MODEL QCC Projects

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Quality Control Circle Projects

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WELCOME National Convention Quality circle 2010 2

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LEADER PHILEMON DEPUTY LEADER MONISHA SAMARTH 3 TEAM MEMBERS

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RECODER TIME KEEPER GEETHIKA DARSHAN 4 SAMARTH

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ACTIVE MEMBER ACTIVE MEMBER RAJESH ANGEL ACTIVE MEMBER ABDUL SAMARTH 5

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6

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Ms.CHETHANA FACILITATORs CO-ORDINATOR: Mrs.ASHA SAMARTH Ms.PALLAVI 7

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8 NEC BANGALORE CP-04 : Diploma in Electronics CP-08 : Diploma in Computer Engineering CP-09 : Diploma In Information Technology CP-10: Post Diploma In Power Electronics Special Course : NCVT(Only for physically challenged ) SAMARTH

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9 TEAM PROFILE: Date of formation Day of meeting Venue of meeting Duration of meeting No of meetings Attendance% Project under taken Project completed : 2nd,Dec 09 : Wednesday : Classroom 3 : 2 Hours : 21 no. : 100% : 01 : 01 SAMARTH

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AIM: “TO DESIGN THE FUTURE WITH QUALITY AND INNOVATION.” SAMARTH

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OBJECTIVE: “TO UNIFY THE POTENTIAL OF OUR TEAM TO REACH THE ESTEEM LEVEL OF QUALITY.” SAMARTH

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S teps followed in our QC process . 12 SAMARTH

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Identification of problem Selection of problem Definition of problem Analysis of problem Cause and effect analysis Root cause analysis SAMARTH

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Data analysis on root cause Development of solution Foreseeing probable resistance Trial implementation Regular implementation Follow up review SAMARTH

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Process Decision Program Chart SAMARTH

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SAMARTH QC team process Identification of the problem Brain storming technique Past experience Data collection Selection of the problem Definition of The problem stratification Matrix diagram Data collection A SAMARTH

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Analysis of the problem Pareto chart & Check list Validation & Why-Why Analysis Root cause analysis Cause & effect diagram Ca use & effect analysis 4W & 1H Technique A B SAMARTH 17

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Pie chart Data collection Development of solutions Data analysis on route cause Regular implementation Trial implementation Foreseeing probable resistance B SAMARTH Follow up review 18

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IDENTIFICATION OF PROBLEMS STEP 1 SAMARTH 19

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20 SAMARTH Identified 67 PROBLEMs BRAIN STORMING & DATA COLLECTION SAMARTH

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No proper utilization of components tester by trainees. No proper maintenance of first aid box. Submission of assignments, notes & records are not done properly by trainees. No frequent conduction of seminars. No proper utilization of transformer winding machine by trainees. No proper utilization of pneumatic and hydraulic labs by trainees. No proper conduction of open forums. Lack of experienced faculties. No proper guidance for doing projects. No proper transportation facilities for 1st years. Non availability of lockers in 1 st year campus. No proper information regarding mess bills. No updating of syllabus for IInd & IIIrd years. Services like Xerox, printout etc, are not provided for trainees. No proper equipments in physics lab for 1 st year trainees. No proper contact with other engineering collages . LISTED PROBLEMS SAMARTH 21

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No proper maintenance of 5’s box . No proper exposure of projects done by the trainees. No proper maintenance of projectors, OHP’s and junction boxes. No proper utilization of the machines using in workshop. No proper allocation of particular workbenches to the trainees. High failure in practical's . Lack of trouble shooting skills in trainees. Lack of knowledge about non-working of equipments in trainees. No updation of components status list in labs. No proper allocation of equipments to the particular trainees in AE-II lab. Consuming more time for taking extra labs. No awareness regarding the safety precaution to be followed in workshop. Lack of basic knowledge in trainees. No proper interaction between seniors and juniors. Lack of component testers in analog lab AE-II. In efficient utilization of working hours by trainees. Improper working of DTK’s and mp-kits. SAMARTH 22

