Application of QC Tools in a Small Manufacturing Unit:A Case Study by Karamjeet Singh, Industrial
Abstract
With increased competition and demand of products it has become very necessary for every industry that their products must possess needed quality at an acceptable cost and also a profit margin for the industry. By quality control, all the factors related with production of a product are reviewed so that final product is according to the needs of the customer. To fulfill these objectives, quality control tools are needed and these tools had already shown their effectiveness from previous sixty years. The seven quality control tools or techniques are Pareto chart, Check sheet, Histogram, Cause and effect analysis, Scatter diagram, Flow chart and Control charts. These tools or techniques can be used at any stage of production process. The aim of these tools is to analyze the problem and then giving appropriate solution so that final product is defect free which in turn will improve the quality and increase the customer satisfaction. In present work, these quality control tools have been used in a small scale Indian manufacturing unit to reveal the causes of various defects in bolts and also to reduce the rejection so that the wastage of money can be stopped. Three types of bolts viz. Clutch housing bolt of TATA ace, Clamp bolt of TATA and Rear hanger bolt of Leyland have shown an overall rejection of 0.73%. Various defects responsible for rejection were bending, cracking, threading, improper head, undersize, oversize and improper coloring etc. Check sheet was used to collect the daily data related to production and rejection of bolts. By using tools like Pareto diagram and Fishbone diagram the major defects indentified were bending, cracking and threading. The overall rejection has been reduced to 0.22%. Earlier the monthly loss of money was Rs. 52486.8 and now it has trimmed down to Rs. 16570.6 per month. Hence savings of Rs. 35916.2 have been made per month.
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