29
020 7QC Tools Press team AWARENESS
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7QC ToolsPress team
AWARENESS
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7QC ToolsPress team
1,Check sheet2,Pareto chart3,Cause & Effect diagram4,Stratification5,Histogram6,Scatter diagram7,Control chart
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7QC ToolsPress team
1 30.04.05 B 71642 W/HSE INR L/R EMXI HPS C GPK MS SRIDHAR CRACK 8 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
2 30.04.05 A 71232 FRT PLR INR UPR LH EMXI HPS B PR RD PURUSHOTHAMAN CRACK 7 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
3 01.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B MM GR KOKILESWARAN DAMAGE HAMMERING 12 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
4 01.05.05 B 64376 DASH LWR CTR LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 15 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
5 03.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B PR RD PURUSHOTHAMAN NECK BUFFING 27 DIE PROBLEM DIE CORRECTION LINE REJECTION
6 01.06.05 C 64571/81 F/APRON OTR L/R LCI HPS B MM GR KOKILESWARAN SMUDGING 10 DIE PROBLEM DIE CORRECTION LINE REJECTION
7 04.06.05 A 77156/66 RR DR UPR L/R EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 10 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
8 04.06.05 A 65722 SD MBR RH TBI HPS C GPK MS SRIDHAR SCRATCHES BUFFING 10 CHROME WORN OUT DIE CORRECTION LINE REJECTION
9 05.05.05 A 64511 F/APRON INR L/R LCI HPS B GPK KB MANJUNATHAN SMUDGING GRINDING 10 3 DIE PROBLEM DIE CORRECTION LINE REJECTION
10 05.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
11 05.06.05 A 65782 EXTN RR FLR FRT LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 4 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
12 05.07.05 B 76231 FR DR H/FACE L/R LCI HPS C MM VR SENTHILKUMAR DAMAGE HAMMERING 20 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
13 06.07.05 C 69111 PNL BACK LCI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 6 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
14 13.07.05 B 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 12 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
15 13.05.05 C 71372 ROOF SD INR LH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 25 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
16 13.04.05 A 71586 C/LAMP HSE RH TBI HPS B MM GR KOKILESWARAN CRACK 8 DIE PROBLEM DIE CORRECTION LINE REJECTION
17 13.06.05 B 71586 C/LAMP HSE RH TBI HPS B PR RD PURUSHOTHAMAN CRACK 6 DIE PROBLEM DIE CORRECTION LINE REJECTION
18 19.06.05 A 77231 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
19 20.07.05 B 69142/52 C/LAMP HSE L/R LCI HPS A GPK MR MAGESH WRINKLES BUFFING 1 D/C PERSSURE VARIATION PROPER PRESSURE SETTING LINE REJECTION
20 20.04.05 A 77231/41 RR DR H/FACE L/R LCI HPS C PR MS SRIDHAR DAMAGE HAMMERING 4 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
21 22.04.05 B 77118/28 RR DR HORIZANTAL L/R LCI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 20 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
22 22.07.05 B 71632/42 W/HSE INR L/R EMXI HPS C GPK VR SENTHILKUMAR FLANGE CUT GRINDING 4 IMPROPER PROFILE PROPER BLANK LOCATION LINE REJECTION
