QC STORY

QC STORY
Team Leader: Shrikant bansode Phone No: 8554992995 Email: shrikant.bansode@ceat.in Team Members Sampayan Kar, Parag Mote, Bobin Sasi, Bhushan Dhanawade, Rajendra Jadhav
Organization: CEAT Limited, Nashik
Mentor: ML patel Phone No: Email: ML.Patel@ceat.in Start Date Planned 15.09.2016 Completion Date Planned: 15.09.2016
1A)Brief Problem Description 1. Reason for Improvement 3.2 Confirm the probable cause(s) Start Date Actual: 30.12.2016 Completion Date Actual: 30.12.2016
Sl.N Probable Cause Testing and Observations Conclusion
a) What : Digitalization Of Rapid Control Laboratory.
b) Where : Rapid Control Lab
c) When : FY17 (Q3)
e) Present level: 0% f) Target 100% digitalization and paperless
1 B - Justification

* CEAT Vision towards Digitization and Innovation

* Muri of QA inspectors to check and write each parameter in log-
book.
* Eco-friendly by eliminating paper usage through online
management system
* Easy analysis of data, storage and retrievable.

1 C - Emergency response and interim action (if required): 2. Current Situation 3.3 Identify the root cause(s) 4. Why Why analysis

2a) Observation of process:

1.1 Theme/Pain Area(Q1):
Tech. Disposition decisions on held-up batches(non conforming batches) after 24 hrs. resulting on unnecessary delay
& increase of floor inventory due to material blockage.
Extensive paper intensive, manual duplication work such as entries in log book by testers.
Adverse Impact on 5S ratings.
1.2 Measures:
Elimination of paper usage with green initiative. From 216 kgs. per Annum to 0 kgs.
Zero breakdown hours.
b) Reduction in tech. deposition time from 24 hrs. to 8 hrs. thus work away of held up batches in the subsequent 4. Counter Measures
shifts.
c) Standardization of SOP from 3 nos. to 1 no.

2b) Understand the current situation

Different make machines for Testing.
Different vendors for AMC.
Motherboard for 2 nos. ODR m/c is Imported and having replacement frequency of 1 year worth Rs.2.25 Lacs.
Paper consuming, as results needs to be in print out only.
As data is in hard copy, analysis and interpretation of results is very difficult job. So lack of results analysis.
Print outs and record management requires place to keep and a workmen once in week for one shift. i.e. non-value adding activity.
As m/c are different make, SOP for each m/c is different and due to MURA increased. 5.1 Verify Results 5. Result Check
One Dot matrix printer require for two machines.
If Printer is breakdown, then testing and releasing of compound batches delays which directly affects further delaying of process.

3.1 Identify all possible causes 3. Analysis

6. Standardization
6.1 Updating of documents:

Microsoft Office
Excel Worksheet

7. Future Plan
1. Integration of Rheo Test Results with SAP.
2. Auto disposition and mail triggered to Concern people.