QUALITY CIRCLE

WELDING SHOP
PROJECT TITLE
DEFECT REDUCTION
IN
ROBO WELDING

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INTRODUCTION
TEAM NAME:
LEADER NAME:

Team A
Mr. V.B Tripathi (Sr. Manager Production)

SUB LEADER:

Mr. Gaurav Goal (Manager sales)

COORDINATOR:

Mr. Sumeet Saini

PROJECT TITLE:
AREA:
DATE:

15/11/16

defect reduction in robo Welding

Welding Shop
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TEAM STRUCTURE
V.B TRIPATHI
(TEAM LEADER)

GAURAV GOAL
(SUB LEADER)

SUMEET SAINI
(COORDINATOR)

TEAM A

TEJVIR

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SUMIT

ANIL B.
MAHENDRA

TEAM B

AKHIL

BOBY

RAGHVENDRA

ANURAG

TANMAY

ARIF KHAN

MAHESH YADAV

SUNIL DUTT

MAHENDRA
PARDESHI

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PROBLEM DESCRIPTION
1. What is the Problem?
Defects in welded parts cause low production and affect quality.
2. Where is the problem?
Welding Shop
3. How much is the problem?
100% parts are defected.
4. Boundaries of the Problem?
Welding area and Welding rework area.

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SIPOC
(SUPPLIER, INPUT, PROCESS,
OUTPUT & CUSTOMER)
Specific Process flow chart with SIPOC.

5. Suppliers

GRINDING
SECTION,
STORE

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4. Inputs

1. Process

2. Outputs

3. Customers

WIRE, GAS, MANPOWER,

FIXTURE

WELDING

WELDED
PARTS

PLATING SHOP

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CAUSE & EFFECT DIAGRAM

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DATA COLLECTION

Data has collected from 5 different lots ( 20 pieces from each lot).
Sample size: 100 Welded assemblies of pin and tab.

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PARETO ANALYSIS

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MAJOR CAUSE LIST

Need to improve top 20% of cause so as to solve 80% of remaining
problem.
Pareto chart state that spatter is the major cause of defects.
This is observed that the root cause of defect is high current and
voltage but low voltage and current can cause low penetration defect.

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IMPROVEMENT
This is very difficult to solve this problem by changing the process
parameters.
Spatfree-113 gel is use to get rid of this problem.

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IMPROVEMENT
Before

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After

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CONTROL
Work Instructions are modified to
standardize the process.

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CONCLUSION
Pareto chart state that spatters are the major defect.
This is observed that the root cause of defect is high current and
voltage but low voltage and current can cause low penetration defect.
This is also observed that its not possible to apply gel on small parts.
100% defect (Spatter) has been removed by this technique.

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Thank You

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