAS WARRANTY COMPLAINTS
ORDER WISE COMPLAIN DETAILS DATASHEET
AIS - VADODARA

10. 0
D M A
I
Summary of % Warranty Complaints - Before
C
Inferences
Summar y f or % War r ant y compl ai nt s = ( Cumul at
Status = 1 Before
A nderson-Darling Normality Test
A -Squared
P-V alue
Mean
StDev
V ariance
Skew ness
Kurtosis
N
35
40
45
50
0.47
0.210
47.617
3.607
13.011
0.841807
-0.085621
13
Minimum
1st Q uartile
Median
3rd Q uartile
Maximum
55
42.727
45.119
46.602
49.765
54.545
95% Confidence I nterv al for Mean
45.437
49.797
95% Confidence I nterv al for Median
45.179
9 5 % Co n f i d e n ce I n t e r v a l s
2.587
Mean
Median
45
46
47
48
49.432
95% Confidence I nterv al for StDev
49
5.954
 Current level of %
Warranty Complaints
 The Mean warranty
complaint % is 47%.
 The Warranty
Complaints % varies
between 42.7% to54.5%
 Majority of the values lie
between 45.1% and
49.7%.
50
10

11. D M A I C
Initial Process Sigma Calculation
Determine number of defect opportunities/unit (O)
Determine number of unit processed
Determine number of total defected unit
Calculate defects per opportunities
1
(N)
149
(D)
70
(DPO)
Calculate Yield
Dpmo=469798.6
5
0.46979865
53.9%
Look up Sigma in the process sigma table (SIGMA)
Determine Z value from Z bench
1.6
0.1
HERE UNITS CONSIDERS AS TOTAL NOS OF ORDERS EXECUTED
AIS - VADODARA

12. 2
Summary of Measure Phase
 Current level of % Warranty Complaints
 The Mean warranty complaint % is 47%.
 The Warranty Complaints % varies between 42.7% to54.5%
 Majority of the values lie between 45.1% and 49.7%.
 Warranty complaint process stands at 1.6 sigma
12

13. 3
Analyze
Analyze
13

14. 4
D M A I C
Deployment Process Flow
14
AIS - VADODARA

15. Problem Type
D M A I C
Par et o Char t of PROBLEM TYPE
80
Count
60
60
50
40
40
30
20
20
10
0
al
ic
an
h
ec
M
Count
Percent
Cum %
ec
El
l
ca
tr i
m
Hu
20
22.5
80.9
52
58.4
58.4
an
ce
en
ig
gl
Ne
ow
Kn
e
dg
le
9
10.1
91.0
0
p
Ga
Per cent
80
70
PROBLEM TYPE
Major Defect type to
focus are
100
90
Mechanical Errors
Electricial Errors
Errors due to Human
Negligence
8
9.0
100.0
PROBLEM TYPE
Dot pl ot of SL of JOB
Electrical
Human Negligence
Knowledge Gap
Mechanical
0
12
24
36
48
SL
60
72
84
AIS - VADODARA

16. Material Affected by Problem Type
D M A I C
PROBLEM TYPE
MECHANICAL
MAJOR AFFECTED
Breaker,Pnl Assly
MATERIAL
Earth Switch
PROBLEM TYPE
Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE
ELECTRICAL
PROBLEM TYPE = Mechanical
60
20
40
10
20
0
0
Count
Percent
Cum %
l T T e
r ly h s s
r T
k r
ke ss i tc m m t t e P ria P C enc rloc t he
ea l a Sw It e r It e hu Bus at e
O
g te
i
S
Br Pn t h ing e
m
gl I n
ar hin Oth
ne
se
E c
o
g
in
a
Lo
M
gg
a
lt
na
Fi
Per cent
80
30
MATERIAL AFFECTED
100
40
Count
50
20 7 5 3 3 3 2 2 2 1 1 1
2
38 13 10 6 6 6 4 4 4 2 2 2
4
38 52 62 67 73 79 83 87 90 92 94 96 100
Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE
PROBLEM TYPE = Electrical
MAJOR AFFECTED LV Wiring,CT,PT,Relay
50
MATERIAL
Count
30
20
10
MATERIAL AFFECTED
0
r
ng CT ac k PT ealy m p it ch CB et e
ir i
p
R La Sw M M
W
er
n
w
io i t
LV
Po
at im
ic L
d
In
Count
3 2 2 2 2 1 1 1 1
Percent
15 10 10 10 10 5 5 5 5
Cum %
15 25 35 45 55 60 65 70 75
r
PT alay elay i tch t he
Re R c sw O
Tn
100
80
60
40
20
0
Powerpack
Per cent
40
1 1 1 1 1
5 5 5 5 5
80 85 90 95 100
AIS - VADODARA