23 26.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 12 SCRAP STICK WITH DIE SCRAP TOBE REMOVED LINE REJECTION
24 28.07.05 A 71586 C/LAMP HSE RH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 13 HANDLING DAMAGE PROPER HANDLING LINE REJECTION
OPERATOR FAILURE MODE REMARKSLINE S INCH COUNTER MEASURER/W QTY
NATURE OF R/W
SCRAP QTY
PRESS SHOP - STAMPI NG PANELS REJ ECTI ON & REWORK DATA ANALYSI S
CAUSES.NO PART NO PART NAME MDL CAP
MONTH :April to J ulySHIFTPRODN
DATECheck sheetPurpose:Purpose: Data collection Data collection
Data should be collected Accuracy & Adequacy
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7QC ToolsPress team
Sample formatSample formatPress shop rejection (Rework) data - April to JulyPress shop rejection (Rework) data - April to July
1 30.04.05 B 71642 W/HSE INR L/R EMXI HPS C GPK MS SRIDHAR CRACK 8 D/C PERSSURE VARIATION LINE REJECTION
2 30.04.05 A 71232 FRT PLR INR UPR LH EMXI HPS B PR RD PURUSHOTHAMAN CRACK 7 D/C PERSSURE VARIATION LINE REJECTION
3 01.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B MM GR KOKILESWARAN DAMAGE HAMMERING 12 HANDLING DAMAGE LINE REJECTION
4 01.05.05 B 64376 DASH LWR CTR LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 15 HANDLING DAMAGE LINE REJECTION
5 03.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B PR RD PURUSHOTHAMAN NECK BUFFING 27 DIE PROBLEM LINE REJECTION
6 01.06.05 C 64571/81 F/APRON OTR L/R LCI HPS B MM GR KOKILESWARAN SMUDGING 10 DIE PROBLEM LINE REJECTION
7 04.06.05 A 77156/66 RR DR UPR L/R EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 10 SCRAP STICK WITH DIE LINE REJECTION
8 04.06.05 A 65722 SD MBR RH TBI HPS C GPK MS SRIDHAR SCRATCHES BUFFING 10 CHROME WORN OUT LINE REJECTION
9 05.05.05 A 64511 F/APRON INR L/R LCI HPS B GPK KB MANJUNATHAN SMUDGING GRINDING 10 3 DIE PROBLEM LINE REJECTION
10 05.05.05 C 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE LINE REJECTION
11 05.06.05 A 65782 EXTN RR FLR FRT LCI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 4 HANDLING DAMAGE LINE REJECTION
12 05.07.05 B 76231 FR DR H/FACE L/R LCI HPS C MM VR SENTHILKUMAR DAMAGE HAMMERING 20 HANDLING DAMAGE LINE REJECTION
13 06.07.05 C 69111 PNL BACK LCI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 6 HANDLING DAMAGE LINE REJECTION
14 13.07.05 B 77241 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 12 HANDLING DAMAGE LINE REJECTION
15 13.05.05 C 71372 ROOF SD INR LH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 25 HANDLING DAMAGE LINE REJECTION
16 13.04.05 A 71586 C/LAMP HSE RH TBI HPS B MM GR KOKILESWARAN CRACK 8 DIE PROBLEM LINE REJECTION
17 13.06.05 B 71586 C/LAMP HSE RH TBI HPS B PR RD PURUSHOTHAMAN CRACK 6 DIE PROBLEM LINE REJECTION
18 19.06.05 A 77231 RR DR H/FACE L/R EMXI HPS B PR RD PURUSHOTHAMAN DAMAGE HAMMERING 22 HANDLING DAMAGE LINE REJECTION
19 20.07.05 B 69142/52 C/LAMP HSE L/R LCI HPS A GPK MR MAGESH WRINKLES BUFFING 1 D/C PERSSURE VARIATION LINE REJECTION
20 20.04.05 A 77231/41 RR DR H/FACE L/R LCI HPS C PR MS SRIDHAR DAMAGE HAMMERING 4 HANDLING DAMAGE LINE REJECTION
21 22.04.05 B 77118/28 RR DR HORIZANTAL L/R LCI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 20 SCRAP STICK WITH DIE LINE REJECTION
22 22.07.05 B 71632/42 W/HSE INR L/R EMXI HPS C GPK VR SENTHILKUMAR FLANGE CUT GRINDING 4 IMPROPER PROFILE LINE REJECTION
