Professional Documents
Culture Documents
Diwakar Bhargav
(110010119093)
Guided by
OBJECTIVE
LITERATURE REVIEW
Author
Journal
Name
Title
Theory
Dick lewis ,
Jose macedo
MIOT
Lean academy
WCECS
Tushar N. Desai ,
Dr. R. L.
Shrivastava
Abhijit
Chakraborty,
Sudip Kr. Deb,
Sitanath
Mukhopadhay
Abhijit
Chakraborty,
SCMHRD
External Obstacles to
Quality for Small Scale
Enterprises
Internal Obstacles To
Obstacle in small
scale industries
Obstacle in small
METHODOLOGY
Literature
review
Conclusion
Problem
definition
Apply six
sigma on
small scale
industry
Collecting
data
suggestions
Observation
s from
analysis
Analyse
data
1. DEFINE
2. MEASUREMENT
3. ANALYSIS
4. IMPROVE
5. CONTROL
specifically?
Potential Answers
The local dealers are the customer.
Low production due to less order & rejection
of product
Five Member in our team.
Our plan is to give appropriate suggestion
for increase productivity of company
Final report is being generated for owner of
SHREE TRIMURTI CHEMICALS.
Increase the production, revenue and
SIPOC
SIPOC is the acronym that stands for five elements: Suppliers, Inputs,
Process, Outputs,
and Customers. A SIPOC diagram is shown here:
Suppliers
Inputs
Process
Outputs
Local factories HCL & Nitrite
Customers
ACID BLACK
The output is
210, ACID
produced for
BLACK 234
dealers
ACID BLACK 1
ACID YELLOW
73
(2)MEASUREMENT PHASE:
NO.
1
2.
Questions to be Answered?
Potential Answers
What is the current measurement? Company produced nearly 90 M ton dyes in year
2014.
What are we going to collect?
Companys Type of product, total production in a
year, profit and losses.
3.
4.
5.
6.
What are the teams deliverables? During this stage team deliverable will be to
collect the data of current manufacturing process
and Production from owner of SHREE TRIMURTI
CHEMICALS.
Batch process:
First we diazotise one material with HCL & Nitrite give 3 hours for stirring then coupled the
same with another material, Allow the whole mask stirring whole day & overnight.
Another day 3rd material being diazotised & coupled with whole mask, set the PH of the
mask with soda.
After that add on more coupler in that mask, allow 3 hours stirring then start heating the
whole mask raise temp. up to 70 c.it takes whole night steaming by boiler.
Precipitate the mask with salt & HCL & start filtering, after that open the filter press take
press cake
dryer,15
then
drying,
Capacity
ofto
Plant:
M Ton
dyespulverising,
per Month. blending, Packing & despatch.
Year: 2014-2015
70 M Ton.
Year: 2013-2014 115 M Ton.
Year: 2012-2013
95 M Ton.
SHREE TRIMURTI
Pvt.
2Type of Constitution
.
(Proprietorship/Partnership/Pvt ltd.)
Pvt
2 Cr
4
.
Employment
15
5
.
10 year
6
.
Turn Over
2 Cr(annual)
Supportive Information:
7.
Quality of Staff:
I ) Skill Level
II ) No. of employees does
Repetitive Task.
III ) No Of Training conducted
In a year.
IV ) Priority of Organization on
quality/Production
8.
Evaluation :
9.
Cost of production :
I) Raw Material cost
II) Manpower
III) Reject Cost
Zero
production
No
No
No
No
250 per kg
15 Rs per kg
12.5 Lakh per year
Private vehicle
Plastic
Usually
I) Number of workers
15
II) Number of machines
10
III) Type of product
Leather dye manufacturing
13. Supplier motive
I) Aware of the product quality
II) Additional care for the material
supplied
III) How Frequently Supplier
evaluation done
No
No
No
During this phase, the data collected during the measure phase is used
to analyse the gap between the current and desired performance.
Root-cause analysis is done to define the possible reasons for the
performance gap and quality issue.
