You are on page 1of 14

QUALITY CIRCLE

WELDING SHOP
PROJECT TITLE
DEFECT REDUCTION
IN
ROBO WELDING

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

INTRODUCTION
TEAM NAME:
LEADER NAME:

Team A
Mr. V.B Tripathi (Sr. Manager Production)

SUB LEADER:

Mr. Gaurav Goal (Manager sales)

COORDINATOR:

Mr. Sumeet Saini

PROJECT TITLE:
AREA:
DATE:

15/11/16

defect reduction in robo Welding


Welding Shop
15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

TEAM STRUCTURE
V.B TRIPATHI
(TEAM LEADER)

GAURAV GOAL
(SUB LEADER)

SUMEET SAINI
(COORDINATOR)

TEAM A

TEJVIR

15/11/16

SUMIT

ANIL B.
MAHENDRA

TEAM B

AKHIL

BOBY

RAGHVENDRA

ANURAG

TANMAY

ARIF KHAN

MAHESH YADAV

SUNIL DUTT

MAHENDRA
PARDESHI

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

PROBLEM DESCRIPTION
1. What is the Problem?
Defects in welded parts cause low production and affect quality.
2. Where is the problem?
Welding Shop
3. How much is the problem?
100% parts are defected.
4. Boundaries of the Problem?
Welding area and Welding rework area.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

SIPOC
(SUPPLIER, INPUT, PROCESS,
OUTPUT & CUSTOMER)
Specific Process flow chart with SIPOC.

5. Suppliers

GRINDING
SECTION,
STORE

15/11/16

4. Inputs

1. Process

2. Outputs

3. Customers

WIRE, GAS, MANPOWER,


FIXTURE

WELDING

WELDED
PARTS

PLATING SHOP

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

CAUSE & EFFECT DIAGRAM

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

DATA COLLECTION

Data has collected from 5 different lots ( 20 pieces from each lot).
Sample size: 100 Welded assemblies of pin and tab.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

PARETO ANALYSIS

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

MAJOR CAUSE LIST


Need to improve top 20% of cause so as to solve 80% of remaining
problem.
Pareto chart state that spatter is the major cause of defects.
This is observed that the root cause of defect is high current and
voltage but low voltage and current can cause low penetration defect.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

IMPROVEMENT
This is very difficult to solve this problem by changing the process
parameters.
Spatfree-113 gel is use to get rid of this problem.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

1
0

IMPROVEMENT
Before

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

After

1
1

CONTROL
Work Instructions are modified to
standardize the process.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

1
2

CONCLUSION
Pareto chart state that spatters are the major defect.
This is observed that the root cause of defect is high current and
voltage but low voltage and current can cause low penetration defect.
This is also observed that its not possible to apply gel on small parts.
100% defect (Spatter) has been removed by this technique.

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

1
3

Thank You

15/11/16

G R I P W E L F AS T E N E R S P R I VATE L I M I T E D

1
4