17. Material Affected by Problem Type
D M A I C
PROBLEM TYPE
KNOWLEDGE GAP
50
MAJOR AFFECTED
Pnl Handling
40
MATERIAL
Transport Damage
PROBLEM TYPE
HUMAN NEGLIGENSE
Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE
Per cent
PROBLEM TYPE = Knowledge Gap
Count
30
20
10
MATERIAL AFFECTED
0
g
e
in
ag
dl
am
an
h
tD
el
or
an
sp
P
an
Tr
Count
4
2
Percent
50.0
25.0
Cum %
50.0
75.0
s
Bu
PT
r
be
us
B
1
12.5
87.5
er
th
O
1
12.5
100.0
100
80
60
40
20
0
0
0.0
100.0
Par et o Char t of MATERI AL AFFECTED by PROBLEM TYPE
PROBLEM TYPE = Human Negligence
MAJOR AFFECTED
50
MATERIAL
Per cent
Count
40
30
20
10
0
MATERIAL AFFECTED
Count
Percent
Cum %
Loose Material
Loose material
8
88.9
88.9
Packaging
1
11.1
100.0
Other
0
0.0
100.0
100
80
60
40
20
0
AIS - VADODARA

18. Material Affected
D M A I C
PARETO CHART of MATERI AL AFFECTED
100
90
80
Count
60
60
50
40
40
30
20
20
10
MATERI AL AFFECTED
0
l
er ri a sly ch ng
ak te as wi t dli
e a l
Br m Pn th S han
r l
se
Ea n e
oo
L
Pa
Count
Percent
Cum %
Per cent
80
70
T T T g s s r k k y e r e p h h B r g T y r
P P C r in em em tte oc ac eal ag b e nc m i tc itc C et e in P al a th e
s
i t t u rl p
s e a
M M ag
e
W g I r I Sh te er R am Bu lig n L Sw Sw
R O
Bu
k
e
n w
D
g io it i t
V in th
I o
ac
t
e t im im
L in
P
n a
P
or
O
g ic L L
ch
sp
n nd
a
gi I
M
an
Tr l t ag
a
n
Fi
20 10 7 5 4 4 3 3 3 3 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4
22 11 8 6 4 4 3 3 3 3 3 3 2 2 2 2 1 1 1 1 1 1 1 1 1 1 4
22 33 41 47 51 56 59 62 66 69 72 76 78 80 82 84 86 87 88 89 90 91 92 93 94 96100
0
It is clearly visible that the majority of the items affected are Breaker(20%),loose Material(11%),Pnl
assly(8%) & EarthSwitch(6%) as these contributes 47 % of total affected material .
AIS - VADODARA

19. Fishbone – Breaker Issues
D M A I C
MATERIAL
MATERIAL
MACHINE
MACHINE
MECHANICA
L
MAN
MAN
ISSUE
A
TRIPPING CLOSING COIL
MISMATCH
POLE CENTERE TO CENTRE
DISTANCE UNEVEN
FAULTY BREAKER
ISOLATING
LIMIT SWITCH
CONTACT
LOOSE
INTERLOCKING PIN
SECONDARY SOCKET
QC STICKER NMISSING
PIN BROKEN
RATING STICKER MISSING
CLUTCH WIRE MALFUNCTION
ELECTRICAL PROBLEM
TEST & SERVICE
STICKER MISSING
MECHANICAL PROBLEM
FABRICATION
SECONDARY SOCKET
MISTAKE
STOPBOLT LENGTH MISHMATCH
WIRE MISSING
SHUTTER PIN HOLDING
BRACKET MALFUNCTION
ON OFF INDICATION
REVERSE
AUXILIARY DRIVE
TEST SERVICE INTERLOCKING LINK
FAULT
BREAKER
(MVIA00055-01) FAULTY OPERATION
ISSUE
LAND
ALTITUDE
EXPOSURE
TO RAIN
SITE
LOCATION
BUS PT SURFACE &
SHUTTER
WRONG BRASS BUSS
ROLLER CENTER TO
CENTRE DISTANCE
PIN RUBBING
WRONG PROCESS FOR BUSPT TRUCK INSERTION
LACK OF KNOWLEDGE
BREAKER INSERTION
IMPROPER SCRAP
EARTH SUPPORT SLOT
NO CONTROL OVER
COMMISSIONING PEOPLE
MISALIGNMENT
WRONG HANDLING AT
SITE
SITE CLIMATE
CONDITION
IMPROPER RACK IN-OUT
SLOT ON THE FACIA
PLATE
NO GUIDELINES AVAILABLE
TOTAL NO OF CAUSE : 26
TOTAL
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
CONTROLLABLE CAUSE : 22
CONTROLLABLE CAUSE : 22
NONCONTROLLABLE CAUSE : 4
NONCONTROLLABLE
4
AIS - VADODARA

