Final Report 8 Semester

THE PROJECT REPORT ENTITLED
“To Reduce Rejection & Quality Improvement by using SPC & QC tools in
Gear manufacturing Industry”
Submitted in
Fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
Submitted by
JOSEPH ALEXANDER V.
(110040119007)
BHATIYA ANKIT L.
(110040119052)
DANADADIYA BHAVIK R.
(110040119058)
Guided By
Prof. S.H.BHATT
DEPARTMENT OF MECHANICAL ENGINEERING

B. H. GARDI COLLEGE OF ENGINEERING & TECHNOLOGY, RAJKOT
DEPARTMENT OF MECHANICAL ENGINEERING

B. H. GARDI COLLEGE OF ENGINEERING & TECHNOLOGY, RAJKOT
GUJARAT, INDIA
Gujarat Technological University, Ahmedabad
DECEMBER, 2014
CERTIFICATE
This is to certify that the project report entitled “To Reduce Rejection &
Quality Improvement by using SPC & QC tools in Gear manufacturing
Industry” has been carried out by Joseph Alexander. (110040119007), Bhatiya
Ankit L. (110040119052) , Danadadiya Bhavik R.. (110040119058) at B.H.
Gardi College of Engineering & Technology, Rajkot City under my guidance in
fulfillment of the degree of Bachelor of Engineering in Mechanical (7th
Semester) of Gujarat Technological University, Ahmedabad during the
academic year 2014.
Date:
Place: Rajkot
Guide: Prof.S.H.Bhatt
Department of Mechanical Eng.
B.H. Gardi College of Engineering &
Technology, Rajkot
Prof. V.H. Oza

Head of the Department
Department of Mechanical Eng.
B.H. Gardi College of Engineering &
Technology, Rajkot
EXAMINER’S CERTIFICATE OF APPROVAL
The project report entitled “To Reduce Rejection & Quality Improvement by
using SPC & QC tools in Gear manufacturing Industry” submitted by Joseph
Alexander . (110040119007), Bhatiya Ankit L. (110040119052) Danadadiya
Bhavik R. (110040119058) impartial fulfillment of the requirement for the
award of the degree in “Bachelor of Engineering in Mechanical Engineering of
B.H Gardi College of Engineering &Technology, Rajkot is hereby approved.
EXAMINERS:
1.
2.
DECLARATION
This is to declare that
The project report comprises of my original work towards the degree of

Bachelor of Engineering in Mechanical Engineering at B.H. Gardi College of
Engineering & Technology, Rajkot and has not been submitted elsewhere for
the award of the degree. Due acknowledgement has been made in the text to
all other materials used.
Joseph Alexander V.
(110040119007)
Bhatiya Ankit L.
(110040119052)
Danadadiya Bhavik R.
(110040119058)
Date:
Place: Rajkot
ACKNOWLEDGEMENTS
It is great pleasure to acknowledge and express our deep gratitude to all

who have helped us with their co-operation and guidance to develop this
project. We are indeed grateful to Prof. S.H.Bhatt. faculty of mechanical
department, B.H.Gardi College of Engineering & Technology, Rajkot. Who have
provided complete guidance and encouragement for this project.
We are deeply indebted to Mr. John Roney. and Mr. Rajesh Palival..
providing his valuable resources and knowledge base to make this project
success. We express gratitude to him for his active guidance and thank him for
sparing his valuable time. Their encouragement and advice has been one of
the prime factors for Successful completion of this project- progress report.
We are also expressing our sincere thanks to whole Mechanical Engineering
Department. Last but not least, we are also thankful to all those who have
directly or indirectly helped us during the project.
CONTENTS
LIST OF FIGURES I
LIST OF TABLE
ABSTRACT II
CHAPTER -1 Introduction 1-6
1.1 Statistical Process Control 1-3

1.2 Quality Control Tools 3
1.2.1 Quality Control Tools And Procedure 3
1.2.1.1 Identification and Data gathering 4
1.2.1.2 Prioritizing 4
1.2.1.3 Analysis Of Selected Problem 5
1.2.1.4 Data Gathering And Initial Charting 6
CHAPTER 2 Literature Review 7-9
CHAPTER 3 Objective of Problem 10-11
12-26
CHAPTER 4 I.P.D Working Procedure
4.1 Plant Lay-Out 12

4.2 Process Lay-out 13-14
4.3 Pareto Analysis 15-16
4.4 Fishbone Diagram 16-18
4.5 SPC 19
4.5.1 Monitoring Parameter 19
4.5.2 Wastage 19-20
4.6 Histogram 21-22
4.7 Control Chart 22-25
4.8 Capability Index 25-26
CHAPTER 5 Result And Conclusion 27-28