23 26.05.05 A 71242 FRT PLR INR UPR RH EMXI HPS B GPK KB MANJUNATHAN SCRAP MARK HAMMERING 12 SCRAP STICK WITH DIE LINE REJECTION
24 28.07.05 A 71586 C/LAMP HSE RH EMXI HPS B GPK KB MANJUNATHAN DAMAGE HAMMERING 13 HANDLING DAMAGE LINE REJECTION
OPERATOR FAILURE MODE REMARKSLINE S INCH R/W QTY
NATURE OF R/W
SCRAP QTY
PRESS SHOP - STAMPI NG PANELS REJ ECTI ON & REWORK DATA ANALYSI S
CAUSES.NO PART NO PART NAME MDL CAP
MONTH :April to J ulySHIFTPRODN
DATE
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7QC ToolsPress team
Rejection at April May June July TotalLI NE REJ ECTI ON 522 669 1078 215 2484INHOUSE REJ 12 15 18 8 53CUSTOMER REJ 2 0 0 0 2
TOTAL 522 669 1078 215 2269
Press shop rejection (Rework) data - April to JulyPress shop rejection (Rework) data - April to July
Sample formatSample format
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7QC ToolsPress team
Failure mode April May June July TotalCRACK 20 12 16 4 52
DAMAGE 161 466 810 137 1574FLANGE CUT 10 5 28 2 45FLANGE VARIATION 3 0 0 0 3HOLE BURR 113 0 0 0 113HOLE DENT 24 12 41 0 77LINE MARK 5 0 0 0 5NECK 10 15 3 15 43SCRAP MARK 69 101 125 48 343SCRATCHES 6 14 18 7 45SMUDGING 15 7 0 2 24TRIM BURR 46 25 7 0 78TRIM DENT 0 0 11 0 11WRINKLES 40 12 3 0 55FLANGE CRACK 0 0 16 0 16TOTAL 522 669 1078 215 2484
Sample formatSample formatPress shop rejection (Rework) data - April to JulyPress shop rejection (Rework) data - April to July
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7QC ToolsPress team
Dam
age
Scra
p m
ark
Hol
e bu
rr
No
Cra
ck /
N
eck
Trim
bur
r/ Tr
im
dent
No
wrin
kle
/ Sm
udgi
ng
Hol
e de
nt
Flan
gecu
t/ Fl
ange
cr
ack/
/ Fla
nge
varia
tion
No
scra
tche
s
Line
mar
k
TOTA
L
1574 343 113 95 89 79 77 64 45 5 2,484QTY
PARETO CHART
PRODUCT CHARACTERISTICS
REJ ECTION- April to J uly
63
7782
8692 92 95
100 100
0
200
400
600
800
1000
1200
1400
1600
0
10
20
30
40
50
60
70
80
90
100
% O
F RI
SK
QTY
Pareto diagramPurpose:Purpose: To under stand vital few To under stand vital few
issue of the problem to decide issue of the problem to decide priority of the issue. priority of the issue.
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7QC ToolsPress team
Tool no: 2- Pareto diagramSample formatSample format
Dam
age
Scra
p m
ark
Hol
e bu
rr
No
Cra
ck /
N
eck
Trim
bur
r/ Tr
im
dent
No
wrin
kle
/ Sm
udgi
ng
Hol
e de
nt
Flan
gecu
t/ Fl
ange
cr
ack/
/ Fla
nge
varia
tion
No
scra
tche
s
Line
mar
k
TOTA
L
1574 343 113 95 89 79 77 64 45 5 2,484QTY
PARETO CHART
PRODUCT CHARACTERISTICS
REJ ECTION (Rework)- April to J uly
63
7782
8692 92 95
100 100
0
200
400
600
800
1000
1200
1400
1600
0
10
20
30
40
50
60
70
80
90
100
% O
F RI
SK
QTY
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7QC ToolsPress team
3. Cause & Effect diagram
Purpose:Purpose: To identify root cause To identify root cause
Fish bone diagramFish bone diagram or ISHIKAWAISHIKAWA diagramdiagram or
Diagnostic toolDiagnostic tool
or
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7QC ToolsPress team
Causes Brain storming should be done Causes Brain storming should be done before, cause & effect diagram.before, cause & effect diagram.
Level:1- All possible causes.Level:1- All possible causes.
Level:2- Identified major causes.Level:2- Identified major causes.Level:3- Validated root cause.Level:3- Validated root cause.