20. Fishbone – Panel Assembly Issues
D M A I C
MATERIAL
MATERIAL
MACHINE
MACHINE
MAN
MAN
PRODUCTION BOM
NOT IN PROCESS
CT CHAMBER EARTHING
CAGE NUT FALLING
MECHANICA
L
ISSUE
B
IMPROPER HARDWARE USED
SHUTTER FOULING WITH SPOUT
INSULATOR FIXING CHANEL
MVIB00162-01, MVIB00162-02
WRONG POSITION
SHORTAGES OF
FABRICATION FROM
SUPPLIER END
BUSBAR CHAMBER TOP BLOW OFF
COVER MVIB00112-01 HOLE NOT
MATCH WITH TOP COVER
(MVIB00143-01 ) HOLE
NO STANDARD HARDWARE LIST
IMPROPER SUPER MARKET
ARRENGEMENT (2 BIN)
NO SYSTEMATIC PROCESS
BRK GUIDE CHANNELMVIB0005901/ MVIB00050-02 OPPOSIT BEND
IMPROPER LIMIT SWITCH
OPERATION
RED-YELLOW SHUTTER POSITION
OPPOSITE
LOOSE TITGHTENING OF
FASTENERS
SIDE SHEET BULGING
CT CH DOOR CLOSING PROBLEM
INSULATOR, DROPPER CONN
LOSSE ASSEMBLED
IMPROPER GASKETTING
SHUTTER SLIDING BRACKET
MVIB00O97-01/98-01 SLOTE
NOTFILED
LV DOOR ISSUE
PANEL ASSLY
ISSUE
BAD UNEVEN
FLOOR
BAD QUALITY
SEMIFINISHED PNL
FROM SUPPLIER END
INSULATOR, DROPPER CONN
LOSSE ASSEMBLED
WORKSHOP CONDITION
NO INCOMING INSPECTION FOR
PANEL FRO SUB-CONTRACTORS
IMPROPER PROCESS
NO QUALITY CHECK FROM
SUPPLIER END
IMPROPER PANEL
ASSLY
LACK OF KNOWLEDGE
BREAKER CHAMBER DOOR
PROBLEM
POOR QUALITY BENDING.
WRONG PAINT THICKNESS
RUST COMES IN PANEL
Since all causes for the PANEL
Since all causes
ASSLY ISSUES are very minute
ASSLY ISSUES are very minute
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
so whole panel assly considered
so whole panel assly considered
as 1 controllable cause
as 1 controllable cause
AIS - VADODARA

21. Fishbone –Earth Switch Issues
D M A I C
MATERIAL
MATERIAL
MACHINE
MACHINE
ISSUE
DESIGN ISSUE
EARTHSWITCH
INDICATION
IMPROPER
NO DESIGN
LLI INSULATOR
WIRING ISSUE
INSULATOR OF LLI
EARTH SWITCH HV
FAILED
MECHANICA
L
MAN
MAN
C
EARTHSWITCH
STICKER MISSING
MVIB00373-01 ,
MVIB00375-01
ASSEMBLY BROKE
WRONG TYPE OF
EARTH SWITCH
FITTED
LINK IN S/E EARTH
SWITCH FOULING
WITH EARTHING
CONN
CONFUSION BELWEEN LLI
& NORMAL EARTHWITCH
CONTACT
LOOSE
LOOSE FITTING OF BOLT
& NUT IN CONTACT
WRONG CALL
IN BOIM
KNOWLEDGE
GAP
EARTH-SWITCH
ISSUE
THE HOLE OF CAM
LEVER(MVIB0036901AND MVIB0035001) NOT PROPER
EXTERNAL THREAD OF ESW
INTERLINK MVIB00530-01
AND MVIB00353-01 NOT
PROPER
THE CAM ASSEMBLY
MVIB00350-01 FOULED WITH
B/B CHAMBER SIDE SHEET
DURING MOVEMENT
BECAUSE THE SLOT OF
SIDE SHEET ARE SMALL
THE CAM
LEVER(MVIB00350-01)
FIXING HOLE AT ESW
ROD(MVIB00356-04) NOT
MATCHED.
WRONG USING AT
CUSTOMER END
WRONG
HANDLING
PROECSS
THE M6 SCREW LENGTH
ARE SMALL WHICH IS FIXED
WITH ESW ARMS.
KNOWLEDGE
GAP
IMPROPER
MANPOWER
Since all causes for the EARTH
Since
SWITCH ISSUES are very minute
SWITCH ISSUES are very minute
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
so whole panel assly considered
so whole panel assly considered
as 1 controllable cause
as 1
AIS - VADODARA