5.1 Result
27
5.2 Conclusion
27
5.3 Future Scope
28
CHAPTER 6 Reference 29-30
CHAPTER 7 Canvas 31-34
31
7.1 Product Development Canvas
32
7.2 Observation Canvas
33
7.3 Ideation Canvas
34
7.4 Poster Presentation
LIST OF FIGURES
Fig 1.1 SPC Steps 1

Fig 1.2 Pareto Chart 5
Fig 1.3 Fish Bone Diagram 6
Fig.4.1 Plant Lay - Out 13
Fig.4.2 Process Lay - Out 14
Fig.4.3 Pareto Analysis for Tensile Strength 15
Fig.4.4 Fishbone Diagram for the Sharp Edge 17

Fig.4.5 Fishbone Diagram for Excessive Run Out 18
Fig. 4.6 Wastage 20
Fig.4.7 Histogram 22
Fig. 7.1 Product Development Canvas 31
Fig.7.2 Observation Canvas 32
Fig. 7.3 Ideation Canvas 33
Fig.7.4 Poster Presentation 34
LIST OF TABLE
Table-1 Histogram 21
Table-2 Histogram 21
Table-3 Control Chart reading 23
Table-4 New Control Chart reading 24
ABSTRACT
In Present Scenario in any industry the customer need is most

important as Quality concern and also industry have to maximize profit and
minimize the wastage to survival in the market and also for the growth of the
industry. So as above parameter we have to focus on the productivity and Quality
improvement. For this parameter we can use the SPC(Statistical process control) ,
and QC (Quality control tools). SPC is the tool for the reducing wastage and better
quality of the product. By using seven QC tools we can reduce the cost of the
product Rework cost , Worker cost , Time wastage behind that. So as we can
reduce the cost and Improve Quality of the product and minimize cost of the
product.
CHAPTER-1
INTRODUCTION
1.1 Statistical Process Control
The deployment of statistical process control (SPC) in manufacturing

environments is a global phenomenon. Statistical Process Control is Widely used in
industries for the monitoring the process parameters. There are a standard method for
visualizing and controlling processes on the basis of measurements of randomly selected
samples. The decisions about what needs to be improved, the possible methods to
eliminate causes it, and take action after getting results made by humans and based on
experience.
The main objective of SPC is to ensure that the planned process output is achieved
and the related customer requirements are fulfilled. In this process control, randomly some
parts are taken from the manufacturing process and then their characteristics are measured
and shown on the control charts. Statistical indicators are determined from the
measurements and used to evaluate the current status of the process. If required, the
process is rectified with some appropriate actions.
Key tools used in SPC are control charts and cause & effect diagrams, focused on
continuous improvement. Variations in the process that may affect the quality of the end
product or service can be detected and after that corrected,so reducing waste as well as the
similarly that problems will be passed on to the customer With its emphasis on early
detection and prevention of problems, SPC has a distinct advantage over other quality
methods. In mass-manufacturing, the quality of the finished article was traditionally
achieved through post-manufacturing inspection of the product; accepting or rejecting each
article based on how well it meet its design specifications. In short, Statistical Process
Control uses statistical tools to monitoring the performance of the production process in
order to predict significant deviations that may later result in rejected product.
Two kinds of variation occur in all manufacturing processes: both these types of
process variation cause variation in the final product.
 The first is known as natural or common cause of variation and consists of the
variation in the process as it is designed. Common cause of variation may include
variations in temperature, properties of raw materials, strength of an material etc.
BHGCET , Rajkot Page 1

 The second kind of variation is known as special cause of variation, or assignable

cause of variation, and happens less frequently than the first. With sufficient
inspection, a specific cause, such as abnormal raw material or incorrect set-up
parameters can be found for special cause variations. By observing at the right time
what happened in the process that led to a change, the quality engineer of the team
responsible for the production line can correct the root cause of the variation that
has crept in to the process and correct the problem.
SPC indicates when an action should be taken in a process, but it also indicates
when NO action should be taken. An example is a person who would like to maintain a
constant body weight and takes weight measurements weekly. A person who does not
understand SPC concepts might start dieting every time his or her weight increased, or eat
more every time his or her weight decreased. This type of action could be harmful and
possibly generate even more variation in body weight. SPC would account for normal
weight variation and better indicate when the person is in fact gaining or losing weight.
Some Question always ask in the SPC
 What is meant by a process control system?

