A STUDY ON TQM FOR EXISTING PROCESSES USING TOOLS & TECHNIQUES FOR 4ST SOLENOID SWITCH IN LUCAS INDIAN

SERVICE

Submitted as a part of MBA IInd year Course Requirement By P.SATHISH KUMAR Regno : 3511040141

Under the guidance of MRS. VALLIAMMAL

SRM B-SCHOOL FACULTY OF ENGINEERING AND TECHNOLOGY SRM UNIVERSITY (RAMAPURAM II) VADAPALANI, CHENNAI

BONAFIED CERTIFICATE

This is to certify that _________

SATHISH KUMAR. P_(3511040171)_________________ is a

Bonafide Student of SRM B-School, SRM University, Vadapalani, Chennai. He is in the IInd year of Masters Degree Program in Business Administration (MBA). He has done this project under my guidance and supervision towards part fulfillment of II year MBA course requirement..

Project Guide : Mrs . valliammal Date: Place:

HOD

DEPARTMENT SEAL

DECLARATION
I SATHISH KUMAR. P (3511040171) studying in II year MBA program at SRM B-School, SRM University, Vadapalani, Chennai, hereby declare that this project is an original work of mine and I have not verbatim copied / duplicated any material from sources like internet or from print media, excepting some vital company information / statistics and data that is provided by the company itself.

Signature of the Student : Date: Place:

ACKNOWLEDGEMENT

I am extremely glad to present my summer project report as a part of our curriculum. I take this opportunity to express my sincere gratitude those who have helped me in bringing out the project report. First and foremost I wish to thank God, the almighty his immense blessings and guidance throughout the training programmer. I express my heartfelt thanks to Mr.PATCHAMUTHU founder and chairman of SRM GROUP OF EDUCATIONAL INSTITUTIONS. Mr.N.VASUDEVAN, our beloved dean for their support and encouragement to carry out this project. I wish to convey sincere and heartiest thanks to Professor Mr.T.P.NAGESH, Head of the department of the management studies, Srm University, Vadapalani for his kind approval to work on this project. I express my deep profound feeling of gratitude to Mrs. VALLIAMMAL my respected project guide for the help and critical suggestions for timely completion of the training. I further express my deep sense of gratitude to Mr. C.SATHYA MURTHY, HR of Lucas Indian Service Ltd., Chennai for his constant encouragement and valuable help. I would like express my sincere gratitude to Mr. VEERA RAGAVAN, External guide for his unfailing guidance and support at every stage of this project. And above all, I would like to express our heartfelt thanks to all members of the HRD and PRODUCTION department of LUCAS INDIAN SERVICE LIMITED, CHENNAI for their constant help & co-operation rendered during the project work.

Place: Chennai Date: P. SATHISH KUMAR

ABSTRACT
To gain an understanding of the theories and concepts of production process to apply concepts to understand what manufacturers do in the real world. To improve skills in the research and analysis of production segments, demand, and market potential. To utilize knowledge of the production to enhance strategic decision-making. To analyze the production process of the manufacturing unit when selecting a particular brand. Bridging the gap between performance expectations of the customer and Most of the people looking for achieving the demand and Next preference are given to the rejection of defectives in daily basis. In the case of LUCAS INDIAN SERVICE LTD. the customer is considering quality & performance of the product. Performance delivered to them will ensure customer delight. It is advised that the customers are educated about the services and employees updated on the expectations of the customers. Even the employees in the retail outlets have to be well trained to help the customers. The data for the study has been obtained from secondary sources i.e., from various books and journals fact sheets of different ignition coils and websites. From this it can be seen that 97.88% of the customers of LUCAS INDIAN SERVICE LTD. They are satisfied with their ignition coil and again they are willing to buy the same.

TABLE OF CONTENTS
S.NO CHAPTER 1 1.1 1.2 1.3 1.4 1.5 1.6 CHAPTER 2 2.1 2.2 2.3 CHAPTER 3 3.1 CHAPTER 4 4.1 4.2 CHAPTER 5 5.1 5.2 CHAPTER 6 CHAPTER 6 PARTICULARS INTRODUCTION COMPANY BACKGROUND STATEMENT OF THE PROBLEM OBJECTIVES NEED FOR THE STUDY SCOPE & SIGNIFICANCE OF THE STUDY LIMITATIONS REVIEW OF LITERATURE NEWSPAPER ARTICLES MAGAZINE ARTICLES INFORMATION FROM WEB RESEARCH METHODOLOGY TOOLS USED FOR ANALYSIS DATA ANALYSIS CLASSIFICATION DESCRIPTIVE STATISTICS INTERPRETATION & FINDINGS DATA INTERPRETATION MAJOR FINDINGS SUGGESTIONS & CONCLUSION BIBLOGRAPHY PAGE NO

CHAPTER NO.1

INTRODUCTION ABOUT THE TOPIC : Total Quality Management : In todays world due to insufficient quality or indifference to quality lead to disputes, which imposes serious drain on the financial resources of a company and limits profit potential. To be competitive in todays market, it is essential for construction companies to provide more consistent quality and value to their owners/customers. It is high time to develop better and more direct relationships with our owners/customers, to initiate more teamwork at the jobsite, and to produce better quality work. Total quality management is a managements approach towards the quality, it can be in regard to products, customer satisfaction and employees satisfaction. The concept of TQM was developed by an American W. Edwards Deming and i.e. why it is called as Demings concept of TQM .He introduced this concept for improving the quality of various products and services. Earlier it was just related with the quality of products which a organization is producing but now other concepts like marketing, finance design, customer service has also joined the area. Which means that now good number of things are there to manage. TQM works on one belief that mistakes can be avoided and defects can be prevented. And management should believe in watching each and every step. TQM is now a days called as TPM (total productivity management) and an organization needs to consider ABCD for the effective application of TQM where A stands for accident cure , B stands for breakdown , C stands for cost reduction and D stands for damage. This policy of ABCD is in relation to product and if TQM needs to be introduced a positive attitude from the side of management and employees is required and then a collective effort will come up. TQM should give chance for unleashing employees creativity and potential. The aim of TQM is to reduce variations in quality of the products as well as in the working of whole organization. For the successful implementation of TQM, an organization must consider the commitment from all the level of organization. A concept of Six sigma is a part of TQM. It is a strategy developed by Motorola and it helps to detect the defects and to remove them.

TQM talks about the satisfaction of customer, supplier, employees etc. and it requires continuous improvement. If the workers of an organization are efficiently working then their morale will go up. TQM works effectively if the organization works in a family manner. Here management is like a father, employees are the children and manager is like mother and as father and mother takes care for their home collectively the same way , management and managers are supposed to take care for their organization with the help of tool called TQM. Total quality management is called total because entire organization is involved, Quality means degree of excellence. And management in literal sense means getting things done by others. In a TQM effort, all members of an organization participate in improving processes, products, services and the culture in which they work. The earlier introduced quality management concept is now taken over by Total quality management. To have effective TQM the first requirement is strong internal motivation and emotional involvement for implementation. So the concept of TQM talks about adopting the new policy, creating quality products, eliminate defects, estimate for breakdown, accidents etc . Hence TQM should be purpose driven so first the whole organization should be willing to accept the change then only TQM can actually affect the organization in a positive way. What is Total Quality Management Definition: TQM is a management philosophy, a paradigm, a continuous improvement approach to doing business through a new management model. TQM is a comprehensive management system which: Focuses on meeting owners/customers needs, by providing quality services at a reasonable cost. Focuses on continuous improvement. Recognizes role of everyone in the organization. Views organization as an internal system with a common aim. Focuses on the way tasks are accomplished. Emphasizes team work.