22. Fishbone –LV Wiring Issues
D M A I C
ELECTRICAL
MATERIAL
MATERIAL
MACHINE
MACHINE
SWITCH DEFECTIVE
WIRE MISSING,LOOP OPEN
APPL ENGG MISTAKE
LV CHAMBER FABRICATION
PROBLEM
SWITCH LABEL WRONG
BTB,MTB,DTB & OTHER
WIRING PROBLEM
SUPPLIER’S MISTAKE
WIRE DUCT COVER OPENED
OPERATOR’S MISTAKE
ANNUNCIATOR LABEL MISSING
WRONG COLOR INDICATION LAMP
APPL ENGG MISTAKE
A
WRONG ISSUE OF
RELAY/METER/ANNUNCIATOR/MCB ETC
DISCONNECTOR TERMINAL
BLOCK MISSING
APPL ENGG MISTAKE
ISSUE
MAN
MAN
OPERATOR’S MISTAKE
SECONDARY PLUG WIRE MISSING , WIRE
OPEN, WRONG FERRULING, SOCET BROKEN
EARTHING FLEX MISSING
RELAY POWER SUPPLY CARD
BLOWN OUT
WIRE MISSING,LOOP OPEN
POOR QUALITY WIRE DRESSING
SWITCH HANDLE MISSING
RELAY / METER / ANNUNCIATOR ETC
DEFCTIVE
WRONG FERRULING,LUG
INSRTUMENT STICKER MISSING
LV WIRING
ISSUE
LAND
ALTITUDE
SOFTWARE PROBLEM
OF RELAYS
EXPOSURE
TO RAIN
TRANSIT DAMAGE
WRONG PACKAGING
PALLAVARAM ISSUE
TESTING ENGG ISSUE
SITE
LOCATION
WRONG SETTING OF
INSTRUMENTS
SITE CLIMATE
CONDITION
WRONG HANDLINHG
IN SITE
NO GUIDELINE AVAILABLE
CARELESSNESS
KNOWLEDGE GAP
NO CONTROL OVER SITE PEOPLE
INADQUATE TRAINING
TOTAL NO OF CAUSE : 28
TOTAL
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
CONTROLLABLE CAUSE : 14
CONTROLLABLE CAUSE : 14
NONCONTROLLABLE CAUSE : 14
NONCONTROLLABLE CAUSE : 14
AIS - VADODARA

23. D M A I C
Fishbone –CT, PT, Meter, Relay, Power pack Issues
ELECTRICAL
MATERIAL
MATERIAL
MACHINE
MACHINE
ISSUE
MAN
MAN
WRONG LABELING
OF MODEL NO
B
PT FUSE MISSING
PALLAVARAM ISSUE
POWER PACK FUSE
MISSING
RELAY , METER DISPLAY OUT
CT RATIO WRONG
RELAY,METER LEG MISSING
RELAY CASING, SCREW
INSERT BROKEN
WRONG PROCUREMENT
OF RELAY, METERS
TRANSPORT DAMAGE
PALLAVARAM QUALITY
ISSUE
WRONG TYPE
ELECTRO MAGNETIC RELAY
OPERATING COIL
WRONG CALL IN BOM
PROCUREMENT WRONG
CT,PT,METER
PT RACK IN IMPROPER
RELAY,POWER
LAND
ALTITUDE
WRONG RATIO METERS
EXPOSURE
TO RAIN
APPL ENGG MISTAKE
SITE
LOCATION
OPERATOR’S MISTAKE
PACK ISSUE
WRONG PACKAGING
POOR QUALITY MATERIAL
NO QUALITY CHENK FOR
ELECTRICAL MATERIALS
SITE CLIMATE
CONDITION
TRANSIT DAMAGE
WRONG SETTING OF
INSTRUMENTS
WRONG HANDLINHG
IN SITE
NO GUIDELINE AVAILABLE
NO CONTROL OVER SITE PEOPLE
CARELESSNESS
KNOWLEDGE GAP
TOTAL NO OF CAUSE : 17
TOTAL
INADQUATE TRAINING
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
CONTROLLABLE CAUSE : 12
CONTROLLABLE CAUSE : 12
NONCONTROLLABLE CAUSE : 5
NONCONTROLLABLE
5
AIS - VADODARA

24. Fishbone –Earth Switch Issues
D M A I C
MATERIAL
MATERIAL
MACHINE
MACHINE
HUMAN
MAN
MAN
NEGLIGENSE
A
LOOSE MATERIAL BOX
BROKEN
PT RACK IN HANDLE NOT
IN THE BOX
BUS-COUPLER TO BUSRISER CONN MISSING IN LM
BOX
MISMATCH ITEMS IN BOX & THE
ITEMS MENTIONED IN
ATTACHED LIST
NOT IN SAP LOOSE MATERIAL BOM
CARELESSNESS
SPRING CHARGE HANDLE
MISSING
FAULTY SAP BOM
MISMATCH ITEMS IN LM BOX
SHORTAGE OF MATERIAL IN
LM BOX
LOOSE
MATERIAL
ISSUE
IMPROPER LOOSE MATERIAL
BOM
NO PROPER CROSSCHECK
TOTAL NO OF CAUSE : 10
TOTAL
MOTHER NATURE
MOTHER NATURE
MEASUREMENT
MEASUREMENT
METHOD
METHOD
CONTROLLABLE CAUSE : 10
CONTROLLABLE CAUSE : 10
NONCONTROLLABLE CAUSE : 0
NONCONTROLLABLE
0
AIS - VADODARA