Cause & Effect diagram
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7QC ToolsPress team
MANMACHINE
MATERIAL
METHOD
Pnl Damage
Tool no: 3- Cause & Effect diagram
Lack of Skill
*Operator fatigue
*Rm damage
*Damage in previous operation
*Pnl big size
*Die profile hitting
*Ejector hitting
*Die surface damage*Less shut height
*Improper loading*Over stacking
*Improper stacking*Pnl falling down
*Shearing plunger markDie plunger mark*No quality mind
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7QC ToolsPress team
Tool no: 3- Cause & Effect diagramPanel damagePanel damage
More distance between die More distance between die and operatorand operator
Difficult to locate the panelDifficult to locate the panel
Improper pnl locationImproper pnl locationWhy ?
Why ?
Why ?
Example:1
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7QC ToolsPress team
Tool no: 3- Cause & Effect diagramPanel damagePanel damage
Damaged Raw materialDamaged Raw material
Die surface damageDie surface damage
Damage in previous Damage in previous operationoperation
Why ?
Why ?
Why ?
Example:2
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7QC ToolsPress team
Tool no: 3- Cause & Effect diagramPanel damagePanel damage
M/C shut height lessM/C shut height less
Difficult Pnl locationDifficult Pnl location
Improper pnl locationImproper pnl locationWhy ?
Why ?
Why ?
Example:4
Why ?M/C designM/C design
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7QC ToolsPress team
Tool no: 3- Cause & Effect diagramPanel damagePanel damage
Large size panel loadingLarge size panel loading
Operator fatigueOperator fatigue
Improper pnl handlingImproper pnl handlingWhy ?
Why ?
Why ?
Example:3
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7QC ToolsPress team
Tool no: 3- Cause & Effect diagramPanel damagePanel damage
Soft materialSoft material
Polyolefin bush worn outPolyolefin bush worn out
Ejector hittingEjector hittingWhy ?
Why ?
Why ?
Example:5
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7QC ToolsPress team
StratificationPurpose:Purpose: To group related factors To group related factors compare & under stand depth of compare & under stand depth of
problemproblem
Support tool for cause analysis
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7QC ToolsPress team
Tool no: 4- Stratification
71576/ 86 EMXI 77231/ 41 LCI 71154/ 64 LCI 71564 EMXI 64111/ 21 LCI 64571/ 81 LCI 71632/ 42 EMXI 65782 LCI 65538/ 48 EMXI 69142/ 52 LCI TOTAL780 313 120 80 59 56 50 52 34 30 1574
DAMAGE ITEMS
PART NOQTY
PRESS SHOP - REWORK CONTROL DATA78
0
313
120
80
59 56 50 52 34 30
0
100
200
300
400
500
600
700
800
900
J SL
DAMAGE ANALYSIS - APRIL TO JULY
Sample formatSample format
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7QC ToolsPress team
Tool no: 4- StratificationSample formatSample format
IMPROPER PNL LOADING
EJ ECTOR HITTING
DIE PROFILE HITTING
IMPROPER PNL HANDLING RM DAMAGE DIIIFFICALT
PNL LOCATION OTHERS TOTAL
780 313 120 80 59 56 50 1458
PRESS SHOP - REWORK CONTROL DATA78
0
313
120
80 59 56 50
0
100
200
300
400
500
600
700
800
900
CAUSEWISE DAMAGE ANALYSIS - APRIL TO J ULY
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7QC ToolsPress team
HistogramPurpose:Purpose: To under stand To under stand
frequency distributionfrequency distribution
To assess process capability & to under stand variation
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7QC ToolsPress team
Tool no: 5- HistogramSample formatSample format
MONTH APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR TOTAL
EMXI 200 250 200 170 820
LCI 130 150 158 130 568
TBI 60 79 30 17 186
594
PRESS SHOP MONTHWISE FAILURE CONTROL GRAPH - APRIL TO J ULY
MODELWISE - GRAPH
200
250
200
170
130
150158
130
60
79
3017
0
50
100
150
200
250
300
MONTH
NO
OF
PNLS
EMXI
LCI
TBI
SHEARING M/ C UPH GRAPH
3004005006007008009001000
1MO NT H
UPH
#REF!
#REF!
#REF!
#REF!