 How dose variations affect process output?
 How can statistical techniques tell whether a problem is local nature or involves
broader systems?
 Statistical Process Control What is meant by a process being in statistical control?
 What is meant by a process being capable?
 What is continual improvement cycle, and what part can process control play in it?
Steps Involved In Using Statistical Process Control
Plan
Act Do
Study
Fig 1.1 – SPC Steps

1) Planning
Proper Statistical Process Control starts with planning and data collection also
information. Statistical analysis on the wrong or incorrect data is Wrong, The analysis
Should Correct for the data collected.
Identify the problem and the possible causes that occurs during the process. For
that QC tools may help industry identify problems and possible causes, and to prioritize
corrective actions to that problem.
2) Do
Make changes designed to correct or improve the situation if there are necessary.
3) Study
Study the effect of those changes on the industry. This is where they are used – they
show the effects of changes on a process over time. Find the results and then the change it
and try something different if required.
4) Act
If the result from study is successful then standardize the changes and then
work on further improvements or the next prioritized problem. If the outcome is not
successful, try other ways to change identify different causes for the problem.
1.2 Quality Control Tools
The preparatory phases of SPC involve several steps, using a number of different
tools.There are Seven quality tools are available to help organizations to better understand
and improve their processes. The essential tools for the discovery process are: Check Sheet,
Cause-and-Effect Sheet, Flow Charting(Run chart), Pareto Chart, Scatter Diagram, Histogram
and Control Charts Known as Quality control tools.
1.2.1 Quality Control Tools And Procedures
There are seven quality control tools which are mentioned above are used in the
process and categorized likewise below.

 Identification and Data gathering
 Prioritizing
Pareto Charts
 Analysis Of Selected Problem

Cause-and-Effect or Fishbone Diagram
 Flowcharting
Scatter Plots
 Data Gathering And Initial Charting

Check Sheets
Histograms
1.2.1.1 Identification and Data gathering
First you need to set out to improve quality. This should be done using a number
of methods like surveys, focus groups about their experiences. Once the problem areas are
identify a brainstorming session must occur with a variety of people who are involved with
the processes. The target problems are decided upon and then listed of possible causes is
identified to problem and causes.
1.2.1.2 Prioritizing
After a number of possible problems are got, the next step is to prioritize. The
problems that are having the highest effect are the highest priority items. It has been
discovered time and again that a great percentage of the trouble in nearly all processes is
caused by a small percentage of the total factors involved. Service departments daily find
that 5% of the problems are taking over 80% of their time. Therefore, in order to maximize
quality, identify the key outcomes for improvement, these items that will provide the most
advantages to your industry.
The Pareto chart must be used to display categorized of problems graphically so
they might be properly prioritized.
Pareto chart can be generated with given format manually or can be by software.

Pareto Chart
Cumulative % of Total
Individual Count
Fig 1.2 Pareto Chart
1.2.1.3 Analysis Of Selected Problem
Once a major problem has been selected, it must be analyzed for possible
causes. Cause-and-effect diagrams, scatter plots and flow charts can be used in this part of
the process.
This chart can helps organize the brainstorming process. The major categories of
causes are put on major branches connecting to the Sub-branches, and various sub-causes
are attached to the branches. A tree-like structure showing the many facets of the problem.
Flowcharting also breaks the process down into its many sub-processes.
Analyzing each of these separately minimizes the number of factors that contribute to the
variation in the process.
A Scatter plot can be used to uncover possible cause-and-effect relationships. It
is constructed by plotting two variables against one another on a pair of axes. A Scatter plot
cannot prove that one variable causes another, but it does show how a variables is related
and the strength of that relationship.

Fig 1.3 FishBone Diagram
1.2.1.4 Data Gathering And Initial Charting
Check sheets are charts for gathering data. check sheets are designed clearly . they
assist in gathering accurate and data, and allow the data to be easily read.
You Might put the data from the check sheets into a histogram. A histogram is a
snapshot of the variation of a product or the results of a process. It alwayes forms the
bellshaped curve which is characteristic of a normal process.
Capability index value and comparing the calculated capability index to the
desired index value, making a decision concerning process changes, and recommending any
suggestions to reach the desired goal. The popularity of capability measures continues to
increase because of the more advantages. Terminology associated with this subject must be
relatively easy and provide a common method for discussing quality on the shop floor with
suppliers and with customers also.

