summer training project-tqm

7/29/2019 Summer Training Project-tqm

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TRAINING REPORT

ON

“QUALITY CONTROL / QUALITY IMROVEMENT WITHSTATISTICAL ANALYSIS”

(With special reference to PTC INDUTRIES LIMITED,LUCKNOW)

(Transforming Metal)

(IN PARTIAL FULFILLMENT OF THE TQMPROGRAMME OF LUCKNOW UNIVERSITY, Lucknow)

SUBMITTED TO:

SUBMITTED BY:



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DECLARATION

I, do hereby declare that the project report titled “QUALITY

CONTROL / QUALITY IMROVEMENT WITH STATISTICAL

ANALYSIS ” is a genuine training project work undertaken by me and it

has not been published anywhere earlier and is only beneficial to me.

Date:

Place:



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Acknowledgement

My sincere thanks to faculty supervisor__________ and company

supervisor____________under whose able guidance and kind cooperation I

was able to complete the project work titled “ QUALITY CONTROL /

QUALITY IMROVEMENT WITH STATISTICAL ANALYSIS & AUDIT

PROCEDURE”. All those employees of P.T.C.INDUSTRIES LTD. deserve

special thanks for their cooperation and help in the collection of necessary and

relevant material for this work.

I am highly thankful to the DIRECTOR of Total Quality

Management Programme, University of Lucknow, Dr. AQIL AHMAD who

arranged my training in such an esteemed organization.

We are indebted to our respected faculty members R. NATH (AVM), GR.

CAPTAIN H.C.UPRETI and SHRI. P. K.SETHI who nurtured my quality

instincts, sharpened analytical skills and honed my understanding &knowledge of the quality discipline by sharing the distillate of their lifelong

experiences and insights with us.

Every effort has been made to enhance the quality of work. However, I owe the

sole responsibility of the shortcoming, if any in the study.



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Contents

1. SCOPE OF THE PROJECT

2. PREFACE

3. CUSTOMER FOCUS

4. INSIGHT OF PTCIL

5. INTRODUCTION TO PTCIL

6. CERTIFICATES AWARDED TO PTCIL

7. AWARDS AND RECOGNITION

8. ORGANISATION CHART OF PTCIL

9. QUALITY MANAGEMENT SYSTEM

10. QUALITY ORGANISATIONAL CHART

11. 5 S CHECK LIST

12. CASTING PROCESS FLOW CHART

13. REJECTED CASTINGS

14. Q C TOOLS

15. FISHBONE DIAGRAM SHOWING VARIOUS DEFECT’S CAUSE & EFFECT

16. STATISTICAL DATA

17. CUSTOMER WISE REJECTION ANALYSIS (FOR FY 2010-11)

18. DEFECT WSIE REJECTION ANALYSIS (FOR FY 2010-11)

19. QUARTERLY REJECTION ANALYSIS AND COMPARISION

20. TERMS AND DEFINITIONS AS PER ISO 9001:2008

21. CLAUSES APPLICABLE IN PTCIL

22. AUDIT TYPES AND PROCEDURE

23. NON CONFORMITY REPORT AND ITS CLOSURE

24. ENVIRONMENT, HEALTH & SAFETY POLICY

25. CONCLUSION



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CHAPTER 1

Scope of the Project

During my training, I tried to find out the causes which affect most of

the processes through INTERNAL PRE- AUDIT, so that the

company can improve its process and provide Customer Satisfaction.

During the production of the castings, as it goes through various

processes, I found the compiled report of Process Description and

rectified Quality System Procedure (QSP) in various departments.

In most of the departments of PTC, there were no major issues found

to be raised as Non Conformities. In this project, I have evaluated the

Statistical Quality by using control tools which PTCIL is committed

to improve for Total Quality product as well as for the benefit of the

organization.

In the short span of two months, I visited almost all the departments

e.g. Production, Maintenance, Fettling, CFS, CNC, CMM, IT,

Marketing and Stores etc. and thoroughly learnt all the related things.

Apart from the critical learning from all the departments, I got the

working knowledge about the world’s best machineries e. g. CMM,

CNC, Robotic machines etc.

I also grasped fruitful knowledge about the calibration of various

gauges being used in PTCIL for maintaining higher accuracy in its

measurements.



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Though I have tried to express all the gathered knowledge but project is

having some limitations and I hope it will be a good reading material for

the Quality Professionals

CHAPTER 2

PREFACE

Quality as a concept has been widely used in the business for improving the

performance of organizations. In its initial stages, it was applied only to the

manufacturing sector, but subsequently it spread to the service sector.