25. Controllable & Non-Controllable Causes
D M A I C
Total No of Causes : 83
Mechanical : 28
Electrical : 45
Loose Material : 10
Total No of Controllable Causes : 60
Mechanical : 24
Electrical : 26
Loose Material : 10
Total No of Non-Controllable Causes : 23
Mechanical : 4
Electrical : 19
Loose Material : 0
CONTROLLABLE CAUSES REF DETAILS:
REF
DETAILS
M-A
M-B
M-C
E-A
Mechanical Issue- Breaker
E-B
HN-A
Mechanical Issues- Pnl Assly
Mechanical Issues- Earth Switch
Electrical Issues- LV Wiring
Electrical Issues- CT,PT,Meter,
Relay,Powerpack
Human Negligence
Loose material issue
AIS - VADODARA

26. Prioritizations Matrix for Controllable Causes
D M A I C
• Mechanical
M-A-2
M-A-3
M-A-4
M-A-5
M-A-6
M-A-7
M-A-8
IMPACT ON ROOT CAUSE
WEIGHT M-A-1
6
4
6
3
6
2
2
3
4
4
5
3
2
7
4
4
6
3
2
2
4
6
9
8
7
FINANCIAL BENEFIT
5
3
7
4
5
3
3
4
4
2
5
1
5
5
6
3
2
4
5
4
3
6
7
7
8
QUALITY OF PRODUCT
4
5
8
2
4
3
7
5
5
5
4
3
7
6
5
2
6
4
3
7
8
6
8
8
5
CUSTOMER SATISFACTION
3
5
5
6
6
4
5
6
7
4
6
6
7
6
4
6
4
6
8
4
6
3
8
6
4
MANAGEMENT ACCEPTANCE
2
4
6
5
4
6
7
7
7
5
4
6
8
9
5
7
4
6
7
9
4
5
6
9
8
SIDE EFFECT ON OTHER CTQ
1
5
3
6
6
6
7
3
5
6
7
8
8
4
6
6
7
7
5
5
5
9
6
6
5
87
133
80
109
69
91
93
104
82
104
73
110
131
102
85
97
91
92
95
102
118
163
157
135
E-A-2
E-A-3
E-A-4
E-A-5
E-A-6
E-A-7
E-A-8
E-A-9
TOTAL
• Electrical :
WEIGHT E-A-1
M-A-9 M-A-10 M-A-11 M-A-12 M-A-13 M-A-14 M-A-15 M-A-16 M-A-17 M-A-18 M-A-19 M-A-20 M-A-21 M-A-22 M-B-1 M-C-1
• Top five are : M-A-22 , M-B-1 , M-C-1 , M-A-2 , M-A-13
E-A-10 E-A-11 E-A-12
E-A-13 E-A-14 E-B-1 E-B-2 E-B-3 E-B-4 E-B-5 E-B-6 E-B-7 E-B-8 E-B-9 E-B-10 E-B-11 E-B-12
IMPACT ON ROOT CAUSE
6
4
6
3
6
2
7
3
4
4
5
3
2
7
4
4
6
3
2
8
8
6
8
8
4
6
4
FINANCIAL BENEFIT
5
3
7
4
5
3
5
4
4
2
5
1
5
5
6
3
2
4
5
6
6
6
8
7
8
7
5
QUALITY OF PRODUCT
4
5
8
2
4
3
7
5
5
5
4
3
7
6
5
2
6
4
3
8
8
6
8
0
3
5
5
CUSTOMER SATISFACTION
3
5
0
6
6
4
5
6
7
4
6
6
7
6
4
6
4
6
8
8
8
3
5
6
4
6
6
MANAGEMENT ACCEPTANCE
2
4
0
5
4
6
4
7
7
5
4
6
8
9
5
7
4
6
7
6
6
5
4
0
8
3
5
SIDE EFFECT ON OTHER CTQ
1
5
3
6
6
6
7
3
5
6
7
8
8
4
6
6
7
7
5
5
5
9
6
6
5
5
5
87
106
80
109
69
125
93
104
82
104
73
110
131
102
85
97
91
92
109
120
102
TOTAL
• Loose material :
151 151 118 149 107
• Top Six are : E-B-5 , E-B-6 , E-B-8 , E-A-13 , E-A-6 , E-B-11
WEIGHT
HN-A-1
HN-A-2
HN-A-3
HN-A-4
HN-A-5
HN-A-6
HN-A-7
HN-A-8
HN-A-9
HN-A-10
IMPACT ON ROOT CAUSE
6
5
6
3
9
7
5
8
4
4
7
FINANCIAL BENEFIT
5
3
5
4
7
5
5
8
4
2
5
QUALITY OF PRODUCT
4
6
7
2
5
5
7
5
5
5
7
CUSTOMER SATISFACTION
3
5
4
6
9
8
5
7
7
4
5
MANAGEMENT ACCEPTANCE
2
5
3
5
9
6
4
7
7
5
4
SIDE EFFECT ON OTHER CTQ
1
5
3
6
7
6
7
6
5
6
7
99
110
80
161
129
113
149
104
82
125
TOTAL
• Top five are : HN-A-4 , HN-A-7 , HN-A-5 , HN-A-10 , HN-A-6
AIS - VADODARA

