tqm project title
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TQM PROJECT TITLE. Additional shifting of finished goods resulting in higher cost due to extra work. FACILITATOR & TEAM . Facilitator : Sh.Shantanu Daga ji Team leader : Sh.P.C .Mittal Member : Sh.Rachhpal Singh Sh.Purshottam Singh. - PowerPoint PPT PresentationTRANSCRIPT
TQM PROJECT TITLE
Additional shifting of finished goods resulting in higher cost due to extra work.
FACILITATOR & TEAM
Facilitator : Sh.Shantanu Daga ji
Team leader : Sh.P.C .Mittal Member : Sh.Rachhpal Singh Sh.Purshottam Singh
ATTENDENCE OF MEETINGSR. NO. DATE TOPICS P.C.M R.S P.S.
01 25/07/11 TQM MEETING (TEAM FORMATION) P P P
02 26/07/11 PROBLEM STATEMENT & MISSION STATEMENT P A P
03 27/07/11 PROJECT DISCUSSION P P P
04 05/08/11 BRAIN STORMING P P P05 07/08/11 FLOW DIAGRAM P P P06 09/08/11 EVALUATION ON BRAIN STORMING P P P
07 10/08/11 CAUSE-EFFECT DIAGRAM (FISH BONE DIAGRAM) P P P
08 15/08/11 GRAPH AND CHARTS P P P09 12/08/11 PROJECT REVIEW P P P10 15/08/11 HISTOGRAM AND PARETO DIAGRAM P P P11 02/09/11 DATA ANALYSIS P P P12 16/09/11 TEST THEORY P P P13 30/09/11 DATA ANALYSIS OF TEST THEORY P P A14 19/10/11 PROJECT REVIEW P P P15 04/11/11 PROJECT REVIEW P P P
TOTAL ATTENDANCE 15 14 14
PROBLEM STATEMENT
The finished goods are shifted from one place to another resulting in a loss of Rs. 20000/mth.
MISSION STATEMENT
To reduce loss incurred due to shifting of material to Rs.5000/month by 31 Mar,
2012
EXPENSES ON SHIFTINGMonths
EXPENSES ON SHIFTING
JAN. 113935
FEB. 118696
MAR. 117540
APR. 115775
MAY. 119455
JUN. 115934
JUL. 1112188
AUG. 119210
SEP. 11 6308
OCT. 116816
Nov. 118116
EXPENSES ON SHIFTING
JAN. 11 FEB. 11 MAR. 11
APR. 11 MAY. 11
JUN. 11 JUL. 11 ADG. 11
SEP. 11 OCT. 11
Nov. 11 0
2000
4000
6000
8000
10000
12000
14000
Series 1
AMOU
NT I
N R
s.
MONTH & YEAR
QC TOOLS USED
1.Process/Flow diagram
2.Cause & Effect Diagram
3.Stacked graph/Line graph
FLOW DIAGRAMStart
Packing Lifting of final yarn Godown
Space available In yarn godown
Final shifting to yarn Godown
Storage
Dispatch
Shifting in Deptt. Gallery
Stored in Deptt.
Re-check Space availability
BRAIN STORMING1. Insufficient space in godowns2. Wide dispatch fluctuations on daily basis.3. Godowns far off from packing deptt. 4. Manual movement to first floor of consumes time & labor. 5. Untimely dispatch advice.6. Unavailability of canter for material shifting7. Road congestion on the way to Godown IV.8. Difficulty in material identification due to poor lighting.9. Loading delays due to uncovered shed during monsoons11. Contractor workers – delay in work, delay in reporting, etc12. Labor less than requirement provided by contractor. 13. Stock stored inside department is damaged by workers.14. Stock at various places causes delays during loading – truck owners complain. 15. Delays in arrival of transport – container for export16. Repacking because sample is required after packing. 17. Pallet machine faulty.18. Uncovered shed cause delay in shifting during rain.
CAUSE EFFECT DIAGRAM
Additional shifting of FG resulting in
higher cost due to extra work.
LOCOMOTION
METHOD
CUSTOMERMAN
Lifts unavailabilityPallet lifting
Machine faulty
Shifting delay
Canter breakdown
Uncovered shed causes delay during rain
Internal movement
Small forklift unavailable
Manual shifting causes broken cases
Irregular dispatch
Stock
Excess form export/short wt.
Loading mistake
Reloading
Wrong loading
Rechecking
Undefined timings
Heavy work
Labour
Wage structureTired/sick
Contract labour irregular
Godown too farPacking at different places
Storage
Manual shifting & extra time
Canter availability
Production not as per plan
Poor planning
Advice delay
Vehicle not available
Ranking of brainstorming pointsS.No.