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Non availability of class rooms for extra classes. No proper allocation of time for sports, to the trainees. No proper net facility for second year trainees. No proper co-curricular activities are conducted for trainees. Insufficient no. of technical portraits in labs and class rooms. No proper conduction of safety week. Completion of syllabus is not done on time by the faculties. Activities are not carried out as mentioned in the activity calendar. Non availability of tools in workshop. Lack of necessary books in library for trainees. No fire alarm system in campus. No proper information regarding the absence of faculties. No proper information regarding industries. Non availability of components during extra labs. Mis -utilization of library cards by trainees. Wastage of time in collecting the components in labs. No proper maintenance of class rooms. SAMARTH 23

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No lab manuals to guide the trainees. Lack of components in analog lab II Wastage of electricity in classrooms. No hobby projects are allocated in 4 th semester. No drinking water facility in working area. Non- availability of required software's. No proper engagement of classes in the absence of allocated facilities. Components are not issued in right time for projects. Insufficient stationary items in general stores. Time is not allocated for utilizing library facility. Improper time management in conducting assembly No proper guidance from faculties during extra labs. Lack of library facility for first year trainees. No proper usage of daily dairy by trainees. No proper guidance for visitors No proper awareness regarding new software. No proper 5’s activities are followed in labs and classrooms by the trainees. SAMARTH 24

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SELECTION OF PROBLEM STEP 2 SAMARTH 25

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IDENTIFIED PROBLEMS a C B CATEGORIZATION: SAMARTH 26

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The problems which can be solved only by the trainees. The problems which can be solved by the trainees with the minimum help of the management . The problems which can be solved only by the management . Category A: Category B: Category C: SAMARTH 27

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-CATEGORY A 13 SAMARTH

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A- category SAMARTH High failure rate in practical's. Lack of trouble shooting skills in trainees. No improvement in the internal’s percentage level of CP04 II year trainees. Consuming more time for taking extra labs. Lack of basic knowledge in trainees. No proper interaction between seniors and juniors. Lack of component testers in analog electronics lab-II. No regular check up of suggestion box. No updating of component status list in labs. Lack of knowledge about the working of equipments in first year trainees . No awareness, regarding the safety precautions to be followed in workshop. Lack of junction boxes in CP04 II year class rooms. No proper allocation of particular workbench to the trainees. 29

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20 -CATEGORY B SAMARTH

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No proper maintenance of 5’s box . No proper exposure of projects done by the trainees. No proper utilization of the machines using in workshop. No proper utilization of components tester by trainees. No proper maintenance of first aid box. Submission of assignments, notes & records are not done properly by trainees. No frequent conduction of seminars. No proper utilization of transformer winding machine by trainees. No proper utilization of pneumatics and hydraulics labs by trainees . No proper 5’s activities are followed in labs and classrooms by trainees. Improper working of DTK’s and mp-kits. No proper usage of daily dairy by trainees. No proper guidance for visitors. No proper awareness regarding new software. No proper information regarding industries. Non availability of components during extra labs. Mis -utilization of library cards by trainees. Wastage of time in collecting the components in labs. No proper maintenance of class rooms . Consuming more time for taking extra labs. B- category SAMARTH 31

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-CATEGORY C 34 SAMARTH

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No proper conduction of open forums. Lack of experienced faculties. No proper guidance for doing projects. No proper transportation facilities for 1st years. Non availability of lockers in 1 st year campus. No proper information regarding mess bills. No updating of syllabus for IInd & IIIrd years. Services like Xerox, printout etc, are not provided for trainees. No proper equipments in physics lab for 1 st year trainees. No proper contact with other engineering collages. No proper guidance from faculties during extra labs. Lack of library facility for first year trainees . Non availability of class rooms for extra classes. No proper allocation of time for sports, to the trainees. No proper net facility for second year trainees. No proper co-curricular activities are conducted for trainees. Insufficient no. of technical portraits in labs and class rooms. c - category: SAMARTH 33

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18.No proper conduction of safety week. 19.Completion of syllabus is not done on time by the faculties. 20.Activities are not carried out as mentioned in the activity calendar. Non availability of tools in workshop. Lack of necessary books in library for trainees. No fire alarm system in campus. No proper information regarding the absence of faculties. No lab manuals to guide the trainees. Lack of components in analog lab II Wastage of electricity in classrooms. No hobby projects are allocated in 4 th semester. No drinking water facility in working area. Non- availability of required software's. Components are not issued in right time for projects. Insufficient stationary items in general stores. Time is not allocated for utilizing library facility. Improper time management in conducting assembly. c - category: 34 SAMARTH