Total Quality Management (TQM) is a management approach to longterm success through customer satisfaction. In a TQM effort, all members of an organization participate in improving processes, products, services and the culture in which they work. The methods for implementing this approach come from the teachings of such quality leaders as Philip B. Crosby, W. Edwards Deming, Armand V. Feigenbaum, Kaoru Ishikawa and Joseph M. Juran. A core concept in implementing TQM is Demings 14 points, a set of management practices to help companies increase their quality and productivity: Create constancy of purpose for improving products and services. Adopt the new philosophy. Cease dependence on inspection to achieve quality. End the practice of awarding business on price alone; instead, minimize total cost by working with a single supplier. Improve constantly and forever every process for planning, production and service. Institute training on the job. Adopt and institute leadership. Drive out fear. Break down barriers between staff areas. Eliminate slogans, exhortations and targets for the workforce. Eliminate numerical quotas for the workforce and numerical goals for management. Remove barriers that rob people of pride of workmanship, and eliminate the annual rating or merit system. Institute a vigorous program of education and self-improvement for everyone. Put everybody in the company to work accomplishing the transformation.

1.1 COMPANY BACKGROUND

INTRODUCTION ABOUT THE COMPANY: Lucas Indian Service (LIS) established in 1930, is a specialist organization in sales and service of "Lucas-TVS" auto electricals and "Delphi-TVS" diesel fuel injection equipment. LIS also manufactures automotive products like ignition coils and solenoid switches in Chennai which are marketed under the brand name "Lucas". LIS distributes "LISPART" range of auto parts and "Lucas" range of automotive batteries through tie-ups with leading manufacturers. Besides manufacturing, sales and distribution, LIS offers servicing and training in auto electrical and diesel fuel injection equipment. Lucas - TVS established in 1961 as a joint venture between Lucas UK and T V Sundram Iyengar & Sons (TVS), India to manufacture Automotive Electrical Systems. Lucas-TVS is the Leader in Auto Electricals in India today with 48 years experience in design and manufacturing. 4 out of 5 vehicles rolled out daily are fitted with Lucas-TVS products. Lucas - TVS is a TS16949 and OSHAS 18001 certified company. Lucas-TVS has bagged the Deming application price in 2004 from the Japanese Union of Scientists and Engineers (JUSE). LucasTVS, believes that quality begins and ends with the customer. This means identifying customer needs and comprehensively meeting them. For the company, quality is not just conformance to drawings or specifications but ensuring customer satisfaction. The TVS Group traces its origin to a rural transport service, founded in 1911 in Tamil Nadu, India. Today, this renowned business conglomerate remains faithful to its core ideals of trust, values, service and ethics. The TVS Group is India's leading supplier of automotive components and one of the country's most respected business groups. With a combined turnover of more than USD 5 billion, the TVS Group employs a total workforce of around 25,000. Charting a steady growth in terms of expansion and diversification, it currently comprises around 43 companies. These companies operate in diverse fields ranging from two-wheeler and automotive component manufacturing to automotive dealerships, finance and electronics. Uniting these multiple businesses is a common ethos of quality, customer service and social responsibility. Lucas-TVS Limited, along with its subsidiaries, designs, develops, manufactures, and supplies automotive electrical systems. The company offers starter, wiper, blower, and fan motors; and alternators, headlamps, dynamo regulators, dynamos, ignition coils, diesel fuel injections, fuel injection
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equipment, electronic ignition systems, and automotive lighting products. Its products are used in passenger cars, commercial vehicles, tractors, jeeps, two-wheelers, and off-highway vehicles; earth moving equipment and gensets; and stationary and marine applications. Lucas-TVS Limited offers its products through a network of branches and outlets serving customers in the United States/European markets.

INDUSTRY PROFILE: The features of the industries that produce ignition coils other than Lucas Indian Service ltd. is listed below.

Aaditya Auto Care

Manufacturer & exporter of Ignition coil, primary ignition coil, motorcycle ignition coil, honda ignition coil, trigger coil, vehicle brake shoes, motorcycle brake shoes, engine parts, roller and needle bearings, gear shifter for lml vespa

Hueco Electronic (India) Pvt. Ltd.

Manufacturer & exporter of coils ,ignition coils, automotive ignition coils, auto ignition coils, heat resistance coated o rings, enameled o ring, ring washers, rubber rings, communication tower parts, ms diptrey glass top model, automotive fuel pump, feed pumps, high pressure pumps.

United Traders Corporation:

Manufacturer & exporter of ignition coils, automotive ignition coils, two wheeler ignition coils, three wheeler ignition coils, three wheeler parts,etc..

Neha Implex:
Engaged in exporting of auto ignition coil system, ignition coil for bajaj vehicles, induction coils, Honda ignition coils, primary ignition coils, trigger coil, motorcycle ignition coils.
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Swami Auto Products:

Manufacturer of source coil, pick up ignition coil, electronics part, 2 wheeler & 3 wheeler pick up coils, magnet wires, regulators, lighting coils, ignition coils, flashers, startors,etc..

Diksha Springs Udyog:

Exporter, manufacturer and supplier of coils, choke coil, cooling coils, dc coils, economizer coils, field coil, hot dip galvanized coils, hot rolled steel coils, ignition coil, ss.

Punjnad Auto & Rubber Inds. Pvt. Ltd.

Manufacturer of coil, pressure blade, primary ignition coil, pvc grip cover, rear control rod, rear drum plate, rear fork, rotor cover,etc..

COMPANY PROFILE Basic Information Company Name: Business Type: Product/Service (We Sell): Address: Number of Employees: Lucas Indian Service Ltd Manufacturer Ignition coil,4st switch #6, Pattulos Road, Anna Salai 51 - 100 People

Ownership & Capital Year Established: Legal Representative/Business Owner:

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1930 B.Sreeram

Trade & Market North-America South-America Western-Europe Eastern-Europe Main Markets: Eastern-Asia Southeast-Asia Mid-East Africa Oceania Total Annual Sales Volume: US$1 Million - US$2.5 Million

MISSION: The mission of Lucas Indian Service is to provide high proactive after sales and service to vehicle makers and users in its areas of specialization(electrical and diesel systems).LIS will continuously expand the scope of its sales and service offerings for vehicle and non-vehicular applications in anticipation of customer needs. LIS will continuously expand its network and enhance the technical skill of its people & the network through use of contemporary technology. VISION: Lucas Indian Service (LIS) will strive to become Indias dominant and most respected service

provider in its areas of specialization by 2013. LIS will expand overseas with focus on SAARC, ASEAN and Middle East.

