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International Journal of Innovative Research in Technology, Science & Engineering (IJIRTSE)

www.ioirp.com ISSN: 2395-5619, Volume – 1, Issue – 3. May 2015

110

TURTLE DIAGRAM-PROCESS APPROACH

TECHNIQUE TO IMPROVE QUALITY OF A

MANUFACTURING ORGANIZATION

1Piyush Jain, 2Prateek Verma, 3Sharad Shrivastav 1M.TEch, Production Engineering. RIET, Jaipur, Rajasthan, India

23Assistant Professor, Mechanical department, RIET, Jaipur, Rajasthan (India) [email protected], [email protected], [email protected]

Abstract— This Report gives the quality improvement that are needed to reduce the defectives at the various machine shops which also

helps in reducing rejections in process shop of manufacturing of reflectors at Autolite (India).ltd.vishwakarma industrial area, Jaipur.

The manufacturing process of Reflectors of head lights are studied in detail and the problem areas that contribute more significantly to

the defectives are identified. The technique used to obtained the detail analysis of various process is TURTLE DIAGRAM which helps

in maintaining the detail study in single diagram

Keywords— Turtle diagram, with what, with whom, How many, How)

I. INTRODUCTION

Autolite Group is a focused, dynamic and progressive group providing customers with Innovative Products at economic

Prices. The Group has core competencies in manufacturing of Automotive Head Lamps, Work Lamps, LED Lamps, Fog Lamps,

Turn Signal Lamps, Halogen Bulbs, and Incandescent Bulbs & Miniature Bulbs. These competencies are supported by

specialization in Engineering Design, Information Technology, and Tool Manufacturing & Machine Building. The company was

formed with the objective to design, manufacture and market automotive lighting products globally.

II. SCOPE AND OBJECTIVE OF RESEARCH

Basically Autolite (India) ltd. is the manufacturing company in which various manufacturing process has been performed

such as sheet metal operations, process operations, injection moulding and assembly operations. hence as many as manufacturing

operations the problems also been generated regularly and hence there is a lot of scope for research in the solutions of these

problems.

The main objective of research is two understand how the problems can be identified, and observations can be taken and how to

find out the solutions of problem in order to improve the quality of the product in order to improve the customer satisfaction and

also how improve the productivity in the organization to increase the profit.

A. Objectives:

1. To find the detail with what equipments or machines operation is performed in particular stage

2. To find the detail with whom such as operators or automatic machine operation is performed in particular stage

3. To find the detail how many Parts per month (PPM) is manufactured or we can say the manufacturing capacity of

Machine

4. To find the detail how parts are to be manufactured or methods/processes of manufacturing.

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III. OPERATIONS PERFORMED AT VARIOUS STAGES OF AUTOLITE (INDIA) LTD.

Shops/operations Press shop Process shop Moulding shop Assembly shop

1 Sheet metal cutting Buffing Injection Moulding Adaptor fitting

2 Drawing Washing Bulk moulding Sealing

3 Out cutting Phosphating Lens fitting

4 Collar bending Lacquering Rim fitting

5 Bottom cutting Metalizing Component fitting

6 Chule bending Plating/painting/powder

coating

Air leakage testing

7 Notching Aiming

8 Parking

9 Embossing

10 Projection welding

IV. TURTLE DIAGRAM

A “Turtle Diagram” is a quality tool used to visually display process characteristics such as inputs, outputs (expectations),

criteria (metrics) and other high-level information to assist in the effective execution and improvement of key business processes.

While there is no requirement per ISO 9001 or TS 16949 to create or manage turtle diagrams, I have worked with organizations

who use turtle diagrams in an effective an lean manner. The use of these “one page plans” for key processes have often times

allowed for the archive of multi-page procedures that no one reads in the first place. The diagrams also work as a contract

between cross-functions, illustrating where product, communication and other hand-offs begin and end.

This discussion will guide you in creating an accurate turtle diagram by defining the expectations for each box within the process

map.

Inputs–Enter details of the actual process input such as documents, materials, schedules, requirements, information, etc.

Process –Enter Customer, Support or Management process.

Outputs – Enter details of the actual process output such as product, documentation, records, etc. linked to an actual measure of

effectiveness. What: Equipment & Materials –Enter details of the machine, materials, test equipment, computer systems, software, etc. used in the process. Who: Personnel & Competencies –Enter personnel requirements, including special skills, competence requirements, training requirements, restrictions, etc. How: Documentation/Methods – Enter linked process controls, support processes, instructions, procedures, set-up illustrations, specific methods used, etc. Criteria: Objectives & Targets – Enter the measures of the process effectiveness & efficiencies such as goals, targets & objectives

Block Diagram of Turtle Diagram




112

TURTLE DIAGRAM OF PRESS SHOP

TURTLE DIAGRAM OF BUFFING




113

TURTLE DIAGRAM OF ULTRASONIC CLEANING

TURTLE DIAGRAM OF PHOSPHATING




114

TURTLE DIAGRAM OF LACQUERING

TURTLE DIAGRAM OF PAINTING




115

TURTLE DIAGRAM OF POWDER COATING

TURTLE DIAGRAM OF METALIZING




116

TURTLE DIAGRAM OFPLASTIC MOULDING

TURTLE DIAGRAM OF ASSEMBLY

V. DISCUSSION ON RESULTS

1. Turtle diagram is helpful to obtain the detail analysis of various manufacturing processes at each stage

2. Turtle diagram is helpful to obtain the Problem occurs at various manufacturing stages

3. Turtle diagram is helpful to obtain the root cause of the problem




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4. Turtle diagram is helpful to reach at the solution of problem

VI. CONCLUSION

1. Productivity of the plant will be increased.

2. Accidental closer will be less.

3. Better quality check will automatically effect the production quality.

4. Find the problem easily

5. Find the solution of the problem easily

A. FUTURE SCOPE

The above suggestions which are described above are helpful to improve the quality of Reflector in various manufacturing. By

utilizing the Turtle diagram technique we can also find the root cause of problems in sales and marketing.

ACKNOWLEDGEMENT

The authors are thank full to Shri. Ram.Avtar.SHARMA H.R. and Shri Manoj .Mathur Plant Head and Mr. Balwant Production

in charge at Autolite (India). Ltd. Viswakarma industrial Area, Jaipur for providing their full

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