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1. No regular check up of suggestion box. Sol: Allocating leaders to collect the suggestions and to inform the academic in-charge for every month. 2. No updation of component status list in labs. Sol: Updating the component status list in labs. 3. Lack of knowledge about the working of equipments in first year trainees . Sol: Preparing and pasting the checklist on each and every work bench. 4. No awareness, regarding the safety precautions to be followed in workshop. Sol: Preparing and pasting the safety precautions on the machines in the workshop. 5. Lack of junction boxes in CP04 II year class rooms. Sol: Provided junction boxes for CP04 II year class rooms. 6. No proper allocation of particular workbench to the trainees. Sol: Preparation of seating sequence to the trainees in AE-I and AE-II labs. 35 SAMARTH The problems which can be solved then & there, and their solutions

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1. High failure rate in practical's. 2. Lack of trouble shooting skills in trainees. 3. No improvement in the internal’s percentage level of CP04 II year trainees. 4. Consuming more time for taking extra labs. 5. Lack of basic knowledge in trainees. 6. No proper interaction between seniors and juniors. 7. Lack of component testers in analog electronics lab-II. 36 SAMARTH The problems which cannot be solved then & there

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REPRESENTATION OF SELECTED DATA IN THE FORM OF CHECK SHEET SAMARTH 37

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PROBLEM TALLY NO.OF VOTES CUMULATIVE FREQUENCY % CUMMULATIVE % 1 . No improvement in the internal’s percentage level of CP04 2 nd year trainees IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII IIII 70 70 44.03 44.03 2. Lack of trouble shooting skills in trainees. IIII IIII IIII IIII IIII IIII IIII 35 105 22.01 66.04 3 . Lack of basic knowledge in trainees. IIII IIII IIII IIII 19 124 11.95 77.99 4 . Consuming more time for taking extra labs. IIII IIII III 13 137 8.18 86.17 5 . High failure rate in practical’s. IIII IIII 10 147 6.29 92.46 6 . No proper interaction between seniors and juniors. IIII III 8 155 5.03 97.49 7 . Lack of component testers in analog electronics lab –II. IIII 4 159 2.51 100 CHECK SHEET SAMARTH 38

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0 10 20 30 120 110 100 90 80 70 60 50 40 140 130 10 20 30 90 80 70 60 50 40 92.46 44.03 66.04 86.17 Vital few Trivial many 100 1 2 3 4 5 6 frequency PERCENTAGE NO.OF PROBLEMS 70 35 19 13 10 08 77.79 150 160 04 97.49 7 No improvement in the internal’s percentage level of CP-04 II year trainees. Lack of trouble shooting skills in trainees. High failure rate in practical's. Consuming more time for taking extra labs. Lack of basic knowledge in trainees. No proper interaction between seniors and juniors . Lack of components in analog electronics lab-II PARETO CHART: SAMARTH 39

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OUR PROBLEM: NO IMPROVEMENT IN THE INTERNAL’S PERCENTAGE LEVEL OF CP 04 II YEAR TRAINEES. SAMARTH 40

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41 Definition of the problem STEP 3 SAMARTH

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DEFINITION OF PROBLEM By Considering the Statistics (i.e., the Internal’s Percentage Level ) of CP04 II year Trainees from the Exam Cell. SAMARTH 42

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P E R C E N T A G E Graph, representing the “THEORY” internal’ s percentage level of past 3 batches of cpo4 II year. SAMARTH 43 Batches

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A Graph, representing the “PRACTICAL” internal’s percentage level of past 3 cpo4 II year batches . P E R C E N T A G E SAMARTH 44 Batches

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45 We aim, To Improve the Internal ‘s Percentage Level of CP04 II year trainees. SAMARTH

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6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Analysis of the problem Cause and effect analysis Root cause analysis Data analysis on root cause Development of solutions Foreseeing probable resistances Trial implementation Regular implementation Follow up review Meeting no Steps Milestone chart SAMARTH 46

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STEP 4 SAMARTH Analysis Of The Problem

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What is the problem? No improvement in the internal’s percentage level of CP04 II year trainees. When does it occur? During an academic year. Where does it occur ? In internal’s percentage level of CP04 II year trainees. Who are affected ? Second year trainees are affected. How does it effect ? No decrement in the backlogs of trainees. 4 W 1 H Analysis SAMARTH 48