Applying quality principles to government industry (PTC INDUSTRIESLIMITED) is a small step from their application to the service sector. At the

first glance, one might believe that the relevance of quality or total quality

management (TQM), to be precise, might be restricted to public sector

undertaking, particularly those engaged in manufacturing activities.

However, in the context of the citizen’s charter in various parts of the

world, including India, customer focus has permitted all segments of

government. This has in turn, led to the realization of importance of quality

initiative in government enterprise.

Increasing public awareness has further made the citizen ask the question:

‘why can’t the government be more like the private sector?

A Quality initiative has necessarily to focus on customer satisfaction,

continuous improvement, people involvement, empowerment of the

employees, team work, data-driven decision making etc.

In the entire context, TQM is a difficult and unending journey. It is more in

government organizations which are hamstrung by several overarchingrules, procedures and practices. However, Quality is a state of mind and it is

possible to practice it, in howsoever small a measure, under any

circumstances.



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The quality project which is covered to PTC INDUSTRIES LIMITED,

LUCKNOW, UTTAR PRADESH, is;

QUALITY CONTROL/ QUALITY IMPROVEMENT WITH STATISTICAL

ANALYSIS and AUDIT PROCEDURE.

INSIGHT OF PTCIL SHOP FLOOR

(CNC MACHINE) (MELTING PROCESS)

(CMM) (MICRO STRUCTURE ANALYSER)



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(SHOP FLOOR)

(Pouring Of Centrifugal Casting)



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CHAPTER 3

ORGANIZATIONAL PROFILE PTC INDUSTRIES LTD was established in the year 1963 and its

commercial production started in the year 1968. Its activities include manufacturing of high quality ferrous and non-ferrous castings, finish machining of valves and

equipments. PTC INDUSTRIES have been manufacturing and exporting almost 2/3rd of

production to United State of America, Finland, Spain, Germany, Italy, United

Kingdom, Japan & other developed countries since 1986.

A dynamic, forward looking innovative company, PTC INDUSTRIES is

continually seeking to improve its capability through investment in new technology

process, and people. PTC INDUSTRIES LTD now offers its customer still more value

for money by offering value castings produced by REPLICAST process that would to

give them a distinct edge in highly competitive market.

PTC INDUSTRIES LTD is the first company in Asia to offer this

advanced technology developed by Castings Technology International, Sheffield, UK.

PTC has invested considerably to extract maximum benefits frominformation technology & internet in order to improve and monitor its system and to

provide a much better service to its esteemed customers. Customers can now keep

themselves informed of their order status, search & download material test reports andtrack their shipments.

With foundries located at Lucknow, Bhiwadi and Mehsana and also

machining facilities at Lucknow and Mehsana, PTC has capacity to produce more than

2000 tons per year, of castings.

1.CUSTOMER PROFILE

PATRONS OF THE PRODUCT OF PTC INDUSTRIES LIMITED

1. INTERNATIONAL-

• Metso, Metso paper-Finland

• Sulzer pump

• Siemens automation-Germany

• KITZ-Japan



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• Nigita masollean-Japan

• Westad industry-Norway

• Metso automation-Shanghai

• Endress +hauser-Switzerland

• Tyco valves & controls-Switzerland

• Alfa Lval ltd. –UK

• Weatherford uk ltd. –UK

• Worcester controls limited –UK

• Flowserve corporation –USA

• Neles jamesbury –USA

• Textron inc. –USA

• Trinity marine product –USA

• Weir valves &control –USA

• Yokogava corporation –USA

2. DOMESTIC

• Bharat Earth Movers ltd- Bangalore

• Caterpillar industries Ltd. –Chennai

• Bharat heavy eletricals Ltd. –Hardwar

• Hyderabad , Trichannapalli

• Rail coach factory – kapoorthala

• Nevyveli lignite corporation –Nevyveli



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• Alfa Laval India –pune

• Gas turbine research establishment –Hyderabad

3. ASSORTMENT OF INDUSTRIES CATERED TO FOLLOWING :

• Auto Tractors

• Construction & Bridges

• Fertilizer & Chemicals

• Mining : Coal & Mineral

• Oil exploration & Rigs

• Petroleum Refining

• Power Generation : steam and hydro

• Pumps

• Rail Transportation

• River Transportation

• Road transportation

• Valves & Pipe Fitting

ABOUT PTCIL – LUCKNOW PLANT

Molding Processes: 1. Centrifugal

2. Rapidcast/ Replicast

Melting Capacity: The installed Induction Furnaces are –

1. 350 KW - 2 No. (500 kg.)2. 1000KW – 1 No. (1500 kg.)



