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Quality analysis of Machine Shop (HMC)
Presenting:
GROUP # 01
Abu Bakar Siddique ME123009
Shahid Hussain ME123019
Muhammad Ifraheem ME123022
Fahad Akhter ME123082
Introduction of HMC
• Leading enterprise in a country.
• Two main Production unit
• Mechanical works
• Foundry & Forge works
• Mechanical works starts 1971
Machine Shop
• Most Important Shop
• Contributes major part in income of industry
• Divided in three categories
• Small Bay
• Medium Bay
• Heavy Bay
• Batch Production
TurningDrawing Reading
Dimension Correct
Facing
Dimension CorrectMilling
Dimension CorrectDrilling
Store
Dimension Correct
If YES
If YES
• If NO
If YES
If NO
If NO
If NO
If NO If NO
If YES
Flow Chart
Turning Data
Turning 1 2 3 4 Avg Dia Range
1 420.2 419.6 419.8 420.1 419.925 0.6
2 419.9 420.3 420.1 419.9 420.05 0.4
3 420.8 420.2 420.5 420.3 420.45 0.6
4 420 419.9 419.8 420 419.925 0.2
5 420.4 420 420.3 420.1 420.2 0.4
6 419.5 420.2 419.9 420.1 419.925 0.7
7 420.4 419.8 420.2 419.9 420.075 0.6
8 420.2 419.9 420 420.1 420.05 0.3
9 420.3 419.9 420.2 419.9 420.075 0.4
10 420.2 419.6 420.1 419.7 419.9 0.6
Charts and Capability
Cp= 0.574 Cpk=
1 2 3 4 5 6 7 8 9 10419419.2419.4419.6419.8
420420.2420.4420.6
X- Bar Chart
Avg. Diameter MeanUCL LCL
Dia
met
er (
mm
)
1 2 3 4 5 6 7 8 9 100
0.2
0.4
0.6
0.8
1
1.2
R-Chart
Range R UCL(R) LCL(R)
Rang
e
Facing Data
Facing 1 2 3 4 Avg. Width Range
1 36.4 35.8 36.2 35.9 36.075 0.6
2 35.8 36.2 36 36.1 36.025 0.4
3 36.5 35.5 36.2 35.3 35.875 1.2
4 36.3 35.9 36.1 35.8 36.025 0.5
5 35.7 36.2 35.9 36 35.95 0.5
6 35 36.5 36.4 36.1 36 1.5
7 35.8 36.4 36.2 35.9 36.075 0.6
8 36.2 35.7 35.9 36.2 36 0.5
9 36.8 36.4 35.9 36 36.275 0.9
10 35.6 36.3 36.3 35.8 36 0.7
Charts and Capability
Cp= 1.66 Cpk=
1 2 3 4 5 6 7 8 9 1034.8
35.2
35.6
36
36.4
36.8
X- Bar Chart
Avg, Width MeanUCL LCL
Wid
th (
mm
)
1 2 3 4 5 6 7 8 9 1000.20.40.60.8
11.21.41.61.8
R-Chart
Range R UCL(R) LCL(R)
Rang
e
Milling DataMilling 1 2 3 4 Avg Depth Range
1 24.4 23.8 24.2 23.7 24.025 0.7
2 24.6 24.2 24.3 24.6 24.425 0.4
3 23.7 24.2 24.1 23.9 23.975 0.5
4 24.4 23.6 23.9 24.2 24.025 0.8
5 24.2 23.9 23.9 24.1 24.025 0.3
6 23.9 24.7 24.5 23.9 24.25 0.8
7 24.2 23.7 23.9 24 23.95 0.5
8 24.3 23.7 23.9 24.1 24 0.6
9 23.8 24.1 24 23.9 23.95 0.3
10 24.5 23.6 23.7 24.4 24.05 0.9
Charts and Capability
Cp= 1.15 Cpk=
1 2 3 4 5 6 7 8 9 1023.223.423.623.8
2424.224.424.6
X- Bar Chart
Avg. Depth MeanUCL LCL
Dep
ht (
mm
)
1 2 3 4 5 6 7 8 9 1000.20.40.60.8
11.21.4
R-Chart
Range R UCL(R) LCL(R)
Rang
e
Drilling Data
Drilling 1 2 3 4 Avg. Depth Range
1 15.8 16 15.9 15.8 15.875 0.2
2 16.4 16.5 16.1 16.2 16.3 0.4
3 15.9 16 16 16 15.975 0.1
4 16.5 16.2 16.3 16.4 16.35 0.3
5 15.8 15.9 16 15.9 15.9 0.2
6 15.8 15.9 15.9 15.9 15.875 0.1
7 16.1 15.8 15.9 16.1 15.975 0.3
8 16.3 16.1 16.2 16.1 16.175 0.2
9 16 16 15.9 15.9 15.95 0.1
10 16.4 16.1 16.3 16.4 16.3 0.3
Charts and Capability
Cp= 0.877 Cpk=
1 2 3 4 5 6 7 8 9 101515.215.415.615.8
1616.216.416.6
X-Chart
Avg. Dia UCL LCL Mean