STRENGTH: MANUFACTURING: Manufacturing Products are manufactured using State-of-the-Art facilities organized in Product Units, Modules, Nagare Cells and Assembly Cells and incorporating Quick Change Tooling, Pokka Yoke, Chakku Chaka (Auto Unloading). The condition of machines is monitored and maintained by TPM techniques and the schedule adherence is monitored by
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DRM (Daily Routine Management) while Process & Product Quality is sustained and improved by ZED-Q (Zero Defect Quality) activities. The Manufacturing system is competently backed up by an advanced Tool Room and an in house SPM/ Process Plant manufacturing facility. The entire organization is firmly entrenched in the change process and committed to CIP (Continuous Improvement Program me). Our Journey Towards Manufacturing Excellence: Products are manufactured using State-of-the-Art facilities organized in Product Units, Modules, Nagare Cells and Assembly Cells and incorporating Quick Change Tooling, Pokka Yoke, Chakku Chaka (Auto Unloading). The condition of machines is monitored and maintained by TPM techniques and the schedule adherence is monitored by DRM (Daily Routine Management) while Process & Product Quality is sustained and improved by ZED-Q (Zero Defect Quality) activities. Total Quality Management (TQM): Lucas-TVS, believes that quality begins and ends with the customer. This means identifying customer needs and comprehensively meeting them. For the company, quality is not just conformance to drawings or specifications but ensuring customer satisfaction. This belief forms the basis of its approach to Total Quality Management (TQM). Quality Assurance methods like Advanced Product Quality Planning, Statistical Process Control Techniques, Effective Tool Management System, Process Capability Improvements, Preventive Maintenance, Producer Control and Small Group Activities form the backbone of the system approach adopted. In its continuous pursuit of both technological as well as methodological excellence, Lucas-TVS has scripted yet another new dimension to manufacturing by not only adopting the Cellular Manufacturing System / JIT but also extending the same to its Suppliers. By the implementation of this system components from its suppliers are delivered on a pull basis with First In First Out concept supported by simple visual controls and supplied to the line on an hourly basis with KANBAN system. Distribution Network: LIS extensively covers the country through its 4 regional offices located at the main metros and 20 branches equipped with warehousing facilities. The widespread distribution network of LIS reaches 650 towns and cities. LIS has established a network of over 1500
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dealers. The company also maintains close bonds with a large number of institutional clients, State Transport Undertakings, Coal fields, Public Sector Undertakings and Defense Establishments. QUALITY POLICY: We are committed to achieving ever increasing levels of customer satisfaction by ensuring delivery of high products, high reliability in the delivery of the offerings and a high quality of after sales service. This is to be achieved continually improving the effectiveness of the quality management system. It will be our endeavor to increase customer trust and confidence in products manufactured, marketed and serviced by LIS. CUSTOMERS: The major customers are:

Maruti Suzuki India Limited. Enfield India Limited. Ashok Leyland Limited. Tata Motors Limited. Cummins India Limited. TAFE. Mahindra & Mahindra Ltd. Lucas-TVS Pondicherry Limited. AVTEC. Swaraj Mazda Ltd. AMW.

Some of the customers are; Yamaha Motor India, LML, Hero Honda, Kirloskar Oil Engines Birla Yamaha, Greaves Cotton, Tata Cummins, Caterpillar India, TAFE, Johndeere, Tata Motors, Ashok Leyland, etc..

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INTERNATIONAL PRESENCE: The company exports its products to U.S.A, U.K, DENMARK, IRELAND, BELGIUM, SPAIN, ITALY, TURKEY, SRILANKA, BANGLADESH, OMAN, EGYPT, U.A.E, KUWAIT, etc.. Some of the OE customers Artic Cat- U.K, IVECO- Italy, Proton- Malaysia, etc.. Milestones: In 1930, Joseph Lucas ltd, U.K. established. In 1930, Lucas Indian Service in Bombay was started. In 1937 Calcutta operation was started. In 1946 Chennai operation was started. In 1960 Lucas Indian Service Ignition Coil factory was started. In 1968 Lucas Indian Service became subsidiary of Lucas- TVS In 1972 New Delhi operation was started. In 1977 marketing of LISPART alto equipment was started. In 1985 promotion of Indian Nippon Electricals ltd was started. In 1994 manufacturing of solenoid switch was started. In 2003 Lucas Care was launched. In 2004 total quality management(TQM) was launched. In 2005 platinum jubilee was celebrated. In 2006 inverters and inverter batteries were launched.

Achievements: Lucas-TVS, believes that quality begins and ends with the customer. This means identifying customer needs and comprehensively meeting them. For the company, quality is not just conformance to drawings or specifications but ensuring customer satisfaction. The awards got by LIS are II PLACE IN NATIONAL ENERGY CONSERVATION, AWARDS 2008 Lucas-TVS is Awarded "OUTSTANDING SUPPLIER & EXCELLENCE PERFORMANCE during the year 2007 by CUMMINS INDIA LIMITED Maruti VA - VE Award: 1. Best Vendor Award (2000 & 2006) 2. VA / VE Award (2006)
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3. Outstanding Overall Performance Award (2004) 4. Superior Kaizen Award (2004)

ACMA Technology Award: 1. Gold Trophy for Manufacturing Excellence (2004-05) 2. Productivity Award (2001-02) 3. Technology Award (1998-99)

Platinum Award for Manufacturing Excellence (2005) Managerial Excellence in Manufacturing (2004-05) 5 Star Award on 5S (2002) Energy Conservation Award(2000 and 2001) Best Supplier Award (2007) Rajiv Gandhi National Award (2006) Best Performer Award (2001-2002) VA/VE Award (2002-2003) Deming Application prize JUSE, Japan:
1. INTERNATIONAL RECOGNITION 2. 3. 4.

JIT Innovation Award from JIT Management Lab, Tokyo (2001 & 2004) JIT Grand Prix Award from JIT Management Lab, Tokyo (2002, 2005 & 2006) 3 Times Deming Application Prize 2004

Best Quality Award (2007) 100 PPM Award (2003)

ZONAL SALES CENTRES: Andhra Pradesh Karnataka Kerala Tamil Nadu Maharashtra Goa Gujarat Madhya Pradesh
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West Bengal Totally there are 21 sales centers in India.

Service Policy: Lucas Indian Service is dedicated to providing high quality service to its customer focus and solution process. Customer focus means: 1. To understand the problems and needs of the customer 2. To ascertain the nature of the problem and understand the root cause based on the past history of the vehicle recorded in our system. 3. To provide warranty back up for a period of six months to all services rendered to customers. 4. To extend customer friendly facilities like- extended work hours, Sunday working, call centers and mobile service 5. To measure the satisfaction level of customers and implement corrective actions for improvement. Solution process means: 1. To offer solutions aimed at corrective and preventive action to avoid recurrence of the same problem. 2. To follow standard operating procedure on all workshop processes. 3. To provide customized infrastructure with a choice to include preventive maintenance, float units, pick up & drop facility etc., to customers. Benefits & Features: Lucas Indian Service Limited (a subsidiary of Lucas TVS) is a specialist organization, providing solutions for auto electrical and diesel fuel injection equipment. With over seven decades of expertise in the automobile industry, we know how important your car is to you. Lucas Indian Service Limited provides you with a unique preventive maintenance program "Lucas Care" which optimizes your car's performance and helps to prevent breakdowns.
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What is Lucas Care? Lucas Indian Service is one of the first organizations to introduce a solution-based program, which focuses on preventing breakdown through regular maintenance checks. What are the car systems that the program covers?

Starting System Charging System Ignition System(Petrol) Fuel Injection System(Diesel) Lighting System Wiping System

What is the process involved during the periodic check up?