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7QC ToolsPress team
Scatter diagramPurpose:Purpose: To establish relation ship To establish relation ship between cause between cause oror cause and effect cause and effect
To support cause validation to establish process parameters
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7QC ToolsPress team
Sample formatSample formatTool no: 6- Scatter diagram
IMPROPER PNL LOADING
EJ ECTOR HITTING
DIE PROFILE HITTING
IMPROPER PNL HANDLING RM DAMAGE DIIIFFICALT
PNL LOCATION OTHERS TOTAL
450 313 280 214 147 90 80 1574
9856 9645 8951 7542 7214 6583 5462 55253
PRESS SHOP - REWORK CONTROL DATA
PRODN QTY
CAUSE
QTY
147
214
280
313
450
0
100
200
300
400
500
J SL
CAUSEWISE ANALYSIS - APRIL TO J ULY
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7QC ToolsPress team
Panel getting neckPanel getting neck
Burr in Raw materialBurr in Raw material
Die surface damageDie surface damage
Panel scratchesPanel scratches
Tool no: 6- Scatter diagram71232/42 05000 - Neck71232/42 05000 - Neck
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7QC ToolsPress team
Control chartPurpose:Purpose: To set limit To set limit
Prevention action by timely correction
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7QC ToolsPress team
71576/ 86 EMXI 77231/ 41 LCI 71154/ 64 LCI 71564 EMXI 64111/ 21 LCI 64571/ 81 LCI 71632/ 42 EMXI 65782 LCI 65538/ 48 EMXI 69142/ 52 LCI TOTAL780 313 120 80 59 56 50 52 34 30 1574
DAMAGE ITEMS
PART NOQTY
PRESS SHOP - REWORK CONTROL DATA
780
313
120
80
59 56 50 52 34 30
0
100
200
300
400
500
600
700
800
900
J SL
DAMAGE ANALYSIS - APRIL TO JULYGraphPurposePurpose:: A picture is A picture is
worth more then thousand worth more then thousand wordswords
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7QC ToolsPress team
Purpose:Purpose: To know the Trend To know the TrendLine graph
MONTH APR'05 MAY'05 JUNE'05 JULY'05 AUG'05 SEP'05 OCT'05 NOV'05 DEC'05 JAN'05 FEB'05 MAR'05 TOTAL
EMXI 289 250 230 175 944
LCI 130 200 158 142 630
MXI 0 0 0 0 0
594
PRESS SHOP MONTHWISE DAMAGE CONTROL GRAPH - APRIL TO J ULY
DAMAGE ANALYSIS DATA-GRAPH
289
250230
175
130
200
158142
0 0 0 00
50
100
150
200
250
300
350
400
450
500
MONTH
NO
OF
PNLS
EMXI
LCI
MXI
SHEARI NG M/ C UPH GRAPH
3004005006007008009001000
1MO NT H
UPH
#REF!
#REF!
#REF!
#REF!
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7QC ToolsPress team
Bar graphPurpose:Purpose: To compare To compare
71576/ 86 EMXI 77231/ 41 LCI 71154/ 64 LCI 71564 EMXI 64111/ 21 LCI 64571/ 81 LCI 71632/ 42 EMXI 65782 LCI 65538/ 48 EMXI 69142/ 52 LCI TOTAL780 313 120 80 59 56 50 52 34 30 1574
DAMAGE ITEMS
PART NOQTY
PRESS SHOP - REWORK CONTROL DATA78
0
313
120
80
59 56 50 52 34 30
0
100
200
300
400
500
600
700
800
900
J SL
DAMAGE ANALYSIS - APRIL TO JULY
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7QC ToolsPress team
Purpose:Purpose:To know the % To know the % distributiondistribution
Pie chart
MONTH APRIL MAY JUNE JULY AUG SEP OCT NOV DEC JAN FEB MAR TOTALEMXI 254 253 147 90 744
LCI 157 201 322 104 784
TBI 25 5 12 4 46594
PRESS SHOP MONTHWISE DAMAGE CONTROL GRAPH - APRIL to J ULY
EMXI, 253, 55%
TBI, 5, 1%
LCI, 201, 44%
EMXI, 254, 58%
TBI, 25, 6%
LCI, 157, 36%
EMXI, 147, 31%
LCI, 322, 67%
TBI, 12, 2%
90, 45%
104, 53%
4, 2%
