WELCOME

VAPO MINERALS UNIT

A1
IN
SMALL GROUP ACTIVITY
 SGA team members
Facilitator : R . Ramadurai
Leader : T. Vinoth Christober
Dy Leader : R. Kumaresan

Present Members
1. Kalaiarasi - Extrusion
2. Indra - ND & DH
3. Saravanan - Cutting
4. Prabhu - CG
5. Kalaiselvi - Visual
6. Praveena - Packing

Venue : UNIT A I
 SMALL GROUP ACTIVITY

AIM :

YIELD IMPROVEMENT

From 4000 Nos to 4400 Nos. per

BATCH
 SCOPE OF MEETING

Reduce the process loss rejection

Yield Improvement

Manpower effective usage

REASON FOR IMPROVEMENT

 Yield level is very low

 Rejection level to be high

ROOT CAUSE : BEND
Men
1.poor method of collecting.
2.improper pinching.
3.improper movement at the time of batch shifting.
4.improper feeding in cutting.

Machine
1.Nozzle alignment
2.Hydraulic pressure variation
3.Bryair - air flow direct expose to the batch.
4.Bryair variation temperature

Material
1.Bend pipe process
2.Colloidal material
3.High Moisture content
ROOT CAUSE: BEND

Method
1.Improper wet rod collection in the pipe, poor pinching and
pallet movement.

Measurement
1.Diameter of nozzle selection
ROOT CAUSE : CUTTING AND CHIPPING
MAN
1.Improper feeding in cutting and cg

MACHINE
1.Cutting and cg m/c blade issue
2Non-uniformity of blade shaft and roller shaft
3.Guide foam damage and replacement
4.chute problem
3.uneven movement of piston rod

MATERIAL
1.Short length of the rod
2.bend rod issue
3.improper pinching in corner of the rod

METHOD
1. Poor method of feeding
ROOT CAUSE : HOLES
MAN

1.Could not covered wet cloth in material.

MACHINE

1.Stroke length to variation

2.Rods qty. extended in single stroke.
3.Ribbon formation

MATERIAL

1.colloidal and sponge

2.Dry material mix up during process

NATURE

1.Over dryness issue

ROOT CAUSE : WHITE EDGE

MEN
1.Improper cutting (pinching)
2.Not effectively cut the rod

MACHINE
1.pieces are holding in chute

MATERIAL
1.Short length of the rod
2.Bend rod issue
ROOT CAUSE : OTHERS
MEN
1. feeding not in proper in both cutting and cg
2.finger impression of the rod
3.Collecting the bulging pieces in extrusion

MACHINE
1.Cutting and CG blade issue
2.Guide foam not placed in proper
3.Dust forming in cg wheels
4.oil spillage

MATERIAL
1.Bulging in rod and non uniform diameter on its length
2.Line marks and wastage
3.Bend pieces
(YIELD BEFORE SGA)
4250
4200 4190

4150
4100
4050 4021 4030
4000 3982
3962
3950
3900
3850
3800

Jan Feb Mar Apr May

REJECTION TREND (BEND)
4.5 4.14
4
3.5 3.25 3.36
3.15 3.1 3 3 3.08
3
2.42
2.5 2.07 1.98
2
1.5 BEFORE SGA AFTER SGA
1
0.5
0
BEND
JAN FEB MAR APR MAY JUNE
JULY AUG SEP OCT NOV
REJECTION TREND (HOLES)
3.5
JAN
3 2.86 FEB
2.5 MAR
2.17 APR
2
2 1.74 1.8 MAY
1.5 JUNE
1.5
JULY
0.94 1 1.1 1 1
1 AUG
BEFORE SGA AFTER SGA SEP
0.5
OCT
0 NOV
HOLES
REJECTION TREND (CUTTING)
1.2
1.02 1 JAN
1 FEB
MAR
0.8 APR
0.7
MAY
0.6 BEFORE SGA AFTER SGA
JUNE
0.4 JULY
0.4
AUG
0.18 0.16 SEP
0.2
0.1 OCT
0.02
0 NOV
0 0 CUTTING
REJECTION TREND (CHIPPING)
3.5
3.18
2.89 JAN
3
2.7 FEB
2.5 MAR
2.23
2 2 APR
2 1.83 1.8 MAY
1.51 1.5 JUNE
1.5 1.26 JULY
1 BEFORE SGA AFTER SGA AUG
SEP
0.5 OCT
NOV
0
CHIPPING
 REJECTION
2.5
TREND(WHITE PIECES)
2.14
2 JAN
2
FEB
1.64 1.64
1.54 MAR
1.5 1.42
APR
MAY
1 0.94 1
1 JUNE
0.7 JULY
0.5 BEFORE SGA AFTER SGA AUG
SEP
OCT
0
WHITE PIECES
REJECTION TREND (OTHERS)

2.5
2.24
2.12 JAN
2 FEB
1.77
MAR
1.5 APR
1.27
MAY
0.97 1 1.09 1 1
1 0.9 JUNE
JULY
BEFORE SGA AFTER SGA
0.5 AUG
SEP
0 OCT
OTHERS
 (STANDARDIZE -ACCEPT YIELD)
4520
4507
4500
4481 4478
4480
4462 6-Oct
4460 12-Oct
4438 13-Oct
4440 4432
15-Oct
4420 16-Oct
4400 23-Oct
26-Oct
4380
4360 4419
ACC YIELD
YIELD AFTER SGA

4350 4322
4300
4250
4250 4226
4200 JULY
4150 AUG
4100 SEP
4050 OCT
4000 NOV
3950 DEC
3900
3850
4022 4208 4203
ACC YIELD
REJECTION TREND – MAR(2017)
3.5
3
2.42
2.5
2 1.77
1.64
1.5 1.26
0.94
1
0.5
0
0
BEND CHIPPING CUTTING
HOLES WHITE PECES OTHERS
REJECTION TREND – APRIL(2017)

3.5 3.25 3.18

3
2.5
2.16
2
1.64
1.5
0.97
1
0.5
0.02
0
BEND CHIPPING CUTTING
HOLES WHITE PECES OTHERS
COUNTER MEASURES :
 Close Monitoring to the process in all the
stage
 Clear trained by extrusion manpower
method of collecting
 Bend pipe segregation
 New pipe purchased for the issue of short
length of the pipe.
 Manual cutting correction (pinching)
 N.D & D.H observation process
 Avoiding direct expose to the air in D.H
 Use of poly bag to cover the upside pallet in
N.D and D.H
 Visual inspection miscellaneous process.
 Avoid the spillage causes in all the area.
RESULT OF SGA PROCESS

 Currently yield improved from 4000 to 4200.

 YIELD improvement (acceptance and received

quantity is increased)

 Close monitoring of Extrusion and N.D area is

improved.
FUTURE PLAN
To improve and maintain the yield level

Reduce the rejection level less than 1 % to

all the stage
THANK
YOU