27. 7
Root-cause Validation
D M A I C
SL
CAUSES
VALIDATION PLAN
METHOD
ROOT CAUSE
1
BREAKER INSERTION
No of Warranty Complains happened due to Breaker Inertion
YES
2
PANEL ASSLY ISSUE
Warranty Complain
Warranty Complain
&
Gemba Investication
No of Warranty Complains happened due to Panel Assly issue
& Gemba Investication carried out in POPULAR(Subcontractor)
YES
3
EARTH-SWITCH ISSUE
4
No of Warranty Complains happened due to Earth Switch issues
YES
ISOLATING CONTACT LOOSE(BKR)
Warranty Complain
Warranty Complain
&
Gemba Investication
No of Warranty Complains happened due to loose isolating contact of
breaker & Gemba Investication carried out in Components
YES
5
TRIPPING CLOSING COIL MISMATCH (BKR)
Warranty Complain
No of Warranty Complains happened due to Tripping,Closing Coil mismatch
YES
6
PT FUSE MISSING
Warranty Complain
No of Warranty Complains happened due to PT fuse missing
YES
7
POWER PACK FUSE MISSING
Warranty Complain
No of Warranty Complains happened due to Powerpack fuse missing
YES
8
WRONG PROCUREMENT OF RELAY, METERS
No of Warranty Complains happened due to wrong fitted Relay & meters
YES
No of Warranty Complains happened due to Improper wire dressing
& Gemba investication carried out in RNG (Wiring Subcontractor)
YES
No of Warranty Complains happened due to wrong issue of Realy,meter
& Gemba investication carried out in wiring dept.
YES
No of Warranty Complains happened due to Poor qulaity of material
& Gemba investication carried out at Incoming rejections.
YES
11
POOR QUALITY MATERIAL
Warranty Complain
Warranty Complain
&
Gemba Investication
Warranty Complain
&
Gemba Investication
Warranty Complain
&
Gemba Investication
12
MISMATCH ITEMS IN LM BOX
Warranty Complain
No of Warranty Complains happened due to Mismatch items in LM BOX
YES
Warranty Complain
No of Warranty Complains happened due to mismatch items in lm box &
the items mentioned in attached list.
YES
Warranty Complain
No of Warranty Complains happened due to Bus-Coupler to Bus-Riser conn
missing in the LM BOM
YES
9
POOR QUALITY WIRE DRESSING
WRONG ISSUE OF RELAY/METER
/ANNUNCIATOR/MCB ETC
10
MISMATCH ITEMS IN BOX & THE ITEMS
MENTIONED IN ATTACHED LIST
13
BUS-COUPLER TO BUS-RISER
CONN MISSING IN LM BOX
14
15
IMPROPER LOOSE MATERIAL BOM
Warranty Complain
No of Warranty Complains happened due to wrong Loose material BOM.
YES
16
SHORTAGE OF MATERIAL IN LM BOX
Warranty Complain
No of Warranty Complains happened due to shortage of material in LM Box.
YES
27
AIS - VADODARA