CHAPTER-2
LITERATURE REVIEW
[1] Statistical process control process in which visualizing and controlling

processes on the basis of measurements of randomly selected samples. The statistical
process control described in this paper gives the details about the SPC, its advantages and
limitation, applications and information regarding the control charts.
[2] Introduced Control chart in 1924, allows management to look at processes
rather than just at products. Shewhart discussed the concept of statistical control. He
carefully stated that a control chart is not a test of statistical significance. In his first book on
quality control, Shewhart described to select the criterion (the three sigma limits). A control
chart predicts that, in the absence of assignable causes, the process will operate as a
random system and produce the present level of quality in the future. If that level of quality
is not satisfactory, a fundamental change in the process is required.
[3] Added the cause-and-effect chart as an aid to brainstorming, but all the rest of
the methods were the same as those recommended by [5]. The popularity of these
problem-solving tools and the ease of their use caused many to adopt them. [6] carried out
a study on capability indices and examined the uses of capability indices along with their
estimation procedure. When properly applied, statistical tools are an effective way for
improving process quality.
[4] Reviewed Cp, Cpk, Cpm and Cpmk, and their generalizations, and then
proposed a new index Spmk for any underlying distribution, which takes into account the
process variability, departure of the process mean from the target value, and proportion of
non-conformity.
[7] Examined on the applicability of SPC in non-repetitive processes and open

systems, non-routine processes and project-based business activities. They also proposed
guidelines for adjusting the logic of common and specific causes for project-based
businesses are proposed.
[8] Intended to combine the Hourly Data System (HDS) and Statistical Process
Control (SPC) practices to improve manufacturing performances in manufacturing
companies. The focus of their work is to find out the frequencies and time duration of
machine breakdowns as well as the major causes of breakdowns affecting productivity. In
this research SPC is used to increase total output identifying major loss times from various
machine breakdowns using HDS. The obtained result shows that any breakdown can cause a
huge cost and the best approach to address any breakdown is the preventive measure.

[9] Proposed a neural network-based identification model for both mean and
variance shifts in correlated processes. The proposed model used a selective network
ensemble approach named Discrete Particle Swarm Optimization (DPSOEN) to obtain the
improved generalization performance, which outperforms those of single neural network.
The model was capable of on-line monitoring mean and variance shifts, and classifying the
types of shifts without considering the occurrence of both mean and variance shifts in one
time. Result is significant it provided additional information a process changes, which could
greatly aid identification of assignable causes.
[10] Stated that process capability indices (PCIs) are appropriate tools to measure
the inherent capability of a process, but most of them do not consider the losses of a
process, while in today's competitive business environment, it is becoming more and more
important for companies to evaluate and minimise their losses. They presented a review of
loss-based PCIs such as Cpm, Cpmk, Cpc. They also discussed characteristics of loss-based
PCIs such as reject based, asymmetric, bounded, loss based and target based. Finally, they
made some recommendations for developing a new loss-based process capability index
with more excellent specifications.
[11] Gives definition of statistics according to Deming, is to study and understand

variation in processes and populations, interactions among variables in processes and
populations, operational definitions (definitions of processes and populations variables that
promote effective communication between people), and ultimately, to take action to
reduce variation in a process or population. Hence, statistics can be broadly defined as the
study of data to provide a basis for action on a population or process .
[12] Introduce Total Quality Management tools and techniques divided into the
categories of quantitative and non-quantitative. The basic quantitative ones are statistical
process control (SPC). SPC often called “The Magnificent Seven” is comprised of seven tools,
Pareto Chart, Histogram, Process Flow Diagram, Control Charts, Scatter Diagram, Check
Sheets and Cause and Effect Diagram. The main objective of this paper is to apply basic
statistical tools of quality control. SPC seeks to maximize profit by the following ways:
Improving product quality, improving productivity, reducing waste, reducing defects and
improving customer value. A Jordanian manufacturing company was chosen to implement
SPC tools and concepts in order to improve the product quality and reduce process
variability.

[13] Represent the Pareto (pah-ray-toe) chart which is a very useful tool whenever
one needs to separate the important from trivial. A Pareto Chart is simply a frequency
distribution (or Histogram) of attribute data arranged by [14]. It is a special type of bar
charts in which the categories of responses are listed on the X-axis, the frequencies of
responses (listed from largest to smallest frequency) are shown on the left side Y-axis, and
the cumulative percentages of responses are shown on the right side of Y-axis.
[15] Gives method about Brainstorming is a technique used to elicit a large number
of ideas from a team using its collective power. It normally takes place in a structured
session involving between 3 to 12 people, with 5 to 6 people being the optimal group size.
The team leader keeps the team member focused, prevents distractions, keeps ideas
flowing, and records the outputs (or make sure that team members record their own
outputs). The brainstorming session should be a closed-door meeting to prevent
distractions. Seating should be arranged in a U-shape or circle to promote the flow of ideas
among group members.
[16] A team typically used a Cause-and-Effect (C&E) diagrams to identify and isolate
causes of a problem. The late Dr. Kauro Ishikawa, a noted Japanese quality expert,
developed the technique, so some times the diagram is called an Ishikawa diagram. It is also
called a Fishbone Diagram because that is what it looks like. If it is the Pareto diagram that
helps us to prioritize our efforts and focus attention on the most pressing problem or
symptom, it is the Cause-and-Effect (C&E) diagram that helps to lead us to the root cause of
the problem.
[17] The data analyzed by The Cause-and-Effect (C&E) diagram usually comes from a
brainstorming session.