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STEP 5 SAMARTH 49 CAUSE AND EFFECT ANALYSIS

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Material Wastage of time in collecting the components from other labs. Wastage of time to get the belongings in between the class hours. Wastage of time to arrange stationary, junction boxes and OHP for the classes. Consumption of time in identifying working and non working components. Inefficient utilization of working hours by trainees . Insufficient time for doing experiment by the trainees. W astage of time in collecting the belongings in between the classes. Utilization the lab hours for completion of the records. Trainees are not attending the class on time. Man Machine Required software's for the trainees are not installed in systems. Trainees are not sure that whether the existing component testers are working or not No proper outcome in labs due to increase in non working equipments . Interruptions occurring during practical session. No engagement of classes in the absence of concerned faculties. Consumption of time for the trainees to get his doubts cleared for doing the further experiment. Wastage of time for submission of files & records. Method No improvement in the internal’s % level of CP04 2 nd year trainees SAMARTH 50

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Inefficient utilization of working hours by trainees. Insufficient time for doing experiment by the trainees. Utilization the lab hours for completion of records. Variation of time in clocks in our institute. In ability to manage the time by trainees. Lockers are not kept in the required places. Wastage of time for giving daily attendances. Trainees are unable to complete the assignments in the allocated time. Trainees are not attending the class on time. Wastage of time in collecting the belongings in between the classes. There is no centralized timing system. Utilization more time than the allocated time for a particular activity. Trainees are not following the lab procedure. MAN SAMARTH 51

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Mishandling the equipments by trainees . Improper maintenance of working equipments. No proper maintenance record regarding the testers available in lab. No knowledge about the working of equipments. No proper calibration of the working equipments. MACHINE No proper outcome in labs due to increase in non working equipments. Required software's for the trainees are not installed in systems. Trainees are unable to identify whether the existing component testers are in working condition . SAMARTH 52

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Wastage of time to get the belongings in between the class hours. Consumption of time in identifying working and non working components. Wastage of time to arrange stationary items, junction boxes and OHP for the classes. Wastage of time in collecting the components from other labs. No proper component testers available in lab . Non-availability of required components in particular lab. Lockers are not kept near the classrooms . S tationary, OHP and junction boxes are not kept in class room. No arrangement to keep s tationary, OHP and junction boxes safely . Trainees are not knowing, how to check the components. MATERIAL SAMARTH 53

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No time allocated to submit records and files. No information regarding the absence of faculties. No proper time allocated for the cleaner to clean the lab. Allocation of theory classes during lab hours to the faculties. No allocation of other faculties to guide the trainees in absence of particular subject in charge. No engagement of classes in the absence of concerned faculties. Interruptions occurring during practical session. Due to power failure. Wastage of time for submission of files & records. Consumption of time for the trainees to get his doubts cleared for doing the further experiment . SAMARTH METHOD 54

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55 Validation of causes - MAJOR - NEGLIGIBLE - MINOR SAMARTH

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Validation of causes Inefficient utilization of working hrs by trainees. Wastage of time to arrange junction boxes, stationary items & OHP’s for the classes. Trainees are unable to identify whether the existing component testers are in working condition. No engagement of classes in the absence of concerned faculties . MAJOR : MINOR : Insufficient time for doing experiments by the trainees. Wastage of time collecting the belongings in between the classes. No proper outcome in labs due to increases in non-working equipments. Consumption of time for the trainees to get his doubts cleared for doing the further experiment. Wastage of time collecting the components from other labs. NEGLIGIBLE : Utilizing the lab hours for completion of the records. Trainees are not attending the class on time. Required software's for the trainees are not installed in systems. Wastage of time to get the belongings in between class hours. Consumption of time in identifying the working and non working components. Interruption happening during practical session. Wastage of time for submission of files & records. SAMARTH 56

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STEP 6 WHY ? WHY ? Analysis SAMARTH 57 Root Cause Analysis

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Inefficient utilization of working hours by trainees. In ability to follow right time by trainees. Variation of time in clocks in our institution. No proper check up of timings in all the clocks in our institution . WHY??? WHY??? WHY??? For 1 st major cause SAMARTH 58