28. 8
Improve
Improve
28

29. Action Plan
01 of 02
BREAKER INSERTION
2) Start checking & functionality of MVIA0008501,Clutch wire &
MVIA00150/151-01 before receiving the Breaker.
2
PANEL ASSLY ISSUE
1)The slot of the MVIB00012-01(LV Ch) to be increased to
ensure the proper locking of LV BOX.
2)Viewing window's position changed in MVIB00236-01
CT ch door to ensure the proper locking.
3) Three through hole requied to fix bolt in MVIB00029-01,
MVIB00027-01,MVIB00196-01to solve the shutter-spout foluing.
CONCERNED
DEPT
CONCERNED
PEOPLE
TARGET
STATUS
Component
Mr.Rajib Marwa
25.12.09
In progress
01.08.09
Done
01.08.09
Done
01.08.09
Done
01.08.09
Done
PIX-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
4) Removal of unwanted teeth in Internal arc angle to protrct
Done
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
01.08.09
Done
6) In MVIB00236-01 bottomside 3mm cutting required to ensure
the free movement of CT Ch doors
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
25.09.09
Done
7) CT access cover & Division plate holes should be alligned to
for proper fitment
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
25.09.09
Done
8)Long fishplate to be introduced in the end pnl of BD for proper
earthing fitment.
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
25.09.09
Done
9) Small size of PIN for shutter sliding bearing to be introduced
for PNL with BUS-PT Truck .
EARTH-SWITCH ISSUE
01.08.09
5) In Reinforcement(left & right)(MVIB000595-01) CSK holes to
be implemented for fitment of CSK Rivet.
3
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
TDC &
Mr.Debasish Mahapatra
Pix-36 Manufacturing
Sudip Dutta
Pix-36 Manufacturing
Sudip Dutta
& Quality
Subhajit Das
Pix-36 Manufacturing
Sudip Dutta
& Subhada Ind
Mrs. Kalpana
25.12.09
In progress
25.12.09
In progress
25.09.09
Done
25.09.09
Done
25.12.09
ACT
1
ACTION PLAN
1)Master testing jig to be improved/ A sample pnl can be used for
BKR insertion testing.
DO
ROOT CAUSES
CHECK
SL
PLAN
9
D M A I C
In progress
1) Proper EarthSwitch On-Off indication should be introduced
2)MVIB00373-01 , MVIB00375-01 Welding required to resist
Stress & stop breaking.
4) Before Closing/tagging panel start physical checking of
Earth-Switch arm & contacts tightness.
6) The Length of M6 bolt of the arm to be increased.
29
AIS - VADODARA

30. 0
D M A I C
Action Plan
02 of 02
4
ISOLATING CONTACT LOOSE(BKR)
1)Start Checking the proper tightening of Isolating Contact
at Bkr premises & check Micro-ohm in panel premises
before receiving the Breaker.
5
TRIPPING CLOSING COIL MISMATCH (BKR)
1) Re-Functional test required after changing of faulty coil
6
PT FUSE MISSING
1) Before Closing/tagging panel start physical checking.
7
POWER PACK FUSE MISSING
8
WRONG PROCUREMENT OF RELAY, METERS
9
POOR QUALITY WIRE DRESSING
WRONG ISSUE OF RELAY/METER
/ANNUNCIATOR/MCB ETC
10
11
12
POOR QUALITY MATERIAL
MISMATCH ITEMS IN LM BOX
MISMATCH ITEMS IN BOX & THE ITEMS
MENTIONED IN ATTACHED LIST
13
BUS-COUPLER TO BUS-RISER
CONN MISSING IN LM BOX
14
15
16
IMPROPER LOOSE MATERIAL BOM
SHORTAGE OF MATERIAL IN LM BOX
1) Before Closing/tagging panel start physical checking.
1) Start re-checking of ordered relay ,meters (model no,spec)
from Engg Drg of each Job prior to material delivery.
1) Several Visit require to supplier's end & verify the process
wiring set up,quality of the LV Wiring
1) Separate BOM with Long description of each instruments
to be given to all Wiremen(In-house+Out-side) for respective
LV BOX to visuallly varify all the materials before mounting in
Low Voltage/Instrument chamber
1) Sampling inspection with ordered copy of the Electrical items
to be Started by Incoming Inspection
1) Strict Verification required for each & everything items qty.
1) One standard list should be prepared for each varity of panels
board & that list only to be circulated in LM BOX & with invoice.
PIX-36 Manufacturing,
Testing
Sudip Dutta
Mr. Saibal Boxi
20.07.09
Done
Component
Pix-36 Manufacturing
& Quality
Pix-36 Manufacturing
& Quality
Mr. Vivek patil
Sudip Dutta
Subhajit Das
Sudip Dutta
Subhajit Das
Mr.Satyabreta Manna
Ms. Darshana patel
Mr. Naresh Kumar
Subhajit Das
01.12.09
In progress
01.10.09
Done
01.10.09
Done
30.12.09
In progress
01.07.09
Done
PIX-36 WIRING
Incomin Inspection
Quality
Quality
Mr. Naresh Kumar
30.12.09
In progress
Mr. Indranil Indu
Mr. Indranil Indu
30.12.09
In progress
Done
Quality
Mr. Indranil Indu
01.11.09
Done
Sudip dutta
Mr. Aditya Kota
Respective Engg
Mr.Indranil Indu
Sudip Dutta
01.11.09
Done
30.12.09
In progress
01.11.09
Done
Purchase
PIX-36 Wiring
Supplier-Quality
1) The Connection should be incorporated in LM Bom of Space 2k
Though we are managing entering it in SAP Lm BOM.
PIX-36 Manufacturing
Core Engg
Appl Engg
1) Correct Sap bom to be uploaded in Space2k & sap .
Quality
PIX-36 Manufacturing
2)1) Strict Verification required for each & everything items qty.
30
AIS - VADODARA