CHAPTER-3
OBJECTIVE OF PROBLEM
 To increase the productivity by ensuring the best possible use of human, machine
and material resources and to achieve best quality product at minimum possible
cost.
 To improve operational efficacy.
 In a competitive market we have to increase productivity by reducing the process

time and wastage of material. and it is done with the help of statistical process
control.
 To avoid unusual idle time.
 To minimize and control the cost.
 To The machine capability study with the aim of discovering the machine-specific
effects on the production process.
 The process capability study for the variation arising from the machine .
 To measuring the sources of variation assisted by the use of control charts.

 To eliminating assignable (special) sources of variation.
 To improve process performance by reducing product variability.
 To Improves production efficiency by decreasing scrap and rework

.
 To Leads to higher quality product by reducing variability and defects.
 For the Improving their overall business competitiveness.

 Minimize rework Minimize loss of sales.
 Maintain a desired degree of conformance to design.
 To prevent Eliminate any unnecessary quality checks.
 To reduce the percentage of defective parts purchased from the vendors.
 For Reduce returns from customers.

CHAPTER-4

I.D.P WORKING
4.1 Plant Layout
Good process design requires good plant layout. This involves development of the
workplace so that the location of the equipment introduces low throughput time and
maximum economy during the manufacturing process. In general, plant layouts represent
One or a combination of
(1) product, or straight-line, layouts,

(2) Process, or functional, arrangements. In the straight-line layout, machinery is located so
the flow from one operation to the next is minimized for any product class. To avoid
temporary storages between facilities and excess in-processing inventories there needs
to be a balance in the number of facilities of each type. Process, or functional, layout is
the grouping of similar facilities the principal advantage of product grouping is lower
materials-handling costs since distances moved are minimized.
For the analyze the process flow it’s very important to study about the run chart for
which plant layout is very important parameter so as study about the plant layout concern
the material movement of raw material to the final finish product.
4.1.1 Plant Layout of Industry

Industrial plant lay-out as shown in figure

Design Metullurgy Store for the

Testing
Department Lab Heat treatment
Parking
Heat treatment cell
Area
Conference
room
Quality Inspection
Machine shop -1 Shop-2
Induction
H.R hardening
section Shop -3
Department
Inventory
Store
Fig 4.1 – Plant Lay-out of an Industry
4.2 Process Flow chart

A process flow chart used for the identify the basic process involve in the
production so as we can identify the process parameter and prevent excessive material
movement of the raw material and hence production time.
A Process flow chart of an industry as shown in figure.
Distribute
Disribution Conform to
Suppliar According
According Current
Type Production
process Storage
Production Heat Binding

Inspection
line Delay
Treatment machine
Weight
Lablling Transportation
inspection
Storage
Fig 4.2 Process flow chart
Pareto Analysis

A Pareto Chart is a frequency distribution of attribute data arranged. It is a type of

bar charts in which the categories of responses are listed on the X-axis and , the frequencies
of responses (listed from largest to smallest frequency) are shown on the left side Y-axis,
and the cumulative percentages of responses are shown on the right side of Y-axis.
Pareto chart was constructed based upon data collected by check sheet for the
tests performed on Gear and shown in the following and Figure 4.3. The figure show that
the Execcive run out and Sharp Edge is the vital few quality problems and represents around
73.32% of the total cumulative percentage of non-conformities so that the main reason of
most rework is the Exercise run out and Sharp Edge. The rest of tests are considered as
Useful Many and represents around 26% of the total cumulative percentage.
Fig 4.3 –Pareto Analysis
Hare We take 60 Gear for the study which are reject due to following problem listed below.
Defect in Gear
 Excessive run out(28) = 46.66%
 Sharp Edges(16) = 26.66%
 In proper tooth Cutting(5) = 8.33%
 In proper Grinding (6) = 10%
 Excessive Heat treatment(1)= 1.6%
 In proper tooth profile(2)=3.33%
 Metallurgical defect(2)=3.33%
Here we got defective gear due to Excessive run out and Sharp Edges Which has
total 73.32% defect of total. So if we reduce these defect which would reduce the defective
gear at great level.
4.4 Fishbone Diagram

This Diagram also Known as Ishikava Diagram or called Cause & Effect diagram In
which organize the possible factors that could be negatively impact the stability, center,
spread.
In Fishbone diagram we find the possible causes for which most gear are fail to meet the
specification from the pereto chart. From the pereto chart we know that the Excessive run
out and Sharp Edge is the major problem for the damaged gear.
Here we give two fishbone diagram one is the excessive run out and second is the sharp
edge.Both diagram we make in Software.