Check up, cleaning & top up your car battery Check up of starting system to facilitate quick start Check up of charging system to protect car battery and other electrical accessories Check up and "timing/tuning" of ignition/fuel injection system to facilitate smooth running and minimize pollution Electrical load validation and comprehensive system screening Check up and cleaning of air filter, fuel filter and heater plugs( for diesel cars) Free consultation on car maintenance

Unmatched Features of Lucas Care

Four FREE service check ups in a year covering quote electrical and fuel injection equipment(for diesel cars) FREE labor charges - if the auto electrical units require repair or overhauling during the program period 25% DISCOUNT on labor charges in case the fuel injection unit (for diesel cars) requires repairs, overhauling or re-calibration during the program period
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Breakdown attention within city(up to 25 kms, 9 am to 6 pm) 5% DISCOUNT on spare parts

Lucas Care Benefits

Prevention of breakdowns to enable a stress free driving experience Service at your doorsteps and at your convenience Access to genuine spares

1.2 STATEMENT OF THE PROBLEM The study focused on the quality problems with regard to man & machinery defect free products. Manpower. Machinery. MANPOWER: The quality problems with regard to manpower; Rivet damage. Bracket hole upset. Body bulk plating. Base crack. Thread damage. Sold ring damage. MACHINERY: The quality problems with regard to machinery; Low pulling. Pulling failed. N/C (no continuity).
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Flash failed.

1.3 OBJECTIVES The main objective consists of organizing equipment and working areas in most efficient way, satisfactory and safe for the personnel doing the work.

Primary objective : "To study on total quality management for existing processes using tools and techniques and suggesting improvements for better effectiveness." for 4ST Solenoid Switch.

Secondary objective: To study the existing quality practices done in the factory. Understand the usefulness of existing quality control tools. To minimize In-House rejection and customer complaints in 4st switch. To achieve shipment of 100% defect free products.

1.4 NEED FOR THE STUDY Production of quality products. Customers satisfaction. Good image in public. Better utilization of resources. Reduction in wastages. Highly motivated employees.

For Employer: Review on the functioning of various Production processes of finding and solving the problems. For Employee: Employee involvement improves quality and increases productivity.

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1.5 SCOPE & SIGNIFICANCE Total quality management study is carried out in the LIS for a period of two months. Total quality management study for the existing process to improve in the quality level of production. Those study is carried out using quality control tools like; Check-sheet. Pareto chart. Pie chart. Histogram. The study helps to identify the area in which quality can be improved to achieve 100% defect free product.

1.6 LIMITATIONS Total quality management study is carried out in the LIS for a period of two months. The new quality tools are not used due to lack of time. The collected data have been analyzed in the systematic manner.

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CHAPTER 2
REVIEW OF LITERATURE 2.1 NEWSPAPER ARTICLES

Date:07/06/2011 Lucas to market U.S. firm's lubricants NEW DELHI: The U.S.-based TOP1 Oil Products Company on Monday joined hands with Lucas Indian Service, a part of Lucas-TVS Group, for sale and distribution of its premium range of lubricants in the Indian market. We see huge potential in the Indian lubricant market which today is worth Rs.25,000 crore. Of this, over Rs.2,000 crore is for high quality synthetic and semi-synthetic oil segment, the market which we are targeting in India, TOP1 Oil Products Company Vice-President (Sales & Marketing) Frank Ryan told journalists here. We are known for producing lubricants for niche market segment and new generation vehicles. We hope our high quality and innovative products will soon become popular in the Indian automobile market, which is world's fastest growing market. As our marketing partner, Lucas Indian Service will strengthen our presence in India, Mr. Ryan added. According to Lucas Indian Service President Sandeep Abbi, We are optimistic that the arrival of famous global lubricant brand TOP1 in India will add to the growth of the premium lubricant market. Through our wide distribution network, TOP1 will soon become popular in India.

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LUCAS Indian Service Limited Ties Up with Top1 Oil Products Company Jun 9 11 LUCAS Indian Service Limited tied up with Top1 Oil Products Company to introduce the foreign firm's products in India. The company has been appointed as the distributor for Top1 brands in India, has launched lubricants for the motorcycles, passenger cars and heavy duty diesel vehicles segments. Top1 products for motorcycles will be available in the range of INR 285 to INR 750 per litre, while those for passenger cars are priced between INR 285 and INR 1,200 for every litre. The per litre cost of heavy duty diesel vehicles' lubricants will be INR 310 to INR 370.

TOP1 oil products company, USA launched its premium range of lubricants in India TOP1 Oil Products Company, based in USA has launched its premium range of lubricants for the first time in India at a press meet held at New Delhi yesterday. TOP 1 has tied-up with Lucas Indian Service, a specialist organization in sales and service of auto electrical and automotive products as their marketing partners for distribution.

Mr. Frank Ryan of TOP1 & Mr. Sandeep Abbi during the launch

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Mr. Frank Ryan during his presentation

Mr. Frank Ryan of TOP1 & Mr. Sandeep Abbi of Lucas launching TOP1 Lubricants in India Mr. Frank Ryan, Vice president, Sales & Marketing, TOP1 Oil Products Company, USA and Mr. Sandeep Abbi, President, Lucas Indian Service Ltd. have jointly done the honor of launching this premium category of lubricants from USA in India. Amongst the others present during the occasion were Mr. R. Ramesh, Chief Executive, TOP1 Lubricant Products Company India and Mr. M.S. Kumaran, Business Development Advisor, TOP1 Oil Products Company, USA. Top 1 lubricants target niche market segment which comprises of high quality users and are used mostly in new generation vehicles. Lucas Indian Service has a strong network in distribution of premium products ranges from automotive electrical parts, fuel injection system and automotive filters all across the country. Both being leaders in their respective segments, this strategic tie-up would bring favorable competition in the premium lubricant market in India.
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Speaking on the occasion, Frank Ryan, Vice president, Sales & Marketing, TOP1 Oil Products Company, USA said In the spirit of excellence, Top1 always strive to provide the highest quality lubricants using the most innovative methods and focusing on customer satisfaction and value. We are extremely proud in extending our business in India. Further to this, having Lucas Indian Service as our marketing partners would certainly strengthen our presence in India. The market potential of lubricants is more than 20,000 crore in India. Limited players are there in the synthetic & semi synthetic oil segment, which is estimated of Rs. 1,000 crore of the total market value. In 21st century, it is clear that the lubricant industry is undergoing a tremendous transformation. The companies are facing increasingly stringent lubricant specifications that have been mandated by both the major car manufacturers as well as governments around the world. Oil prices remain at the highest levels in history and raw material shortages remain an ongoing challenge. Despite the challenges, TOP1 think its their prime responsibility to provide the highest quality lubricants using the most innovative and cost-effective methods. During the occasion, Sandeep Abbi, President, Lucas India Service Limited said, We are extremely honored to be chosen as the marketing partners of this lubricant giant from USA. We are also very optimistic about the arrival of TOP1 in the Indian market, as it will add on to the growth of ever growing premium lubricants market in India. TOP1 already have a strong presence in USA and the other western market and are targeting for the same in India too. About top1 oil products company Established in 1979 in USA with the objective of providing its customers premium and high quality automobile and synthetic blend lubricants all across the globe. All Top1 Oil Products Company products made in the USA. are formulated with the latest state-of-the-art base oil called Syngen 2000 technology. This patented Syngen 2000 technology results in lubricants that are significantly less volatile. Today, spread over more than 40 countries, Top 1 brand is the preferred choice of discerning customers of automotive lubricants in automobile centric markets like South East Asia, Latin America, etc. Equipped with modern facilities and automatic batch blending, TOP1 factory consistently manufactures high quality advanced world-class lubricants. About Lucas Indian Service Limited Established in 1930, it is a specialist organization in sales and service of Lucas -TVS auto electricals and Delphi TVS diesel fuel injection equipment. The brand portfolio of LIS consists of leading
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product brands Lucas-TVS Automotive Electricals, Delphi-TVS Diesel Fuel Injection Equipment, LISPART Auto Parts, and LUCUS Automotive Batteries, Ignition Coils & 4ST Switches. LIS also promotes preventive maintenance services under the brand name Lucas Care. Lucas Indian Service extensively covers the country through its 4 regional offices located at the main metros and 23 branches equipped with warehousing facilities. The widespread distribution network of the company reaches 650 towns and cities through 2000+ dealers, 500+ service dealers and 200+ institutional customers.