31. 1
D M A I C
Improvements
BEFORE
AFTER
Gap
reduced
Holes are incorporated in DRG
31
AIS - VADODARA

32. 2
D M A I C
Improvements
BEFORE
CSK holes required
Create rusting in MVIB00236-01
AFTER
CSK holes added
The teeth was obsoluted in DRG
32
AIS - VADODARA

33. 3
D M A I C
Improvement results
Boxpl ot of % War r ant y compl ai nt s = ( Cumul at
% War r ant y complaint s = ( Cumulat
55
50
45
40
35
1 Before
St at us
2 After
Two-Sample T-Test and CI: %Warranty complaints = (Cumulat, Status
Two-sample T for %Warranty complaints = (Cumulat
Status
N Mean StDev SE Mean
1 Before 13 47.62 3.61
1.0
2 After
1.5
4 40.46 3.08
Difference = mu (1 Before) - mu (2 After)
Estimate for difference: 7.16
95% CI for difference: (2.88, 11.43)
T-Test of difference = 0 (vs not =): T-Value = 3.57 P-Value = 0.003 DF = 15
33
AIS - VADODARA

34. D M A I C
Process Sigma Calculation-(JULY,09-OCT,09)
Determine number of defect opportunities/unit (O)
1
Determine number of unit processed
(N)
23
(D)
2
Determine number of total defected unit
Calculate defects per opportunities
(DPO)
Calculate Yield
Dpmo=86956.52
0.08695652
91.2%
Look up Sigma in the process sigma table (SIGMA)
Determine Z value from Z bench
2.9
1.4
HERE UNITS CONSIDERS AS TOTAL NOS OF ORDERS EXECUTED
AIS - VADODARA

35. 5
Benefit Calculation
D M A I C
As per the AREVA Standards we consider the followings,
RE
O
EF
B
• Avg 1 no of PIX-36 pnl cost : 700 KINR
• Avg 1 no of warranty complain attend time: 5 days
• Hotel rent allocated for Service people (Non-metro City) : 3000 Rs / day
• Food cost allowable (Non-metro City) : 750 Rs / day
• Ticket (AIR/TRAIN) cost is not considered as the places may vary.
DURATION
FEB-07 TO JUNE-09
TOTAL NO
NO OF
FREE REPLACEMENT
(KINR)
MONTH OF PNL COMPLAIN SALE (KINR)
29
565
69
395500
114.66
COST INCURRED BY
TOTAL COST
COST OF
SERVICE PERSON FOR WARRANTY WARRANTY/MONTH
(KINR)
CLAIM (KINR)
(KINR)
1293.75
1408.41
48.56586207
Percentage warranty cost = [{(cost of warranty/month) / (sales/month)} x 100]
= [{(48.57) / (395500/29)} x100]
R
TE
AF
= 0.36
DURATION
JULY-09 TO OCTOBER-09
TOTAL NO
NO OF
FREE REPLACEMENT
(KINR)
MONTH OF PNL COMPLAIN SALE (KINR)
4
158
2
110600
11.49
COST INCURRED BY
TOTAL COST
COST OF
SERVICE PERSON FOR WARRANTY WARRANTY/MONTH
(KINR)
CLAIM (KINR)
(KINR)
37.5
48.99
12.2475
Percentage warranty cost = [{(cost of warranty/month) / (sales/month)} x 100]
= [{(12.25) / (110600/4)} x100]
= 0.04
SO TOTAL SAVE / ANNUM WILL BE = {(cost of warranty/month BEFORE-cost of warranty/month AFTER) X 12}
={(48.56-12.24) X 12}
= 435.8 KINR
35

36. 6
D M A I C
Financial Validation
LY
AL
CI
D
AN ATE
N
FI
LID
VA
The savings due to this project is financially validated
36

37. 7
Control
Control
37

38. 8
Warranty Complaints – Current Status
D M A I C
I Char t of % War r ant y compl ai nt s by St at us
55
1 Before
1
2 After
1
I ndiv idual Value
50
UCL= 47.01
45
_
X= 40.46
1
40
35
LCL= 33.92
1
3
5
7
9
11
Obser v at ion
13
15
17
38
AIS - VADODARA

39. 9
D M A I C
Process Standardization
Process checklists introduced to control & maintain the improvement
39

40. 0
D M A I C
Key learning’s & Further Scope
• Fundamentals of DMAIC Methodology & how to apply the same to
improve any kind of process.
• Main Key understanding during this project :
• How important is DATA to evaluate & improve any present process.
• Statistically presentation of any process & evaluate the same .
• Minitab Statistical tool .
• The major points of PIX-36 panels where improvement required .
• Further Scope :
• Next greenbelt can be taken on other products (HWX,PCOB,BREAKER etc)
40

41. 1
Thank you
41