Dia
met
er
1 2 3 4 5 6 7 8 9 1000.10.20.30.40.50.6
R-Chart
Range UCL(R) LCL(R) R
Rang
e
Cause and effect diagram
Flow Process ChartProcesses Time ⃝� → □ D ∇
Drawing Reading 05 min √
Transfer to Turning machine 02 min √
Machine checking 02 min √
Turning 12 min √
Transfer to Grinding machine 02 min √
Tool Grinding 01 min √
Check dimensions 02 min √
Transfer to another machine for facing 03 min √
Facing 10 min √
Check dimensions 02 min √
Transfer to Grinding machine 01 min √
Tool Grinding 01 min √
Supervisor inspection 05 min √
Transfer to Milling 02 min √
Wait for completing job 14 min √
Milling 40 min √
Check dimensions 05 min √
Supervisor inspection 05 min √
Transfer to Drilling 02 min √
Drilling 10 min √
Check dimensions 02 min √
Transfer to QC Department 05 min √
Quality Inspection 07min √
Transfer to store 05 min √
Store ---- √
Calculations
Total Time= 143 min
Operation Time= 79 min, Transport Time=22 min, Inspection Time= 30 min,
Delay Time =14 min
Efficiency % = =%
Questionnaire
Questions SA A N D SD
Material quality of HMC products is good enough. 1 5 2 2 1
Dimensional accuracy is within specified limits. 2 4 3 1 1
HMC is able to ship out products in a given time period. 2 4 1 3 1
Are all design reviewed tested and verified? 1 3 5 2 0
HMC products are reliable. 3 5 3 0 0
HMC manufacture products are low cost as compared to other firms. 4 2 2 2 1
latest technology is being used in HMC. 0 3 4 4 0
HMC has a good benchmark for other relevant firms. 1 4 5 0 1
HMC is meeting all customer requirements. 3 5 3 0 0
Is HMC fulfilling ISO standards? 2 2 1 4 2
19 37 29 18 7
Importance Performance Matrix
IMPORTANCE
HIGHHMC
LOW
LOW HIGH
PERFORMANCE
Total Value=
11x (1+2+3+4+5+6+7+8+9+10)x5=3025
Total obtained=2071
Our Target Value =3
On scale 5=
Cost per Month
Labor cost 104,000 Rs 36.62%
Electricity 150,000 Rs 89.70%
Maintenance 20,000 Rs 96.57%
Others 10,000 Rs 100.00%
Total 284,000 Rsele
ctricit
y
labor
cost
mainten
ance
others
020000400006000080000
100000120000140000160000
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
Cost per Month
Cost of Quality
Years External Cost
Internal Cost
Prevention Cost
Appraisal Cost
Total Quality Cost
1 4.5 2 1 0.55 8.05
2 4.5 2.5 1.2 0.55 8.75
3 4.25 3 1.2 0.54 8.99
4 3.75 3.5 1.3 0.53 9.08
5 2.75 3 1.6 0.52 7.87
6 2.5 2.7 1.5 0.51 7.21
7 2 2.5 1.25 0.5 6.25
Note: Each cost * 100,000 Rs
0 1 2 3 4 5 6 7 802468
10
Cost Of QualityExternal Cost Internal CostPrevention Cost Apperasial CostTotal Quality Cost
Years
Cost
Current Sigma Level
Number of units Nu 5,000Number of opportunities No 04
Number of defects Nd 85
Number of defective units Ndu 53
• 4250 defects per million opportunities.• This corresponds to the 3.2 sigma level.
ISO Standard
• ISO 9001 certified
• Authorized to use 4 ASME stamps U, U2, S & PP for equipment manufacturing
Conclusion
HMC management has to take some decisions.
• Buy new machinery
• Shift machines from manual to Computer Numerical Control
• Hire highly skilled people
• Follow Six sigma principles
Questions???