2.2 MAGAZINE ARTICLES

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2.3 INFORMATION FROM WEB INFOMEDIA YELLOW PAGES

Lucas Indian Service The Retail Connection Business Articles

Chennai headquartered Lucas Indian Service (LIS), a specialized aftermarket playerfocused on auto electrical and diesel injection systems in the countryis firming up its foray into car retail accessories under the brand Car plus. The pilot project, introduced a little over a year ago, is ringing in positive signals for the company to help finalize its plan in this area of business. The company feels that the response from the two dedicated showrooms in Gurgaon and Ludhiana is encouraging and it is now trying out several options to reach out to the discerning customers. As part of its initiative, LIS has opened a counter in a departmental store in Delhi a couple of weeks ago. This move is expected to help the company to understand the customers expectations in terms of reach and convenience besides, the availability of the range of products, said the President, Lucas Indian Service, Sandeep Abbi. Talking to Aftermarket, he said, This is a pilot project, an experiment to see how we can go about it in a big way. It is in the nascent stage and we are trying to understand the retail business. Retailing is different from the normal aftermarket sales and service support business, since it involves vehicles and accessories. Right now, we are going through the learning curve in understanding what the customers look forthe accessories purchasing pattern of both new vehicle owners and the old ones. Opening a smaller format, in the departmental store, is again a learning process to understand whether we should have standalone stores or be part of a mall or a departmental store. The idea is to offer a unique and different buying experience to the customers. They can touch and feel the products and have a different experience as far as car accessories are concerned. Abbi said that at this point of time, these outlets are owned by the company and going forward, when it wants to expand in a big way, it might look at franchise model also. We have a roadmap, which basically envisages us to look at about 120 outlets over a period of five to seven years. This is contingent on us first having our learning and business
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model in place, he said. It will escalate once the learning is completed in about a year or so. The company will be focusing on the entire range of cars. Normally, in high-end cars, a lot of accessorisation has already happened. And so it is really at the A, B and C segments of cars that require accessories. And to support the requirements, Car plus deals with the complete range of accessories from infotainment to security systems, navigation, upholstery, interiors and exteriors. It also deals with different brands. Besides, the retail outlets carry out several services including anti-rust treatment, wheel balancing and such things. The two retail outlets have specific bays where the customers can see the work in progress from an air-conditioned lounge. The retail store also deals with tyres for passenger cars. Asked if LIS would extend a similar concept to two-wheelers, he said, We may consider at a later stage but at this point of time we would like to focus on passenger cars and multi-utility vehicles. The network that LIS has established over a period of time is largely oriented towards dealing with electrical and fuel injection systems of automobiles. And the entire value chain is aligned to that. Therefore the company will be largely confined to these two segments as it feels that there are still many unrepresented avenues within auto electrical and fuel injection systems. However, there are certain items including high performance lamps and HIDs that are currently dealt with by car plus, which might come in as part of the companys distribution network, he said. Lispart already deals with these kinds of products including halogen lamps, and it will only be a natural movement for the company to expand the product portfolio. The entire aftermarket businesses of Lucas-TVS and Delphi-TVS is overseen by LIS. It sees tremendous synergies amongst different business divisions such as Lucas-TVS (auto electrical), Delphi-TVS (diesel fuel injection system), Lispart (outsourced auto parts) and Lucas (batteries, ignition coils and switches). The core business of the company is to provide sales and service to auto electrical components manufactured by Lucas-TVS and diesel injection systems made by Delphi-TVS. We have specialized in auto electrical and diesel injection systems. And we are looking to expand in adjacent areas of business. For example, we have recently tied up with lubricant companyTop1 of the US, to distribute its products all over the country except south India. This is basically for exclusive distribution of synthetic and semi-synthetic lubricants and not the mineral-based lubricants. Although the market is largely towards mineral-based lubricants, the new generation vehicles and quality conscious customers see merit in going for the synthetic lubricants. We would not be playing the volume game. However, it could become the mass market in the future. Its a strategic move for us, he said. The company will be catering to the requirements of motorcycles, passenger cars and diesel segment in both cars and commercial vehicles. Later on, it hopes to cater to industrial lubricants too, he
30

added. Under the brand Lucas, the company sells ignition coils, switches and batteries. Except for batteries, the other two products are manufactured by LIS. It has been supplying ignition coils to the earlier generation of Maruti vehicles. With the change in technology the company has now been catering to aftermarket requirements of those vehicles. Besides, it also deals with switches that are primarily meant for starter circuits. In addition, it also outsources batteries and sells under Lucas brand. This is a small part of its operations. Asked if the company will look at expanding its product portfolio, he said the range of switches may expand. The company directly sells its batteries through its dealerships. Besides, it also sells to OEMs who in turn rebrand and sell as genuine parts. Today, the company has a network of over 2,000 dealers covering close to 700 towns and cities. About two wheelers he said, We are already in two-wheelers through some of our products since Lucas-TVS is catering to two wheeler segment. Also we now handle lubricants. Under Lispart it has some spare parts for this segment and this is the area where the company is hoping to strengthen further. Over the last few years we have started building a portfolio for more two-wheeler parts, he said. Auto electrical and filters are the areas where the counterfeit is more. The industry estimate is around 30 percent, however, he feels that it should be more in the auto electrical and filters. New generation vehicles with advanced technologies become a natural barrier for the counterfeit. The company has three mobile units with auto electrical and fuel injection test equipment, to hold campaigns and also to train the people in the outlets. Each unit caters to one of the three regionsnorth, east and west. The southern region is catered through the TVS group companies themselves, he said. Lucas Care, which was launched few years ago to cater to the passenger car users, is now oriented towards the institutional customers on preventive maintenance. This is because of rigorous demand in this segment. The company deals with over 10,000 parts and it has developed an in house software to manage the supply chain from the manufacturers till the part is delivered to the end customers. The software built within its IT systems with certain principles works on the basis of supply chain management. It helps the company to integrate with its suppliers and subsequently to distributors and dealers. Since retailers are smaller entities, they do not have the capability of holding a wide range of parts. The software developed by the company helps in replenishing the stocks at the earliest possible time, he said. The company has 23 branches with warehousing capabilities. It is currently building Central Warehousing units in Chennai and Pondicherry, which will become part of the larger supply chain management. LIS has 350 service dealers and 40 company-owned workshops through which, it sets the benchmark for servicing. The company-owned outlets will play a significant role in imparting training to the service
31

dealers. LIS maintains the history of vehicles and even if the vehicles move from one city to the other, the service history can be retrieved to facilitate easier service. With the vehicle parch and variety increasing, there will always be growth in the aftermarket business despite the fact that the life-span of the spare parts is significantly increasing. Besides, the increasing awareness of preventive maintenance will also spur the demand. According to him, some categories that fall under the replacement cycle and the aftermarket, will also move from repair to reconditioning. When asked about remanufacturing, he said that LIS is already into this in a small way on starters and common rail systems. These are in very early stages for us to understand on how the processes are to be handled. As we go through our learning, we would definitely look at expanding, he said

