QC STORY -32 QC STORY -32 QC STORY -32 Shop Floor view QC Story-1 QC Story-1 FACTORY OVERVIEW QC Story-1 On Behalf of Susira Industries Ltd., Chennai. We Welcome the Delegates for the QCI – DL SHAH NATIONAL AWARDS ON ECONOMICS OF QUALITY SUSIRA INDUSTRIES LTD ���������� � 2 QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 QC Story-1 QC Story-1 VISION ������������������ ����������������������������������������������������� � To be the number one manufacturer of quality engine valve push rods ����������������������������������������� in the country and to become one among the top five by volumes in the international market. ������������� � To expand the product portfolio by manufacturing other precision auto components/aggregates for national and international customers and � ���������������������������������������������������������� increase the revenue four fold by 2015. ���������������������������������������������� ����������� �� ������������������� � To explore new frontiers of technology to meet the new and emerging market requirements. � ������������������������������������������������������������ ���������������������������������������������������������� � In the process, build a company deeply rooted in values and beyond ������������� profits; a culture of Quality, respect for the individual and an environment of dependability and social responsibility – in short a company “built to � ������������������������������� last”. SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD 4 5 6 1
QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 QC Story-1 QC Story-1 Awards and Recognitions Customers - Domestic Certifications India’s 1st SME to win 16 National awards for Quality and Business Excellence � ��������� �� ����������������������� – Rajiv Gandhi National Quality Award for the year 1993 – ACMA Quality Award – 1994, 1998, 2000 – Golden Peacock National Award for total Quality - 1995 – NIQR-Bajaj ‘Outstanding Quality Man of the year’ - 1994 � ���������������� – ACMA Gold trophy for Export Excellence - 2005 – MMA Award for Managerial Excellence – 2005 – ACMA Certificate of Merit for Excellence in Technology –2007-08 � ��������������� - CII Exim Bank Business Excellence award – Significant achievement commendation for the year 2007-08 � ����������������� - MSME award for ‘Outstanding Entrepreneur’ for the year 2007-08 - ACMA award for Excellence in Quality and Productivity for the year 2008-09 � ���������������� - Also won the 5S par excellent performance award (5 star performance award) from QCFI - Won the best QC story presentation by QCFI � �������������������� - Our team won the Outstanding and Excellent award in the 1st Poka yoke competition conducted by QCFI � ���������������������������������� - Our MD, Mr. Seetharamaiah was awarded the Life Time Achievement award from Ambattur Industrial Estate Manufacturers' Association in the year 2010 SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD 7 8 9 QC STORY -32 QC STORY -32 QC Story-1 QC Story-1 QC Story-1 Products Customers - Prospective Customers - International Push rod Valve seat Inserts ������������������������� Cummins Inc. �������������� ������������������� (USA, UK, Brazil, China & Mexico) Scania, Sweden Tappets Piston Cooling Nozzle �������������� SAME Deutz-Fahr Group S.P.A., Italy ���������������� Iveco, Italy John Deere, USA SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD 11 SUSIRA INDUSTRIES LTD 10 11 12 2
QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 QC Story-1 INTRODUCTION QC Story-1 Methodology SGA Name : PASSION 1 Presentation on Work Area : Induction Hardening ACT PLAN Members : G.Ganesan – Metallurgy R.Sivanesaselvan - Maintenance Reduction in Manufacturing cost 4 P.Dillibabu - Production achieved in Induction Hardening P.V.Ganesan - Production 2 operation through break through machine design Improvement. Meeting Schedule : Every Monday 2.00pm CHECK DO Facilitator : B. Monikandan 3 SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD �� �� SUSIRA INDUSTRIES LTD �� QC STORY -32 QC STORY -32 QC STORY -32 SGA-QA-26 QC Story-1 QC Story-1 List of Problems Identified QC Story-1 List of Problems Identified - Contd Tool : BRAINSTORMING Tool : BRAINSTORMING P P 6. Total Run out high in Cummins push rod 1. Cup Offset L L A A ��������������� 7. Cup ID Black spot 2. Quenching Crack N N ����������� 8. Cup ID pit marks 3. Control Length Under size 9. Low Hardness 4. Low productivity in Induction Hardening 10. Total Length Under size 5. Ball Flat Over Size SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD �� �� �� 3
QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 List of Problems Identified - Contd QC Story-1 QC Story-1 Categorization of problems Tool : BRAINSTORMING A Category Problems CATEGORISATION OF PROBLEMS P 11. Gap between Ball and Cup 1. Cup Offset 7. Cup ID Pit marks L Category Description 12. Cup OD Tool Mark A 2. Quenching Crack 8. Low Hardness P P A Minimum involvement of other N 3. Control Length Under size 9. Total Length U/s 13. Low Weld Strength L L departments in solving them A 4. Ball Flat Over Size 10. Cup OD Tool Mark A B Involvement of other department is 14. Less yield in 961 Push Rod N N 5. Total Run out high in Assembled 11. Gap between Cup and Ball necessary Push Rod 12. Low Weld Strength 15. Induction Hardening Cost High C Management approval and support 6. Cup ID Black Spot needed 16. Induction Hardening Through Put time high SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD �� �� �� QC STORY -32 QC STORY -32 QC STORY -32 QC Story-1 Categorization of problems QC Story-1 Categorization of problems QC Story-1 GUIDE LINES FOR RANKING B Category Problems C Category Problems � Effect on customer 1. Low productivity in Induction � Effect on productivity Hardening. 1. Induction hardening Through put P P time high � Effect on Cost 2. Less Yield in 961 Push rod L L 2. Induction Hardening Cost High � Effect on delivery A A N N Note: Higher the severity lower the rank SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD SUSIRA INDUSTRIES LTD �� �� �� 4
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