Rejection Analysis in Piston Manufacturing Unit

Rejection Analysis is a process of identification of quality and productivity related problems which the key factors in manufacturing process. The application of rejection analysis allows studying the failed parts. It helps to capture the minute failing details. It provides effective suggestion to the problem encountered in manufacturing process. It eliminates the scrap and tells which part can be rework. After preliminary study on machining process of piston in 6M production line at FEDERAL MOGUL GOETZE INDIA LTD, it was apparent that production line was having more defect and rework and had rejection percentage rate of about 10% .In order to examine this project, study was conducted to observe the process going on in the production line, to reduce the rejection rate by tracking the root causes and by providing suggestion. Some of tools and techniques used to achieve the objectives were check sheet, Pareto chart, cause and effect diagram and control charts. The methodology employed to achieve the stated objective, includes the study on nature of defect occurrence, collection of data on number of defects occurred during three months of study using check sheet, identification of major defect percentage using Pareto chart, finding the causes using cause and effect diagram and investigating the process is in control or not by statistical control charts. Lastly providing the suggestion regarding minimizing the defect and rework. The outcome of project was reduction in overall rejection rate in production line from 10% to 7 % and thus the production line was able to meet the required demand