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PRODUCT PROFILE IGNITION COIL Function and Testing - IG-108: Maybe you don't really need to know how an ignition coil works to test it, but it helps. I will try to keep the explanation in layman's terms for simplicity. WORKING PROCEDURE:

WORKING OF IGNITION COIL The ignition circuit on the MGA is quite simple. One primary terminal on the coil gets system power, and the other terminal is connected in series with a capacitor to ground return in the distributor. Additionally the contact points in the distributor parallel the capacitor to complete the ground return when the points are closed. The ignition coil is a transformer with about 100 to 1 ratio between secondary and primary windings. The output voltage will be 100 times greater than the input voltage. Picture here is for reference only. You should never need to open a sealed ignition coil. If it doesn't work it must be replaced. . .

You can think of the capacitor as a small high speed storage battery. It can build up a positive charge on one side and negative charge on the other side. When polarity is suddenly reversed current will flow out of one side and into the other side. No current flows completely through the capacitor, but the current going in one side equals the current coming out the other side for the short time when it is charging or discharging. Meanwhile it

33

simply stores a small electrical charge temporarily. The amount of power stored there is proportional to the voltage and frequency. .

When the contact points are closed the primary winding of the transformer is connected in series with the battery and carries an electrical current of about 4 amps. Since the points are shorting across the capacitor, the capacitor does nothing (at that time). The core of the transformer is an electromagnet with magnetic field induced by the current flowing in the primary winding. .

When the points open to break the ground contact the primary current must stop flowing, and the magnetic field in the transformer will collapse. The collapsing magnetic field forces current to continue flowing in the same direction momentarily, and that current will charge up the capacitor. Forward inertia of this forced current raises voltage at the capacitor momentarily to about 300 volts, at which time this high voltage stops the current. The current then reverses direction, being driven backward by the high voltage at the capacitor. After the charge in the capacitor is depleted, inertia of the current in the transformer continues to drive the current in that direction to charge the capacitor in opposite polarity. The cycle then reverses. The result is an electrical ringing like a bell which reduces rapidly with time. .

The initial 300 volt spike in the primary winding will drive an output in the secondary winding up to 30,000 volts. The output current going to the spark plug will likewise ring in harmony with the input current, for as long as the output voltage is high enough for current to jump the spark gap under compression. Assuming the initial spark ignites the fuel air mixture, combustion pressure will rise rapidly, and the spark will stop almost immediately as voltage falls. By now it should be obvious why the capacitor is an essential part of the ignition circuit, and the engine will not run without it.

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Picture from an oscilloscope showing multiple traces of sparks For those following along with a little math, a four cylinder engine running 6000 RPM generates 200 sparks per second, so the full spark cycle lasts just 0.005 second. Dwell (time when points are closed) for the standard Lucas distributor is 60 degrees out of each 90 degrees of rotation of the distributor shaft, so the points are open only one third of the time, or 0.00167 seconds. How fast can you say "RING"? The only way you can ever see or measure this ringing, as in the picture above, is with an oscilloscope. TESTING OF IGNITION COIL: For preliminary test, use an ohm meter to check the resistance of the windings of the coil. For a non-ballasted ignition system like the MGA, coil primary resistance should be about 3.2 ohms. A high energy coil may have slightly lower primary resistance. A coil for use with a ballasted type ignition system (such as late model MGB) will have about half as much primary resistance, around 1.6 ohms. Resistance for the secondary winding will be very high, something like 10,000 ohms. Check that circuit resistance between the HT output and one of the primary input terminals. .

To test the ignition coil function you will need a battery, a few wires, and a capacitor (about 0.01 mF value). Connect battery power to the coil. Mount the capacitor physically to a grounding point (return to battery opposite the power terminal), and connect the capacitor wire to the other side of the coil (terminal opposite the power input terminal). Connect a jumper wire to the coil along with the capacitor connection. .

Touch jumper wire to ground (the capacitor mounting point) to complete the coil primary circuit. When you disconnect the jumper from ground, and you should get a nice
35

spark from the coil. Touch jumper to ground, then pull away to make spark. Hold the coil output high tension wire near a grounding point to see how far the spark jumps. Spark should jump more than 1/4 inch in open air. .

With all parts in place in the car, you can do this test with a single jumper wire. Leave all wires in the car connected. Remove distributor cap, and rotate engine until the contact points are open. This leaves the grounded capacitor in series with the coil. Turn on the ignition switch. Short the off side coil terminal (the one not connected to ignition switch power) to ground with the jumper wire. When you disconnect the jumper wire you should get the spark. This of course assumes that the primary wires inside the distributor are properly connected and are not shorted to ground. As a point of clarification, the two wires connected

to the contact points must be in contact with the spring arm of the points and must not be touching the mounting screw. .

If you do not connect the capacitor the spark may be so small as to be hardly visible, and lucky if it will jump 1/32 inch gap. The capacitor is an essential part of the circuit, providing an electrical "ringing" in the primary side of the coil at up to 300 volts. Without the capacitor the spark voltage would be reduced dramatically. If you get no spark from the coil, you need a new coil (or a new capacitor). If you get good spark from the coil, you know your problem lies elsewhere.

36

IGNITION COILS VARIETY These are examples of ignition coils you may find on an MGA.

The

primary

terminals

would be screw posts for 1500 and early 1600 cars, but may have Lucar push on terminals like this one for late 1600 and 1600-MK-II cars. The bracket is a more modern replacement type with a tab in the center which might be used to attach a condenser (capacitor) for RF noise suppression, or a bracket for a ballast resistor. .

The coil in the center is a period accessory style Lucas High Energy Coil. This has it's own unique bracket with the Lucas logo in blue. The high tension connector is original screw in type. Primary terminals are original screw posts. .

37

The coil on the right is a modern Lucas Sport Coil (40,000 volts capacity). The gold color case is standard for this item as well as the bracket with the black sticker. The high tension terminal has the more modern push in type connector. The primary terminals have screwed on Lucas connectors which can be removed if you want to use early style ring lugs for the wire connectors. This model has been available since at least the early 1990's, and may be longer. .

If you just need a replacement coil to keep you running, you can pick one up at almost any local auto parts store. You may expect these to be painted black, and they may have push on terminals which may be either riveted in place or removable to expose screw posts. The key feature is that you need a coil designed for 12 volts non-ballasted ignition system. This will have primary coil resistance of about 3.2 ohms. A coil for ballasted ignition system (like late model MGB) will have primary resistance of about 1.6 ohms. You should take an ohm meter with you when you go to buy a coil, and look for about 3.2 ohms primary resistance for the MGA. A high energy coil may have slightly lower primary resistance, perhaps around 2.7 ohms. Ignition coils are available under many brand names such as Bosh, Crane, Mallory, and a great variety of house brands, and the many available colors are irrelevant. Many of the well known brands will feature high energy or high voltage, while the house brands may be either coils. high energy . or lower cost standard .