Description Data
1 Insufficent space in godowns. Available2 Fluctuations in monthly dispatch. Available3 Manual movement to first floor /basement of consumes time & labor Available4 Untimely dispatch advice. Not available5 Contractor workers-delay in work ,delay in reporting,etc. Not available
6 Unavailability of canter for material shifting. Available7 Labor less than requirment provided by contractor. Available8 Godowns far off from packing deptt. Not available9 Pallet machine faulty. Available10 Delays in arrival of transport –container for export. Not available11 Uncovered shed cause delay in shifting during rain. Available12 Difficulty in material identification due to poor lighting. Not available13 Road congestion on the way to godown IV. Not available14 Stock at various places causes delays during loading –truck owner
s complain.Not available
15 Stock stored inside department is damaged by worker.s. Not available16 Loading delays due to uncovered shed during monsoons. Not
available
PRIORITIZATION OF CAUSES Insufficient space in go-downs.Fluctuations in monthly dispatch.Manual movement to first floor of consumes
time and labor.Untimely dispatch advice.Contractor workers - delay in work ,delay in
reporting, etc.Unavailability of canter for material shifting.Labor less than requirement provided by
contractor.
LABOUR SHORTMonths Required Provided JAN. 11 240 158
FEB. 11 224 161
MAR. 11 240 193
APR. 11 248 199
MAY. 11 240 195
JUN. 11 240 193
JUL. 11 224 186
AUG. 11 240 189
SEP. 11 240 249
OCT. 11 248 200
NOV. 11 240 214
LABOUR SHORT
JAN. 11
FEB. 11
MAR. 11
APR. 11
MAY. 11
JUN. 11
JUL. 11
AUG. 11
SEP. 11 OCT. 11 NOV. 11
0
50
100
150
200
250
300
Required
Provided
MONTHS & YEARS
LABO
UR
PRODUCTION VS DESPATCHMonths Opening
StockProd. Desp. Stock Level
JAN. 11312 905 851
350
FEB. 11364 850 840
350
MAR. 11375 892 831
350
APR. 11435 760 636
350
MAY. 11560 744 810
350
JUN. 11494 712 637
350
JUL. 11567 1020 1088
350
AUG. 11502 990 1069
350
SEP. 11 423 937 1130 350
OCT. 11 231 945 645 350
NOV. 11 531 960 822 350
PRODUCTION VS DESPATCH
JAN. 11 FEB. 11 MAR. 11
APR. 11
MAY. 11
JUN. 11 JUL. 11 AUG. 11
SEP. 11 OCT. 11
NOV. 11
0
200
400
600
800
1000
1200
Opening Stock
Prod.
Desp.
Space Capacity
Qty.
in M
T.
Months & Years
CAUSES EFFECT DELAY SHIFTING & LOADING FG.
Months Wrong
loading
Canter breakdown Pilot M/C
Faulty
Vehicle not
AvailableJAN. 11
0 5 0 2FEB. 11
0 3 1 1MAR. 11
1 1 2 2APR. 11
0 2 0 0MAY. 11
0 3 0 1JUN. 11
0 6 2 2JUL. 11
2 2 1 3ADG. 11
1 4 2 3SEP. 11 0 4 0 0
OCT.11 0 2 0 0
NOV. 11 0 2 0 1
CAUSES EFFECT DELAY SHIFTING & LOADING FGS.
JAN. 11 FEB. 11 MAR. 11
APR. 11 MAY. 11
JUN. 11 JUL. 11 ADG. 11
SEP. 11 OCT.11 NOV. 11
0
2
4
6
8
10
12
Vehicle not Available
Pilot M/C Faulty
Canter breakedown
Wrong loading
NO. O
F TI
ME
MONTH & YEAR
REMEDY OF CAUSES
1. Fix inventory levels of finished goods according to production level.
2. Install a lift to facilitate handling of excess stock.3. Revise wages of contract labour annually.4. Old canter should be replaced in order to avoid breakdowns.5. Pallet machine should be serviced as per maintenance
schedule in order to avoid breakdowns.6. Store finished goods inventory according to lot, shade and
counts. 7. Marketing should provide dispatch advice one day in advance.8. One vehicle, dedicated for shifting goods is required at all
times.
IMPLIMENTATION
Lift under construction, would come in operation till 15th Jan 2012.
Storage of finished goods in lot wise. Contractor labour rates revised.Pallet machine maintenance scheduled for
prevention of faults.
VALIDATION OF GAINS
Project is under progress…………..
HOLD THE GAINSCheck to see that elevator is serviced
regularly and maintained according to schedule
Monthly check to ensure that pallet machine is being serviced according to schedule
Check daily that F.G. inventory is stored systematically