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3. 1000 KW – 1 No. (2500 kg.)

Material Range: The Castings that are produced have metallurgies including all

Grades of Carbon Steel like WCB, 1.0619, LCC, Stainless

Steel like CF8M 1.4408, CF3M, CA6NM, 1.4404, 1.4581, Austenitic

ductile iron Nickel & Cobalt based Alloys, Alloy Steel etc Haste alloy,duplex material etc. As per various International Standards like ASTM,

AISI, JIS, EN, DIN, BS & Harmonized Standards.

Service Sectors: PTCIL caters to the requirements of the Core Sector

Industries like:

1. Valves & Pumps

2. Thermal & Nuclear Power 3. Cement4. Railways5. General Engineering Industry

Special In-house Facilities: 1. PTCIL have In-house Computerized Methoding &

Simulation Facilities for Casting Designing, Pattern

Making, Heat Treatment etc. using CAM Software.

2. CNC machine shop for finish machining of castings.

Testing Facilities: PTC has installed full in-house testing facilities both for

Destructive & Non Destructive tests like, Radiography,

Magnetic Particle Inspection, Ultrasonic Flaw

Detection, Dye Penetrant Test,

Vacuum Spectrometer for Chemical Analysis, Tensile &

Impact Testing, Hardness, IGC & Ferrite Percentage,

Microstructure Analysis, Pressure and Sand Testing

Facilities.

CERTIFICATES AWARDED TO PTCIL



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1. ISO 9001: 2008 by TUV Nord India Pvt. Limited

2. PED 97/23/EC

3. AD 2000

Merkblatt

W0



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4. Approval of Manufacturer by Det Norske Veritas

5. Approval of Manufacturer by American Bureau of

Shipping



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6. Approval of Manufacturer by Lloyd’s Register



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7. Approval of Manufacturer by Bureau Veritas

8. Approval of

Manufacturer by

Nuclear Power

Corporation of India



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AWARDS AND RECOGNITION

1. National award for R&D efforts in area of technology

ABSORPTION-2006.

2. Outstanding vendor award for on-time delivery and outstanding

quality by center line -1988.

3. Three star-category award from the state government for excellent

performance in export.

4. Dhatunayak-award from All India induction furnaces Association.

5. Outstanding export performance awards from engineering export

promotion council (Northern Region)India, continuously from 1989-1996.

6. Recognition by central boiler board as well known foundry.

7. Recognition by research design and standards organization as class a

foundry. .

MEMBERS OF

ASSOCIATION



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• CTI

• INDIAN FOUNDRY ASSOCIATION

• EEPC

• FIEE

QUALITY POLICY-

• We are continually striving to identify new growing market and products.

• We are committed to manufacture and supply casting as per the requirement of

the customers.

• Customer’s satisfaction is the keyword and our aim is to become a reliable

supplier.

• We shall continually strive for improvement of our performance by implementing

quality management system.

VISION STATEMENT

We focus on our customer’s success ours will surely follow. We at PTC are driven

by a solitary vision – to be a part of our customer‘s competitive edge , because only

in their triumph lies our success.

MISSION STATEMENT-

“We aim to refurbish ourselves into an organization that can fulfill the needs of our

customers and provide high quality products with prompt delivery.

To work towards being a global leader by implementing constant innovation and

total quality management.

We work towards expanding our capabilities with a sense of responsibility towards our environment.

We also endeavor to provide customer delight to our international and

national customers.”

Organization chart



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Quality Organization Chart



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Process Chart



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SCAN COPY

Deptt wise manufacturing summary & objectives



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Contract Review / Marketting

Accepted customer requirements are communicated to the respective departments for theexecution of Castings delivery conditions and Delivery Schedules.

Objective - 10% growth in turnover

Turnover statics.. blab la bla

2006- 123

2007-145

2008- 150

2010 - 156

2011- 160

Bla bla bla

Planning



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Delivery schedules are the basis for our monthly planning and day today Production andDispatches. Targets are closely monitored and executed.

Objective- Compliance to customer schedule

Capacity utilization

LIKEWISE Describe diff departments and objectives

Show some data and make a chart

In the end take defects/ customer complaint stats and make chart

Department name-

Marketing

CAD

Planning

Quality

Production-

Moulding shop

Melting pouring shop

Fettling

Heat treatment

Stores



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MR

Etc.

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