This methodology will explain how I went about doing my project. It is divided into two sections Sampling details & Data collection + analysis. In this there will be explanation of what kind of sample data I have taken for my project and the collection of that data.
SAMPLING AND DATA COLLECTION:
For the completion of my project I went through the random sampling of data. In which I have picked up some components randomly for the observation and did the analysis as required for the project. Photographs were taken and relevant readings were recorded for documentation & project report.
Data collection includes all the relevant and appropriate data required for the completion of the project. This is of two kinds, Primary data and Secondary data. Primary data includes all the data which I have collected from the crankcase line such as component flow path, dent prone areas on the cover & joint faces, dimensions of the cone plugs and actual dents on KSPG components during the trial PP1 before the mass production of this new model. Some data was collected from the metallurgical lab after hardness inspection of cone plugs and some data was collected from engine assembly.
Apart from this I have also used some data from the department itself as a secondary data. It includes the quotations from vendors, process sheets, PQCS-I & II, plug cone drawings, operation standards, defect flow sheets etc. This collection has been shown in the annexure attached ahead.
These all were the samples that I have taken for the study to complete my project in a better way. I decided to choose this study material from our company itself because this was best and comprehensive according to the executives and the line leaders who themselves have designed it so far. So it was very easy for them to teach me about that. Also it is very clear from the fact that the current documentation is better because the production target was getting achieved very well.
1) THE PDCA APPROACH: -
Among the most widely used tools for continuous improvement is a four-step quality model-the plan-do-check-act (PDCA) cycle, also known as Deming cycle or Shewhart cycle.
Plan- Identify an opportunity and plan for change.
Do- Implement the change on a small scale.
Check- Use data to analyze the results of the change and determine whether it made a
difference.
Act-If the change was successful, implement it on a wider scale and continuously assess
your results. If the change did not work, begin the cycle again.
this approach were incorporated while implementing the countermeasures. It helped in the uninterrupted
flow of project activities. It is a result oriented methodology with side by side analysis of the result. It helps as a perfect effectiveness and improvement monitor. It provides us with appropriate ideas and concrete steps to avoid failures. It is a complete
quality analysis + control package with minimum discrepancies. That is why it is sometimes referred to as root cause of all improvements.
As a whole the PDCA methodology was of immense help during my stint of seven months as an industrial project trainee.
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