06V 180AH -Gel circulation Project full.pptx

Gel circulation Project

1. WORLD QUALITY MONTH CELEBRATION – Q22  "Quality Conscience: Doing The Right Thing"

2. QUALITY CIRCLE – Q22 – TECHNOPARK TOPIC- PRODUCTIVITY LIMITATION 6V180AH

3. Project Charter- PRODUCTIVITY LIMITATION 6V180AH Problem Statement 6V 180AH batteries 48 No's loaded per cycle in gel circulation process. Project Scope Investment: 707.47 USD Quality: No deviation from existing quality standard Team Members Roles and Responsibilities Mr. Raja Natarajan, Team Leader ,Department - Quality Mr. Pankaj , Member , Department-Production Mr. Durga Prasad ,Member –Department- Production Mr. Karthik-Member, Department- Electrical Goals and Business Benefits Existing gel circulation battery quantity of 06V 180AH -48Nos.we are challenging to increase quantity to 80 Nos. Total Saving/month=96000 USD Linkages to strategic objective

4. About Our Team LEADER Durga Prasad Raja Natarajan PANKAJ MEMBER MEMBER MEMBER Karthikeyan

5. LEAD OXIDE MAKING PASTE MIXING PASTING CURING LEAD ALLOY CASTING PLATE CUTTING ACID FILLING CHARGING FINAL ASSEMBLY DISPATCH PROCESS - FLOW CHART 5 Chemical energy converted to Electrical energy ASSEMBLY PASTING GEL CIRCULATION

6. Gel Circulation Process: Silica loading Acid loading NO Gel Preparation Gel Mixing Silica % (12.27) Syringe Test Gel Filing Gel Circulation Temperature < 10 o C Free Gel Removal Take Out YES NO YES

7. IDENTIFICATION of problems BRAIN STROMING

8. PROBLEM IDENTIFICATION In brain storming we listed possible problem in gel circulation

9. CAUSE AND EFFECT ANALYSIS Men Machine Measurement Method Material Lack of training Phosphoric acid not added Sample not taken Improper gel flow. Level sensor fluctuation. Chiller breakdown-alarm Irregular gel sample collection Weighing scale not calibrated Room temp .>25 o C Gel temp.>10 o C Gel preparation Gel mixing / circulation Unavailability of Phosphoric Unavailability of Aerosil Unavailability of Acid Gel Circulation O/P Environmental Wrong Calculation. Work Instruction not available Process specification not available TOOL: Fish Bone Diagram

10. PROBLEM IDENTIFICATION Problem statement: 1.Seeking the improvement in production. 2.6V 180AH batteries 48 No's loaded per cycle in gel circulation process.

11. ROOT CAUSE ANALYSIS: TOOL : Why Why Analysis Why : Low loading capacity of 180Ah batteries why : Only three pallet of batteries can be loaded for gel circulation why : Gel circulation supply / suction tube length not sufficient to accommodate 4th pallet Why : Manufacturer considered 48 no's as maximum output

12. PROBABLE CAUSES : Low length of Suction tube Low Loading Capacity

13. Critical Problem: Poor circulation. Impact of capacity. Affect life cycle. Silica percentage getting low. Various silica percentage in tank and battery . OTHER PROBABLE CAUSES: 1.Poor circulation. 2.Delay in dispatch. 3.unavailability of batteries. 4.Impact of capacity. 5.Affect life cycle. 6.Silica percent getting low 7.Various silica percentage in tank and battery

14. Generate and evaluate alternate solutions Brain storming: Circulation tube length to be modified in order to load the 4th pallet for gel circulation

15. No.of batteries loaded per cycle is improved from 48 no's to 80 no's AFTER IMPLEMENTATION: Before After

16. VALIDATION MEASUREMENT: After Circulation tube length to be modified in order to load the 4th pallet for gel circulation

17. Reduced the lead time. GEL Circulation Productivity Increase. Delivery improvement. Productivity improvement. Increased operator morale. Batteries waiting for gel circulation reduced. BENEFITS & OUTCOME Cost saving – 96000 USD l month