There is nothing magic about a high energy coil, but it may help the engine start a little easier in cold weather or adverse conditions (like fouled spark plugs). When parts of the ignition system are older and somewhat deteriorated the higher voltage may help fire the spark through high resistance plugs or wires. It might also cause arcing and misfire if the high tension wire insulation is breaking down, or the end boots are deteriorating. A final note about terminal markings: Later production ignition coils were marked "+" and "-" on the primary terminals, which makes hook up pretty much self-evident. The primary terminals of early coils for positive earth setup were marked "SW" for Switch, and "CB" for Contact Breaker". In the positive earth system the ignition switch supplies power from the Negative battery post, and the contact points ground the other side of the coil to the Positive battery post. Therefore "SW" = "-" and "CB" = "+". This bit of knowledge and logic
38

can avoid confusion if you change your vehicle from positive earth to negative earth. In that case you reverse the coil wires, and the "CB" terminal connects to the positive Switch wire while the "SW" terminal gets grounded to negative through the Contact Breaker. If you're still confused, buy a new coil with the "+" and "-" markings.

39

Car Ignition System

LAYOUT OF IGNITION COIL:

40

Dismantled Ignition coil

Ignition coil forms the basic and important part of ignition system in petrol engine. An ignition coil is made up of step-up windings or coil immersed in the transformer oil. This step-up winding is placed inside on aluminum container for safety and transportation. The ignition coil consists of primary winding and secondary winding. The primary winding is made up low resistance winding and secondary is made up of high resistance winding. Secondary coil is wound first. The layer of the coil are insulated with kind of glassy transparent paper. The coil are wound with the help of semi-automated machines. The first four layers are wound manually and the rest of the layers are wound with the help of semi automatic machine. Totally 24-25k windings are done with copper wire of dia 0.070mm. Once the secondary winding is done the coil is sent for insulation in Make Of Stage. After make of stage it is sent to primary winding section. In primary winding section the first resistance of the coil is checked. It must be between 7.05 to 14ohms The turns for primary and secondary windings depends upon the demands. For eg:25k

41

25K---46 swg-- secondary windings 310turns--------21.5 swg- Primary windings Then the tested coil is sent for the varnish. The varnish is mainly done to make the copper wire insulated so that the short circuit in the winding can be avoided. Then the coil is heated at about 120c for about 20 minutes. Then the coil is dipped in the varnish for about 2minutes and heated about 30minutes for 120c The tested leads of the coil are tinned with a soldering lead. Then I core is fixed into the coil and the bottom of the coil is fitted with ceramic material. The coil thus produced is placed inside the aluminum container. The top end of the container is closed with plastic cap with two inputs and an output in the centre. Then the container is filled with transformer oil and then sealed. Then the manufactured coil is tested by giving an input. The speed of the input contact point is kept in 1300rpm and the output voltage must be 35kva and at 3000 rpm the output must be 28kva.

QUALITY INSPECTION: At each and every step of the ignition coil manufacturing, there is a quality inspection. The coils are checked for Perfectly sealed Without any damage Proper output Proper packing

SOLENOID SWITCHES: Solenoid switches are used to provide better switching and they help to transfer electric current from battery to the starter motor. Solenoid switches ensure safety and prevent damage. Solenoid switches consists of an input to the coil, an input from battery and an output. The ground connection is given to the frame or the bracket in the case of 12V switches.

42

4ST SOLENOID SWITCH

Lucas Indian Services manufactures 12V and 24V solenoid switches. In 12V switches, the frame or bracket is grounded. In 24V switches a separate lead is provided for grounding purposes. For 12V solenoid switches 450 turns of copper wire are wound around plastic spools. For 24V solenoid switches 870 turns of copper wire are wound. A solid iron core fixed with copper plate at one end is placed inside the coil. The plate comes in contact with the input and output leads. The coil and the core are packed inside the steel bracket. 11A, 13A, 24A solenoid switches are available.

Quality Inspection: Solenoid coils are checked as soon they wound. After the manufacturing process of the solenoid switch is completed, they are tested under pulse condition. They are tested with the help of solenoid switch test rig. The switches are then inspected for any damage or any other missing components then they are packed and labeled.

43

CHAPTER 3
RESEARCH METHODOLOGY In general research can be termed as an inquiry in to the nature of, the reason for, and the consequences of any particular set of circumstances. It is the process of finding solution for a problem after a thorough study and analysis of the situation factors. It tries to solve complex and complicated problem through use of various tools and techniques. These tools and techniques try to bring out a logical, accurate and scientific solution to given problems. METHODOLOGY as the name suggests is the method through which the problem or situation is tackled. Managers in organization constantly engaged themselves in studying and analyzing issues and hence are involved in some form of research activity as they make decisions at the work place. It involves a lot of factors like research design, sample size, segment, and techniques of sampling, tools used etc all these steps and factors put together to bring out a clear and accurate result. The research methodology adopted for the present study has been systematic and was done in accordance to the objectives set, which has been discussed in the earlier pages.

RESEARCH DESIGN A research is the arrangement of conditions for collection and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure. In fact the research design is the conceptual structure within which research is conducted; it constitutes the blue print for the collection, measurement and analysis of data. The research design adapted in the study was descriptive study.

DESCRIPTIVE RESEARCH Descriptive research includes surveys and fact-finding enquiries of different kinds. The major purpose of descriptive research is description of the state of affairs, as it exists at present. The main characteristic of this method is that the researcher has no control over the variables; research can only report what has happened or what is happening. A descriptive study is undertaken in order to ascertain and be able to describe the characteristics of the variable of interest in a situation. Descriptive studies are also undertaken to understand the characteristics of organizations that follow certain common practices.
44

SOURCE OF DATA: Data refers to information or facts. The two main sources of data for the present study have been primary data and the secondary data. Minimize rejection and customer complaints in free product. The secondary data is ensure that delivery of 100% defect free product and thus improves the overall efficiency and productivity using quality tools and techniques.

3.1 TOOLS USED FOR ANALYSIS DATA The collected data have been tabulated and analysed in a systematic manner. The following tools and statistical method have been used in the study for analyzing the data. . Check-sheet. Pareto chart. Pie chart. Scatter diagram. Cause & effect diagram.

1.Check Sheet: Also called: defect concentration diagram Description: A check sheet is a structured, prepared form for collecting and analyzing data. This is a generic tool that can be adapted for a wide variety of purposes.

When to Use a Check Sheet

When data can be observed and collected repeatedly by the same person or at the same location.

When collecting data on the frequency or patterns of events, problems, defects, defect location, defect causes, etc.

45

When collecting data from a production process.

2. Pareto Chart : Also called: Pareto diagram, Pareto analysis Variations: weighted Pareto chart, comparative Pareto charts

Description A Pareto chart is a bar graph. The lengths of the bars represent frequency or cost (time or money), and are arranged with longest bars on the left and the shortest to the right. In this way the chart visually depicts which situations are more significant.

When to Use a Pareto Chart

When analyzing data about the frequency of problems or causes in a process.

When there are many problems or causes and you want to focus on the most significant.

When analyzing broad causes by looking at their specific components.

When communicating with others about your data.

3.PIE CHART:--

Description A pie chart is used to show visually the proportions of parts of something being studied. The area of each slice of the pie shows the slices proportion to the entire category being studied and to the

46

other slices. A pie chart shows data at one point in time, like a snapshot; it does not show change in data over time like a line chart does.

