QC Results - One-time coating of 200-liter steel drums (1)
Lanzhou barrel factory Xin Qiaojuan
Foreword
The 200-liter steel drum is the leading product of our factory. The annual output is about 150,000. Our factory has more than 30 years of production history. Since the double hemming was triple-edged in 1988, he has been rated as a quality product in Gansu Province. In 1989, it was certified by the national commodity inspection to meet the "International Maritime Dangerous Regulations" Class I standard. In the same year, it won the gold medal at the Beijing International Exposition. In 1991, he received the third prize of application and promotion of science and technology in Lanzhou. Due to market changes and user requirements, the original coating process could not meet the requirements, seriously affecting the company's trust and benefits. In order to improve product quality, we organized a QC team to tackle the problem, started with each factor that affects the quality of the glue, and solved the problem item by item, raising the product qualification rate from 60% to 96%.
I. Group Overview
This group was established on November 6, 1991 and registered on the same day with registration number 91-07.
1, team members
91.7% of the team members passed the national comprehensive quality management basic knowledge test, and their grades were excellent.
The panelists proposed 24 rationalization proposals and 15 suggestions.
2. Group activity:
(1) Activity mode: The group activity mode is a combination of centralization and decentralization, in which the concentration activities are distributed 16 times. Activities 28 times.
The following activities are focused on the following activities:
(2) Activity frequency: The frequency of group activities is 70/72×100%=98.7%. Decentralized activities see the activity logbook.
(3) Activity data: QC activity registration form, registration form, activity record, modified craft file, work instruction, process document change notice, achievement report, etc.
Second, the choice of reasons and target value determination
1. Reason for the topic: Since October of last year, the 200-liter steel drum produced by our factory has been in a state of semi-paralysis. The user's requirements for steel barrels are becoming more and more demanding. The steel barrels produced by our factory are suspected to have plastic spots on the inner and outer walls. Although my factory arranged a large number of people to wipe the barrels, vacuum cleaners used to suck the glue and dust on the inner wall of the barrels, but the effect was slight, and a large amount of manpower, material resources, and financial resources were wasted. Our factory is located in Xigu District, Lanzhou City. There are three barrel factories in Xigu District. The competition is fierce. 200 liters of steel barrels have been exported to all over the world. Due to changes in the climate, the exterior uses paint and no glue spots are allowed. In order to ensure the quality of the inner contents, it is required that there should be no plastic spots inside the steel barrel. This urgently requires us to change the spray process. Change the original two-spray glue to one-spray glue to solve the problem of glue splash. The original glue spray process had serious leakage, and the primary rate of steel drums was only 60%. Therefore, a 200-liter steel drum was used to spray the oc: group once. This group is a research-oriented group composed of several departments of the whole plant.
2. Target value: According to the factory's policy goal, our team puts forward the goal of “saving energy, reducing consumption, and civilized production, so that the qualified rate of steel drums reaches 96% at one time, and 300,000 yuan is saved each yearâ€.
3. The feasibility of the target value: Our QC team convened a special meeting to study and discuss selected topics and target values. All the officials of the Dalai Lama have seen and confirmed through enthusiastic discussions and research:
(1) The team has a backbone team that combines design, process, testing, manufacturing, and operation. The team members have a certain amount of overall quality management knowledge. . Problem solving is compatible with the level and ability of the team members.
(2) Our group consists of experienced workers with more than 30 years of field experience as site technicians and staff operating equipment with more than 20 years of operating skills. This topic can be solved. ,
(3) There is a precedent for changing the original technology in the same industry in the country. In order to meet the market requirements to increase the first-pass rate of products, it is possible to reduce costs, and it is possible to save 300,000 yuan each year.
Third, analyze the status quo and find problems
In the past few years our factory has sprayed glue twice. The leakage of steel drums after one spray of glue was severe, and the pass rate of one pass was only 60%. In this situation, our team called an analysis meeting. At the meeting, we identified 10 factors and 17 factors that affected the leakage of glue, and made a causal chart as follows.
A 200-liter steel drum spray glue leakage serious causality diagram
Fourth, find the main reasons from the problems
All the reasons have been found on the cause and effect map, and a statistical report of the gluing defect items was made from the site survey.
One-time gluing defect item statistics
According to the statistics of a gluing defects project, it is arranged as follows:
From the arrangement diagram, it can be clearly seen that there are three main reasons that a steel coating affects the leakage of steel drums in the existing state:
1. Sealant quality;
2. The quality of people;
3. Equipment accuracy.