7. A
• Failure of injection moulding nozzle
• Accidents during maintenance of Grinding
machine
B
• Leakage of Hydraulic oil
• Live circuit in contact with equipment body
C
• Equipment damage due to voltage fluctuations
• Suspended particulate matter and flyaway
• Accidents during machine maintenance
• Injuries during mould transport and storage
• Accidents during hopper loading
• Burns due to handling of hot products
A- Can be solved by themselves
B- Can be solved with help of other departments
C- Requires management support
7
10. Problems Pre determined criteria weightage rank
fatigue quality safety environment production
Equipment damage due to voltage fluctuations 1 1 1 3 1
Live circuit in contact with equipment body 1 1 1 3 1
Suspended particulate matter and flyaway 1 1 1 3 1
Accidents during mould maintenance 1 1 1 3 1
Accidents during EOT crane maintenance 1 1 2 2
Failure of injection moulding nozzle 1 1 1 3 1
Injuries during mould transport and storage 1 1 2 2
Slippage of mould due to improper maintenance of
Platens
1 1 1 1 3
Leakage of Hydraulic oil 1 1 1 3 1
Accidents during hopper loading 1 3
Accidents during maintenance of Grinding machine 1 1 1 3
Burns due to handling of hot products 1 1 3
Absence of appropriate lighting conditions 1 1 2 2
Fire hazards 1 1 1 3 1
10
12. Sl. No Problems Frequency Percentage
1
Injuries during mould
handling
8 34.78
2
Accidents during
machine maintenance
5 21.74
3
Suspended particulate
matter and flyaway
4 17.39
4
Equipment damage due
to voltage fluctuations
4 17.39
5
Live circuit in contact
with equipment body
1 4.35
6 Leakage of Hydraulic oil 1 4.35
7 Fire hazards 0 0
TOTAL 23 100
12
15. Problem 1
• Injuries during mould handling– EOT break
failure, Loose parts falling off during transport of mould by
EOT crane, mould falling on an operator’s feet
Mould
mounted on
machine
Mould
carried
from
workshop to
machine
Mould taken
to Workshop
Mould
carried by
EOT crane
Mould
Dismounted
15
16. Production
is carried
out
Maintenance
is carried
out
Control
panel is
opened up
Machine is
turned off
Cutting
machine is
restarted
Machine
cover is
opened and
blades are
cleaned
Cutout
plastics are
emptied
Main power
switched off
Cutting
machine is
switched off
Problem 2
• Accidents during machine maintenance–
control panel maintenance of injection machine, grinding
machine maintenance.
16
17. The plastic
granules
are stored
The plastic is
converted to
smaller
granules
Scrap plastic
is inserted
into the
machine
Grinding
machine is
started
Problem 3
• Suspended particulate matter and
flyaway – while operating the grinding machine
17
19. S.no Activity Responsibility Oct’
16
Nov’1
6
Dec’1
7
1 Defining the problem All members
2 Analysis of problem All members
3 Identification of
causes
All members
4 Finding out root
causes
All members
5 Data analysis Ashish Rakshit
6 Developing solution All members
7 Foreseeing resistance All members
8 Trial Implementation Swapan Mondal
9 Regular
implementation
All members
10 Follow up and review All members
19
21. What is the problem?
Injuries during mould
handling
Where is the problem?
Production area
When is the problem
observed?
During transportation of
mould
Who noticed the
problem?
The operators at
production line
How did the problem occur?
1) EOT brake failure
2) Falling of loose parts
during mould handling
21
22. What is the problem?
Accidents during machine
maintenance
Where is the problem?
Production zone
(machines)
When is the problem
observed?
During machine
maintenance
Who noticed the
problem?
Maintenance department
operators
How did the problem occur?
1)Sparks during machine
control panel maintenance
2) Accidentally turning the
power supply on during
maintenance
22
23. What is the problem?
Suspended Particulate
Matter and Flyaway
Where is the problem?
Production zone
When is the problem
observed?
During machine
operation
Who noticed the
problem?
Operators at
production zone
How did the problem
occur?
1) Absence of
protective eyewear
24. What is the problem?
Equipment damage due to
voltage fluctuations
Where is the problem?
Production area
When is the problem
observed?
During production
Who noticed the
problem?
Operators at
production zone
How did the problem
occur?
1) Voltage fluctuations in
power supply
24
42. STEP 9:
Foreseeing Problems Of
Resistance
Fund allocation from management
Periodic training and safety drill
implementation
Providing SOP's for machine operation
Enforcing strict safety measures and providing
incentives
42
44. Regular checks are conducted to
ensure compliance with safety
regulations.
Periodic drills conducted and
attendance of employees is
monitored.
Routine maintenance checks for
machinery and components.
44
45. • To provide a zero accident work
environment
• To eliminate all potential risks associated
• To provide enhanced job satisfaction and
sense of security to employees
• To involve all employees in constant
improvement and implementation of
safety regulations
45
50. Step No. Activity Responsibilities Oct'16 Nov'16 Dec'16
3 Defining the Problem All Members
Target
Achieved
4 Analysis of the problem All Members
Target
Achieved
5 Identifying the causes All Members
Target
Achieved
6 Finding out the root causes All Members
Target
Achieved
7 Data Analysis A.Rakshit & S.Mondal
Target
Achieved
8 Developing Solution All Members
Target
Achieved
9 Foreseeing Resistance All Members
Target
Achieved
10 Trial Implementation S.Mondal & C.Das
Target
Achieved
11 Regular Implementation All Members
Target
Achieved
12 Follow up/Review S.Mondal & C.Das
Target
50