When to Use a Pareto Chart

Determine proportions. Find the total value for the entire category being studied and calculate the percentage for each segment or part.

Calculate degress. Convert the percentage values for each segment into degrees relative to the 360 degrees in the circle. (For example, 12% X 360 degrees = 43 degrees)

Construct the chart. Draw a circle and divide it into appropriately sized segments.

Add labels and a title. Label each segment or add a legend to identify the segments. Then clearly title the chart.

4.Scatter Diagram:- Also called: scatter plot, XY graph

Description The scatter diagram graphs pairs of numerical data, with one variable on each axis, to look for a relationship between them. If the variables are correlated, the points will fall along a line or curve. The better the correlation, the tighter the points will hug the line.

When to Use a Scatter Diagram When you have paired numerical data. When your dependent variable may have multiple values for each value of your independent variable. When trying to determine whether the two variables are related,

47

such as When trying to identify potential root causes of problems. After brainstorming causes and effects using a fishbone diagram, to determine objectively whether a particular cause and effect are related. When determining whether two effects that appear to be related both occur with the same cause. When testing for autocorrelation before constructing a control chart.

5.Fishbone:- Also Called: Cause-and-Effect Diagram, Ishikawa Diagram

Variations: cause enumeration diagram, process fishbone, time-delay fishbone, CEDAC (cause-and-effect diagram with the addition of cards), desired-result fishbone, reverse fishbone diagram

Description The fishbone diagram identifies many possible causes for an effect or problem. It can be used to structure a brainstorming session. It immediately sorts ideas into useful categories.

When to Use a Fishbone Diagram When identifying possible causes for a problem. Especially when a teams thinking tends to fall into ruts.

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CHAPTER- 4 DATA ANALYSIS

Data analysis is made based on the collection of data which is done which is shown on the following

1.1 CHECK SHEET:-

For March 2012 to April 2012 REASONS PULLING FAILED

BODY DAMAGE RIVERT NOT OK BRACKET HOLE OFF-SET N/C LOW PULLING SOLDRING NOT OK BODY BULK PLATE

NO OF REJECTION 26 4 86 14 8 15 8 6

1.2 PARETO CHART:SAMPLES 014A 013A 003A 012B 021A 011A 020A 97 30 21 9 4 3 3 DEFECTIVE

49

1.3 PIE CHART:SAMPLES 014A 013A 003A 012B 021A 011A 020A 97 30 21 9 4 3 3 DEFECTIVE CUMULATIVE 97 127 148 157 161 164 167 PERCENTAGE 58 76 89 94 96 98 100

1.4 SCATTER DIAGRAM:REASONS PULLING FAILED MARCH 2012 APRIL 2012

22 3 53 11 5 11 4 2

4 1 33 3 3 4 4 4

BODY DAMAGE RIVERT NOT OK BRACKET HOLE OFF-SET N/C LOW PULLING SOLDRING NOT OK BODY BULK PLATE

50

CHAPTER 5

INTERPRETATION & FINDING CHECK SHEET:For March 2012 REASONS PULLING FAILED
BODY DAMAGE RIVERT NOT OK BRACKET HOLE OFF-SET N/C LOW PULLING SOLDRING NOT OK BODY BULK PLATE
REASON S 01M A r 03M A r 05M A r 09M A r 10M A r

NO OF REJECTION 26 4 86 14 8 15 8 6
12M A r 15M A r 19M A r 21M A r 22M A r 23M A r 24M A r 26M A r 28M A r 29M A r 30M A r 31M A r TOT AL

PULLING FAILED BODY DAMAGE RIVERT NOT OK BRACKET HOLE OFF-SET N/C LOW PULLING SOLDRIN G NOT OK BODY BULK PLATE TOTAL

4 2 3 1 4 1 3 13 2 1 1 4 4 20

18

22 3

53 11

1 5

1 2 2

1 1

1 1

5 11 4

4 2

13

20

30

111

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APR 2012:REASONS 04-Apr

PULLING FAILED BODY DAMAGE RIVERT NOT 16 OK BRACKET 2 HOLE OFFSET N/C LOW PULLING SOLDRING NOT OK BODY BULK PLATE TOTAL

05-Apr

07-Apr

09-Apr

11-Apr

12-Apr

14-Apr

TOTAL

1 1 3 2 2 4 3 3 1

4 1 33 3

2 3 1

3 4 4 3 1 9 4 4 56

23

1.2 PARETO CHART:SAMPLES 014A 013A 003A 012B 021A 011A 020A 97 30 21 9 4 3 3 DEFECTIVE

52

180 160 140 120 100 80 60 40 20 0 1 2 3 4 58 97 89 76 94 127 148 157

161

164

167

180 160 140 120

96

98

100 100 80 60 40 20 0

Series1 Series2

1.3 PIE CHART:SAMPLES DEFECTIVE CUMULATIVE PERCENTAGE 014A 013A 003A 012B 021A 011A 020A 97 30 21 9 4 3 3 97 127 148 157 161 164 167 58 76 89 94 96 98 100

SAMPLES DEFECTIVE PERCENTAGE 014A 013A 003A 012B 021A 011A 020A 97 30 21 9 4 3 3 58 76 89 94 96 98 100

53

9 21

4 33

014A 013A 003A 012B

30

97

021A 011A 020A

1.4 SCATTER DIAGRAM:REASONS MARCH 2012 APRIL 2012

PULLING FAILED BODY DAMAGE RIVERT NOT OK BRACKET HOLE OFF-SET N/C LOW PULLING SOLDRING NOT OK BODY BULK PLATE

22 3 53 11 5 11 4 2

4 1 33 3 3 4 4 4

SHIFT-1

SHIFT-2

22 3 53 11 5 11 4 2

4 1 33 3 3 4 4 4
54

60 50 40 30 20 10 4 0 1 2 3 1 3 4 22 11 3 5 5 3 6 11 4 7 4 8 4 2 33 SHIFT-1 SHIFT-2 53

FINDINGS:

55

CHAPTER 6

SUGGESTIONS & CONCLUSION To eliminate the defect LIS can use cause & effect diagram tool and why? Why? analysis techniques for each type of defects in 4st relay assembly line. It is a tool for discovering all the possible causes for a particular effect.

CE may indicate the best potential areas for further exploration and analysis. It helps to find out the actual root cause of the problem.

They can use 100% cause & effect diagram tool for each type of defects. CE diagrams are best generated in brain storming sessions, when you are talking to the operators about making improvements.

LIS can conduct the tools and techniques refreshment program in a defined intervals to achieve their goals.

Using one of the new qc tools called swap analysis can be used.

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CHAPTER 6

BIBLOGRAPHY

BIBLIOGRAPHY

REFERENCES: TOTAL QUALITY MANAGEMENT DALE H. BESTERFIELD

PRODUCTION PLANNING AND CONTROL

S.K.MUKHOPADHYAY

WEBSITES:-

1. www.google.com 2. www.managementparadise.com 3. www.udel.edu/alex/chapt6.html 4. www.lucas-tvs.com

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5. www.auto.indiamart.com 6. http://articles.yellowpages.co.in/lucas-indian-service-the-retail-connection/ http://economictimes.indiatimes.com/news/news-by-industry/auto/automobiles/lucas-tomarket-us-firms-lubricants-in-india/articleshow/8760191.cms

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59

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