Fig 4.4 – Fishbone Diagram of Sharp Edge


Fig 4.5 :- Fishbone Diagram of Excessive run out
4.5 Statistical Process control

Statistical process control is process that we are using in the industry for the
monitoring the different parameter related to process which are useful for the
brainstorming diagram. Also wastage that are occurring in the industry are find.
4.5.1 Monitoring Parameter

1) Man- Man in means of including worker, Engineers etc. they are affecting parameter in
production as well as Quality also due reason like shift changes.
2) Machine- Machine are also affect parameter in production like below reasons.
 Speed
 Feed rate
 Tools
 Cycle times
 Coolant flow rate and temperature
 Change status (in the case of optimization measures)
3) Material- Row material that are used in the industry or part from the vendors and
different lot from different vendors are also affect the Quality also Semi-finished products,
rough parts or blanks from different lots or Manufacturers
4) Method- Method that you are using for the measuring the parameter or Run-in (warm-
up) time of the machining facility before sampling ,Differing pre-machining or production
flow too.
5) Milieu (Environment)- Room temperature ,Relative humidity, atmospheric pressure

,Vibration acting upon the machining facility are found affecting parameter in our
project.
4.5.2 Wastage
There are many wastage or scrape in the industry which led to low profitable to its
we can reduce it by proper action on the system.

Following are the Seven Wastage activities identified in the organization and find the ways
to eliminate.
Over
Processing
Processing more
than necessary
to get same
Defect output
Inventory
Errors causing Having material
effect to be more than
redone for correct needed
the problem
Wastage
Waiting Transportation
Waiting for Moving Material
material
Motion
Moving people
to access or
information
Fig 4.6 – Wastage

4.6 Histogram
Histograms are tools to examine distributions. A histogram is a bar graph that shows
how frequently data come within specific cells, that is a ranges of values. Histograms make
it simple to estimate where the process is centered and how much fluctuation about the
center. Here we take the reading for 100 gear for I.D shown in below.
Table -1
40.019 40.015 40.016 40.018 40.015 40.016 40.016 40.015 40.015 40.015
40.018 40.019 40.018 40.014 40.014 40.017 40.018 40.016 40.018 40.014
40.016 40.016 40.016 40.018 40.01 40.019 40.014 40.018 40.018 40.013
40.018 40.014 40.017 40.015 40.018 40.016 40.02 40.017 40.017 40.019
40.019 40.018 40.02 40.016 40.016 40.018 40.019 40.021 40.018 40.02
40.024 40.015 40.014 40.017 40.016 40.015 40.015 40.015 40.021 40.023
40.009 40.017 40.018 40.015 40.018 40.016 40.018 40.014 40.011 40.012
40.019 40.019 40.016 40.014 40.014 40.018 40.018 40.013 40.018 40.013
40.022 40.016 40.017 40.018 40.02 40.017 40.017 40.019 40.019 40.018
40.014 40.018 40.02 40.016 40.019 40.02 40.018 40.02 40.016 40.018
Table -2
Cell Point Frequency

40.009 0
40.01 1
40.011 1
40.012 1
40.013 3
40.014 10
40.015 11
40.016 13
40.017 16
40.018 23
40.019 12
40.02 2
40.021 0
40.022 0
40.023 0
40.024 0
40.025 0

Based upon that we drew the histogram as shown in figure 4.7
25
20
15
10
0
40.01 40.01 40.01 40.01 40.01 40.01 40.02 40.02 40.02 40.02 40.02 40.02 40.02 40.02 40.02 40.02 40.03
Fig 4.7:- Histogram
4.7 Control Chart

Control charts report savings in scrap, including material and labor, lower rework costs,
reduced inspections. Here we take reading of 100 gear for the calculation.