SUMMARY OF QUESTIONNAIRE
1. Quality management system
Strongly
Agree
Dont
know
20%
27%
40%
Strongly disagree
Disagree
Agree
Strongly agree
Dont know
2. Management commitment
Strongly
Agree
Strongly
Agree
Dont
know
20
21
Management commitment
21%
10%
25%
4%
20%
20%
Strongly Disagree
Disagree
Neiter agree nor disagree
Agree
Strongly agree
dont know
3. Quality Policy
Strongly
Agree
Strongly
Agree
Dont
know
11
23
Quality Policy
20%
12%
3%
27%
38%
Strongly disagree
Disagree
Neiter agree nor disagree
Agree
Strongly agree
dont know
4. Customer Satisfaction
Strongly
Disagree
Disagree
Percenta
ge
11
34
Neither
agree
Nor
disagree
16
Strongly
Agree
Strongly
Agree
Dont
know
11
25
Customer satisfaction
23%
5%
11%
34%
11%
16%
Strongly disagree
Disagree
Neither agree nor disagree
Agree
Strongly agree
Strongly
Disagree
Disagree
Percenta
ge
10
25
Neither
Strongly
agree Nor Agree
disagree
20
21
Strongly
Agree
Dont
know
15
Strongly disagree
Disagree
Neither agree nor disagree
agree
Strongly agree
Dont know
6. Resource Management
Strongly
Disagree
Disagree
Percenta
ge
10
30
Neither
Strongly
agree Nor Agree
disagree
16
26
Strongly
Agree
Dont
know
10
Resource management
8%
10% 10%
30%
26%
16%
Strongly disagree
Disagree
Neither agree nor disagree
agree
Strongly agree
Dont know
7. Purchasing
Strongly
Disagree
Disagree
Percenta
ge
27
Neither
agree
Nor
disagree
39
Strongly
Agree
Strongly
Agree
Dont
know
14
18
Purchasing
17%
3%
9%
14%
29%
27%
Strongly disagree
Disagree
Neither agree nor disagree
agree
Strongly agree
Dont know
Percent
age
19%
7%
27%
17%
30%
Strongly disagree
Neither agree nor
disagree
Strongly agree
Disagree
agree
Dont know
AFFECTING FACTORS
The quality improvements problematic sides are observed during the study
(survey) & interview with the Employees & staff of the management of small scale
enterprise.
1) What are the main causes or factors that can create problem?
I. Internal factors
II. External factors
. Process of Production
. Leadership
Customer
. Workers
Government policies
. Safety tools
Material
Workers are
not encouraged
lack of
communication
worker
lack of experience
Poor raw
material
lack of education
lack of skill
Improper mixing
of raw
bad working
environment
lack of internal
lack of prior
outdated process
machines are in
dirty condition
lack of customer
lack of
consistency
Company does
Absence of
measurement
Lack of standard
process
process
decrease in
productivity
of plant
lack of maintenance
outdated machines
Machines
OBSERVATIONS
The employees are not having require qualification & expertise in the aspect of
improvement quality
The entrepreneur do not carry out any sort of quality study that is required for their own
survival and existence
Some staff members are having ideas but fear from their higher authority restricts them
from suggesting new concept for the improvement of quality
The management is just interested to sale more number of units they produce. Thus,
they always go for short term benefit and no long term planning is there
Industry does not aware about Total Quality Management framework
They only focus toward the customer requirement, do not concern about satisfaction of
workers
Industry does not update technology on time to time basis. They still do work manually.
To reduce the production cost Small scale industry chooses suppliers on the basis of
price only. It affects quality of product.
CONTINUED.
They do not give priorities to the workers in a case of management
decision making process.
They produce the product on the basis of order only. So there is no
policy, procedure and discipline in factory.
Irregularity of delivery of raw material from supplier.
Poor raw materials from supplier affect the quality and rejection rate.
Bad maintenance system.
Bad and dusty working environment .
Customer feedback system is not available.
3) IMPROVE PHASE
Below are few suggestion given to the industry to
overcome the above factors that affect the
productivity of the Plant :
1) Better manpower should be hired
2) Understand customers need properly & increase communication with customer
3) Planning of regular training and development of manpower are needed.
Organisation is to plan such training programme in its site or can depute the
persons to related training institute. The training curriculum should be both
technical and managerial
4) Suppliers evaluation, Quality Control at supplier site, to make aware of voice of
customer and voice of process.
5) Improvement in Safety tools
6) Up gradation of machines available in plant
7) Do regularly maintains of machines
CONCLUSION
To sustain in the present competitive age, Six Sigma is emerging as one
of the most effective business strategies in the small scale organisations
over the world.
The multiple gains achieved by Six Sigma efforts over different
productivity problems in a company prove the usefulness of this strategy
for small industries as well.
By applying six sigma in small scale industry,crictical factors of quality
can be known and overall performance of plant will increase
GANTT CHART
Month
February
March
April
April
work
Problem
definition
Literature
review
& selection of
company for
case study
Implement
various phases
of six sigma in
dye
manufacturing
industry
Submission
REFERENCES
Lean Academy by Dick lewis and Jose marcedo .
Six Sigma A New Direction to Quality and Productivity Management by
Tushar N Desai and Dr. R. L. Shrivastava
Raghunath A, Dr. Jayathirtha R V Barriers for implementation of Six
Sigma by Small and Medium enterprises
Ploytip Jirasukprasert,A Case Study of Defects Reduction in a Rubber
Gloves Manufacturing Process by Applying Six Sigma Principles and
DMAIC Problem Solving Methodology
Mohammad Israr A Comparative Analysis between Small and Medium
Scale Manufacturing Company through Total Quality Management
Techniques