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Wastage of time to arrange junction boxes stationary items and OHP’s for the class rooms . WHY??? OHP’s junction boxes ,stationary items are not kept in class rooms. WHY??? No arrangements made to maintain OHP’s junction boxes and stationary items safely in the class rooms. For 2 nd major cause SAMARTH 59

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Trainees are unable to identify whether the existing components testers are in working condition. WHY??? No proper maintenance record regarding the testers available in lab. WHY??? No regular maintenance for the component testers. For 3 rd major cause SAMARTH 60

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For 4 th Major cause No engagement of classes in the absence of concerned faculties. WHY??? No information regarding the absence of faculties . WHY??? No one is allocated for checking the absence of faculty. SAMARTH 61

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Data Analysis On Root Cause STEP 7 SAMARTH 62

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SLNO CAUSES VOTES GIVEN BY TRAINEES VOTES IN PERCENTAGE 1. Inefficient utilization of working hours by trainees. 92 57.86% 2. Wastage of time to arrange junction boxes ,stationary items and OHP’s for the class rooms . 38 23.9% 3. No regular maintenance for the component testers. 21 13.21% 4. No one is allocated for checking the absence of faculty. 8 5.03% DATA FOR INDIVIDUAL CAUSES: SAMARTH 63

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Graphical representation of data SAMARTH 57.86% 23.9% 13.21% 5.03% 64

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2.50p m-4.50pm Practical session WORKING Schedule of CP04 II year trainees Break 10.00am-10.10am Lunch break 12:10pm-12:40pm Break 2:40pm-2:50pm The same procedure is followed alternately for the other batches of CP04 II year trainees. Arranging OHP 7.55 am- 8.00am 65 SAMARTH

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How the time is exactly getting wasted 66 SAMARTH

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SAMARTH 67 Activities Actual Time(min.) Utilized Time(min.) Wastage of time(min.) Allocating OHP 0 5 5 T-Break 10 25 15 Lunch break 30 50 20 T-Break 10 25 15 Allocation of faculties 0 10 10 Identifying components 0 10 10 TOTAL WASTAGE OF TIME : 1 Hr. 15 mins. AVERAGE WASTAGE OF TIME PER DAY:

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SAMARTH So by this, trainees are wasting 5 min from the first hour of the theory session. 68 Allocated time for arranging OHP: 7:55am – 8:00am Utilized time for arranging OHP : 7:55am -8.05am Wastage of time during working hours:

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SAMARTH 69 So by this trainees are wasting 15 mins from the 3 rd hour of the theory session. Allocated time for break: 10:00am – 10:10am Utilized time for break: 10:00am -10.25am Wastage of time during working hours:

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SAMARTH By this trainees are wasting 20min from the next practical session 70 Allocated time for lunch: 12:10pm -12:40pm Utilized time for lunch: 12:10pm - 1.00pm Wastage of time during working hours:

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SAMARTH 71 By this trainees are wasting 15min from the next practical session Allocated time for break: 2:40pm – 2:50pm Utilized time for break: 2:40pm -3:05pm Wastage of time during working hours:

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SAMARTH 72 By this, its clear that the wastage of time is “1Hr.15 Mins” per day.

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SAMARTH 73 “Moments unfold into hours, Hours unfold into days, Days unfold into months, Months unfold into years & Years unfold into lifetime”. “If you waste even a moment you end up wasting a life”

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74 So, we decided to solve this wastage of time “1Hr.15Mins” by developing a solution. SAMARTH

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STEP 8 Development of solutions SAMARTH 75

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SAMARTH Taking initiatives by trainees to set the clock. Informing Faculties Regarding Classes Through Software Developing alarm system in our institute. By Designing centralized timing system in our institute. List of solutions 76

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Graphical representation of data SAMARTH 50.32% 23.9% 16.98% 8.8% 77

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S amarth C entralized T iming S ystem Our Project: 78 SAMARTH

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SAMARTH 79 Demonstration of the project SAMARTH

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SAMARTH 80 PDCA cycle:

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SAMARTH 81 PROCEDURE FOLLOWED FOR THE PROJECT “SCTS”

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82 SCTS SAMARTH

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SAMARTH 83 Printed circuit board 50RS chassis 100RS components 200RS Total cost estimation 350RS PROJECT COST ESTIMATION

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84 Solving one cause will not solve the problem completely. So we designed the solutions for other causes also as follows.. SAMARTH