Table-3
Calculation
 As From the calculation
 X Double bar = 40.0161
 R Bar = 0.00525
Now,
UCL = X Double bar + A2*R Bar = 40.019
LCL = X Double bar – A2*R bar = 40.013
 Here For Subgroup size 5 The Value of A2 =0.577

Here From UCL and LCL From the data as shown in table ,
Subgroup no. 4 is out of control. Which has value 40.012 lower than the LCL.
So , here Process is out of Control for Subgroup no. 4
So , For this eliminate Subgroup no. 4 and then take new readings for the calculation as
shown in table.
Table-4
Calculation

 As From the calculation
 X Double bar = 40.0161
 R Bar = 0.00532
Now,
UCL = X Double bar + A2*R Bar = 40.019
LCL = X Double bar – A2*R bar = 40.013
 Here For Subgroup size 5 The Value of A2 =0.577
Now It’s in control process.
4.8 Process capability

The first steps in an SPC program must be to establish control. An out-of-control
process is unstable, and therefore estimates of process centering and variation are of
little use for reduce process variation.
Only after establishing control can we examine the process’s ability to meet
specifications requirement.
Here for capability index should be greater than 1 then it will be useful.
 Now for the capability index
We have specification limit 40.017+-0.007.
LSL = 40.009
USL = 40.025
Cp = (USL – LSL) ÷ 6σ
= (40.025-40.009) ÷ 6*0.002
= 1.16
Here σ= R bar / D2

Where D2 = 2.326 for subgroup size 5
Now account for process variation and for centering relative to the target, we use another
process capability index, Cpk.
 Cpl = (µ – LSL) ÷ 3σ=0.88
 Cpu = (USL –µ ) ÷ 3 σ= 1.33
 Cpk = Min (Cpl , Cpu) = 0.88
Here we have to take lowest value out of Cpl , Cpu and it is Cpl which is 0.88 which
is less than 1.so something goes to wrong in the machining and we have to take care about
for that for reduce rejection.
So we shifted the process center from 40.018 to 40.016 it would decrease the defective part.

CHAPTER-5
RESULT AND CONCLUSION
5.1 Result
 SPC (Statistical Process Control) is the systematic examination of the methods of
carrying on activities so as to improve the effective use of resources and to
set up standards of performance for the activities being carried out.
 We have Currently 2.7% Defection rate which is reduced to 1.8% by Control tools.
 Than By using Pareto chart and fishbone diagram we can know that most defect
Occurrence in the gear is Excessive run out and sharp edge. Which has a 73.32% of
total defective percentage.
 We get the Cp>1 ,Cpk<1 it show that the process is capable to manufacturing
without much variation but it’s not meet the customer satisfaction.
So, we need to take care of rake error and profile error of the gear.
5.2 Conclusion
Pareto diagram identifies that the Excessive run out and sharp edge is the vital
view steel characteristic that need attention.
There is a necessity in Mahindra Gear to introduce ongoing education and
training programs of management and line staff on interrelation between SPC tools and its
implementation steps.

Mahindra Gear lacks the ability to properly forming quality teams and hold
brainstorming sessions according to standard rules and procedures.
5.3 Future Scope

 Analysis in Minitab Software for better accuracy.
 We can also take Fishbone diagram for the uncover causes like In proper tooth
Cutting= 8.33% ,In proper Grinding (6) = 10% ,Excessive Heat treatment =1.6% ,In
proper tooth profile=3.33% ,Metallurgical defect=3.33.
 It’s possible to find another wastage or damage in the gear.
 We can Also use another method for the monitoring like Exponentially Weighted
Moving Average (EWMA) charts , Cumulative Sum (CUSUM) charts.

CHAPTER-6
REFRENCES
[1] Ved Parkash, Deepak Kumar, Rakesh Rajoria International Journal of Research in
Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
[2] Shewhart, W. A. 1931. Economic control of quality of manufacturing product, Van

Nostrand, New York.
[3] Ishikawa, Kaoru, 1985. What is Total Quality Control?, D. J. Lu (trans.), New Jersey:
Prentice Hall, ISBN 0139524339.
[4] Chen, J.P. and Ding, C.G. 2001. A new process capability index for non-normal
distributions. International Journal of Quality & Reliability Management, Vol. 18, Issue 7,
pp. 762 – 770.
[5] Juran, J. M. 2010. Quality Handbook, 5th Edition, McGraw- Hill.
[6] Kane, V.E. 2009. Process Capability Indices, Journal of Quality Technology, Vol. 18,
pp. 41-52.
[7] Lillrank, P. and Kujala, J. 2006. Managing common and specific causes of quality
problems in project-based organizations, International Journal of Productivity and
Quality Management, Vol. 1, No-1/2, pp. 56-68.
[8] Sultana F., Razive, N. and Azeem, A. 2009. Implementation of statistical process
control (spc), Journal of Mechanical Engineering, IEI (Bangladesh),Vol. 40.

[9] Wu, B. and Yu, Jian-bo. 2010. A Neural Network-Based On-line Monitoring Model of
Process Mean and Variance Shift, International Conference on E-Business and E-
Government, pp. 2615-2618.
[10] Abdolshah, M., Yusuff, R. M., Hong, T. S. and Ismail, M. Y. B. 2011. Loss-based
process capability indices: a review, International Journal of Productivity and Quality
Management, Vol. 7, No.1, pp. 1 - 21.
[11] Deming, W. Edwars, Some Theory of Sampling”, 3rd Edition, New York: John Wiley.
[12] Besterfield, D. H., Quality Control, 8th Edition, Pearson-Prentice Hall, (2009).
[13] Besterfield, D. H., Michna, C. B., Besterfield, G. H., and Sarce, B. M., Total Quality
Management, 3rd Edition, Prentice Hall, 2003.
[14] Montgomery, D., Introduction to Statistical Quality Control, 5 th Edition, John Wiley,
2005.
[15] Gitlow, H. S. and Levine, D. M., “Six Sigma for Green Belts and Champions”, FT Press,
7th Edition, 2009
.
[16] Goetsch, D. L. and Davis S. B.,”Quality Management: Introduction to Total Quality
Management for Production, Processes, and Services”, Pearson Education, 5 th
Edition, 2006.
[17] Devor, R. E, Chang, T. and Sutherland, J. W. Statistical Quality Design and Control:
Contemporary Concepts and Methods, Pearson Prentice Hall, 2nd Edition, 2007.

CHAPTER-7
CANVAS
7.1 Product Development Canvas
Fig 7.1 -Product Development Canvas

7.2 Observation Matrix
Fig 4.7 – Observation Matrix

7.3 Ideation Canvas
Fig 7.3 – Ideation Canvas

“To Reduce Rejection & Quality Improvement by using SPC & QC tools
in Gear manufacturing Industry”
7.4 Poster Presentation
Fig 7.4 Poster Presentation

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THE PROJECT REPORT ENTITLED

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

Gujarat Technological University, Ahmedabad

Prof. V.H. Oza

This is to declare that

The project report comprises of my original work towards the degree of

It is great pleasure to acknowledge and express our deep gratitude to all

CHAPTER -1 Introduction 1-6

1.1 Statistical Process Control 1-3

CHAPTER 2 Literature Review 7-9

CHAPTER 3 Objective of Problem 10-11

4.1 Plant Lay-Out 12

CHAPTER 5 Result And Conclusion 27-28

Fig 1.1 SPC Steps 1

Fig.4.4 Fishbone Diagram for the Sharp Edge 17

Fig.7.4 Poster Presentation 34

In Present Scenario in any industry the customer need is most

1.1 Statistical Process Control

The deployment of statistical process control (SPC) in manufacturing

BHGCET , Rajkot Page 1

 The second kind of variation is known as special cause of variation, or assignable

Some Question always ask in the SPC

 What is meant by a process control system?

Steps Involved In Using Statistical Process Control

Fig 1.1 – SPC Steps

BHGCET , Rajkot Page 2

1.2 Quality Control Tools

1.2.1 Quality Control Tools And Procedures

BHGCET , Rajkot Page 3

 Identification and Data gathering

 Analysis Of Selected Problem

 Data Gathering And Initial Charting

1.2.1.1 Identification and Data gathering

BHGCET , Rajkot Page 4

Fig 1.2 Pareto Chart

1.2.1.3 Analysis Of Selected Problem

BHGCET , Rajkot Page 5

Fig 1.3 FishBone Diagram

1.2.1.4 Data Gathering And Initial Charting

BHGCET , Rajkot Page 6

[1] Statistical process control process in which visualizing and controlling

[7] Examined on the applicability of SPC in non-repetitive processes and open

BHGCET , Rajkot Page 7

[11] Gives definition of statistics according to Deming, is to study and understand

BHGCET , Rajkot Page 8

BHGCET , Rajkot Page 9

 To improve operational efficacy.

 In a competitive market we have to increase productivity by reducing the process

 To avoid unusual idle time.

 To minimize and control the cost.

 To measuring the sources of variation assisted by the use of control charts.

 To Improves production efficiency by decreasing scrap and rework

 For the Improving their overall business competitiveness.

BHGCET , Rajkot Page 10

BHGCET , Rajkot Page 11

4.1 Plant Layout

(1) product, or straight-line, layouts,

4.1.1 Plant Layout of Industry

BHGCET , Rajkot Page 12

Design Metullurgy Store for the

Machine shop -1 Shop-2

Fig 4.1 – Plant Lay-out of an Industry