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Cause 2 : Wastage of time to arrange junction boxes stationary items and OHP’s for the class rooms . Equipments Maintenance List Batch : Date of updating : Signature : (Class Representative) Equipments Equipment no Status OHP Junction Box For this , we allocated OHP’s , junction boxes,& stationary items to the class rooms permanently, and prepared a maintenance list for that. 85 SAMARTH

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Cause 3 : Trainees are unable to identify whether the existing component tester are in working condition . So, We solved this cause by Implementing Maintenance Record of Component Testers SAMARTH 86

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No Engagement of classes in absence of allocated faculties We solved this cause by preparing a faculties allocation chart SAMARTH Cause4 : 87

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SAMARTH Sl.no Activity done Done by days 01 Digital clock Rajesh Abdul 10 02 Allocation charts Geethika Angel 01 03 Check sheet Philemon Monisha 01 04 Development of maintenance records Angel Darshan 02 05 Data collection all _ Activity plan sheet 88

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STEP 9 Foreseeing Probable Resistances SAMARTH 89

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SAMARTH If power fails how the clock works. we provided the backup circuit for the clock. 2. If there is variation in time due to mal-functioning of the clock. we provided the facility to set the time manually. 3. If the power fails the circuit may consume more power for the backup provided. we have provided a logic circuit for consuming less power so that it will have a long backup. Probable Resistances: 90

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4 .If OHP’s and junction boxes are not working what can be done. we have provided maintenance report for testing OHP’s and junction boxes every weekend. 5 .If trainees are not knowing how to work with the testers . we have provided guidelines for each component testers to the trainees. 6. If class representative is absent how the work continues. we have allocated substitute for doing that particular work. SAMARTH 91

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STEP 10 SAMARTH 92 TRIAL IMPLEMENTATION

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Progress of trainees Before & after implementation of “SCTS ” SAMARTH 93

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SAMARTH In efficient utilization of working hours by trainees. Trainees are utilizing working hours efficiently and effectively. 94 1. Before implementation After implementation Progress of trainees:

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SAMARTH Wastage of time in arranging OHP’s junction boxes and stationary items for classes. There is no wastage of time in arranging OHP’s junction box and stationary items for the class rooms. 95 2. B efore implementation After implementation

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SAMARTH Trainees were unable to identify whether the existing component testers are working condition. Trainees are sure that the particular component testers are working by seeing the maintenance record. 96 3. Before implementation After implementation

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SAMARTH No engagement of classes in the absence of concerned faculty. Classes are engaged with the substitution of absence faculty. 97 4. Before implementation After implementation

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SAMARTH 98 THEORY PRACTICAL 60.46% Increment internal’s percentage level of CP-04 II year trainees.

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99 We achieved our target by improving the average internal’s Percentage level from 63.64% 87.74% SAMARTH

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STEP 11 Regular Implementation SAMARTH On 30 th March 2010 100

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TANGIBLE GAINS Efficient utilization of working hours by trainees. No wastage of time for arranging OHP’s, Junction box for the class room. Time is utilized by the trainees with the substitution of absence of faculty. SAMARTH 101

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we improved our thinking power. Increased our communication skills. Increased our Presentation Skills. Developed our team work. Developed leadership quality. Can identify easily the component tester. INTANGIBLE GAINS SAMARTH 102

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STEP 12 FOLLOW UP REVIEW SAMARTH 103

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STANDARDIZATION: SAMARTH 104 Records regarding Samarth Centralized Timing System ( S C T S ). Maintenance record for junction boxes, OHP’s. Implementing check list. Maintenance record for component tester.

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SAMARTH 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Analysis of the problem Cause and effect analysis Root cause analysis Data analysis on root cause Development of solutions Foreseeing probable resistances Trial implementation Regular implementation Follow up review Meeting no Steps Milestone chart 105

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SAMARTH Future problem : Lack of trouble shooting skills in trainees 106

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SAMARTH QC tools used Sl.no QC tools 01 Pareto chart 02 Check sheet 03 Graphs 04 Cause & Effect diagram 05 Process Decision Program Chart (PDPC) 06 Matrix diagram 107

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108 SAMARTH THANK YOU

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SAMARTH Any Quires ?? ?? ? ? ? . 109 SAMARTH

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